Integra Printer CROMA24 User Manual
®
CROMA24™  
COLOR PRINTER  
SERVICE MANUAL  
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®
Croma24™  
COLOR INKJET  
PRINTER  
SERVICE MANUAL  
Part Number 208817  
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Croma24 Service Manual  
Copyright © 1995 and 1996 ENCAD®, Inc. All rights  
reserved.  
ENCAD is a registered trademark of ENCAD, Inc.  
CROMA24™ is a trademark of ENCAD, Inc.  
Other trademarks and registered trademarks are the  
property of their respective owners.  
No part of this manual may be copied or distributed,  
transmitted, transcribed, stored in a retrieval system, or  
translated in any human or computing language, in any  
form or by any means, electronic, mechanical, mag-  
netic or otherwise, or disclosed to a third party without  
the express written permission of ENCAD, Inc., 6059  
Cornerstone Court West, San Diego, CA 92121, U.S.A.  
Printing history  
1st Edition  
Rev A  
May 1997  
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Croma24 Service Manual  
FCC Statement (U.S.A.)  
The United States Federal Communications Commision has specified  
that the following notice be brought to the attention of the users of the  
Croma24 printers.  
FEDERAL COMMUNICATIONS COMMISION RADIO AND TELEVI-  
SION INTERFERENCE FOR CLASS B DEVICE  
This equipment has been tested and found to comply with the limits for a  
class B digital device, pursuant to part 15 of the FCC Rules. These  
limits are designed to provide reasonable protection against harmful  
interference in a residential installation. This equipment generates,  
uses, and can radiate radio frequency energy and, if not installed and  
used in accordance with the instructions, may cause harmful interfer-  
ence to radio communications.  
User Instructions:  
If the equipment does cause harmful interference to radio or television  
reception, which can be determined by turning the equipment off and on,  
the user is encouraged to try to correct the interference by one of the  
following measures:  
•
•
•
Reorient or relocate the receiving antenna.  
Increase the separation between the equipment and receiver.  
Connect the equipment into an outlet on a circuit different from  
that to which the receiver is connected.  
•
Consult the dealer or an experienced radio/TV technician for  
help.  
Changes or modifications not expressly approved by ENCAD, Inc. could  
void the user’s authority to operate the equipment.  
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Croma24 Service Manual  
VDE Statement  
Hiermit wird bescheinigt, daß der CROMA24 in Übereinstimmung mit  
den Bestimmungen der BMPT-AmstbIVfg 234/1991 funkentstört ist. Der  
vorschriftsmäßige Betrieb mancher Geräte (z.B. Meßsender) kann  
allerdings gewissen Einschränkungen unterliegen. Beachten Sie  
deshalb die Hinweise in der Bedienungsanleitung.  
Dem Zentralamt für Zulassungen im Fernmeldewesen würde dan  
Inverkehrbringen dieses Gerätes angezeigt und die Berechtigung zur  
Überprüfung der Serie auf die Einhaltung der Bestimmungen  
eingeräumt.  
ENCAD, Inc. U.S.A  
6
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Croma24 Service Manual  
Material Safety Data Sheet  
CROMA24 QIS (Quality Image Supplies) ink is nonhazardous, requiring  
no special disposal handling. It can be harmful if swallowed and should  
be kept away from children.  
To obtain a Material Safety Data Sheet, contact ENCAD, Inc. at:  
6059 Cornerstone Court West  
San Diego, CA 92121-3734  
(619) 452-4350  
International users should contact their local dealer or distributor.  
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Croma24 Service Manual  
WARRANTY OR DAMAGE CLAIMS  
United States  
ENCAD®, Inc., warrants its printers ("PRODUCT") to be free from defects in workmanship  
and materials for a period of one year from the date of purchase. In order to submit a  
Warranty claim, please contact the ENCAD Help Desk at (619) 452-4350.  
ENCAD reserves the right to make changes or improvements to Products, without  
incurring any obligation to similarly alter Products previously purchased.  
Buyer's sole and exclusive rights pursuant to this Warranty shall be for the repair or  
replacement of defective Product. ENCAD specifically disclaims any and all other  
warranties, expressed or implied, including but not limited to, implied warranties of  
merchantability and fitness for a particular purpose. In no event shall ENCAD be liable  
for any loss of profit or other commercial damages, special, incidental or consequential  
damages, or any other damages or claims, whatsoever.  
This Warranty gives Buyer specific legal rights, and Buyer may also have other rights  
that vary from state to state.  
This Warranty applies only to printers purchased from ENCAD, or authorized ENCAD  
distributors or dealers. The intent of this Warranty is to repair or replace defective  
Products subjected to normal wear and tear, when operated according to ENCAD  
instructions.  
This Warranty does not cover damage to the Product resulting from the following:  
•
•
•
•
•
Accident or negligence.  
Unauthorized modification of the Product.  
Adverse environmental conditions.  
Service of the Product by other than an ENCAD authorized service provider.  
Unauthorized or improper use, including but not limited to:  
–
–
Use in applications for which the Product was not designed.  
Using cartridges or ink other than those supplied by ENCAD or authorized  
ENCAD resellers.  
–
–
Using media other than that supplied by ENCAD or authorized ENCAD  
resellers.  
Lubricating any part of the printer.  
Internationally: Contact your dealer or distributor for warranty information.  
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Table of Contents  
Chapter 1 General Description............................................................. 17  
Introduction ...............................................................................................................17  
Overview ...................................................................................................................18  
Related Publications ...........................................................................................18  
Electrostatic Discharge (ESD) Sensitivity ..................................................................18  
Warnings, Cautions, and Notes.................................................................................19  
Printer Specifications ................................................................................................20  
Contents of this Service Manual................................................................................21  
Technical Support .....................................................................................................23  
Chapter 2 Theory of Operation............................................................. 25  
Introduction ...............................................................................................................25  
Croma24 Printer General Block Diagram ..................................................................25  
Paper (Media) Axis Drive ..........................................................................................27  
The Carrier Axis Drive...............................................................................................28  
Main Printed Circuit Board (MPCB)...........................................................................29  
Microprocessor ...................................................................................................30  
Gate Array ..........................................................................................................30  
Memory Circuits..................................................................................................31  
Stepper Motor Controller.....................................................................................33  
Servo Motor Controller........................................................................................34  
Interface Circuits: Serial & Parallel......................................................................36  
Carrier Assembly Circuits..........................................................................................37  
Power Supply ............................................................................................................38  
System Grounding ....................................................................................................38  
Front Key Controls ....................................................................................................40  
Chapter 3 Maintenance ......................................................................... 43  
Introduction ...............................................................................................................43  
Scheduled Maintenance............................................................................................43  
Cleaning Procedures ..........................................................................................44  
External Cleaning .........................................................................................44  
Slide Shaft Cleaning .....................................................................................44  
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Table of Contents (cont)  
Chapter 3 Maintenance (cont)  
Service Station Cleaning ..............................................................................45  
Linear Encoder Strip Cleaning......................................................................46  
Cartridge Dimple Cleaning ...........................................................................47  
Flex Cable Contact Cleaning ........................................................................48  
Clean and Inspect Stepper Motor Gears ......................................................48  
Clean and Inspect MPCB .............................................................................49  
Clean and Inspect Carrier Assembly ............................................................49  
Reseat Connectors on MPCB and Carrier Board................................................50  
Replace Carrier Bushings ...................................................................................52  
Servo Motor Winding Resistance Check ...................................................................52  
Stepper Motor Winding Resistance Check................................................................53  
Banding: Hardware vs Software ................................................................................53  
Alignments/Adjustments............................................................................................55  
Color Calibration .................................................................................................55  
Deadband Alignment ..........................................................................................56  
X-Axis Calibration ...............................................................................................57  
Pinch Roller Adjustment Procedure ....................................................................57  
Head Height Alignment Procedure......................................................................60  
Croma24 Control Panel.............................................................................................65  
Manufacturing Menu ...........................................................................................66  
Print Quality Test ..........................................................................................67  
Deadband.....................................................................................................67  
Diagnostics Menu ...............................................................................................68  
Paper Sensor Test........................................................................................69  
Fan Test .......................................................................................................69  
Carriage Vibration Test .................................................................................70  
Color Test .....................................................................................................70  
Keypad Test .................................................................................................71  
LED Test ......................................................................................................72  
Servo Motor Test ..........................................................................................72  
Paper Motor Test..........................................................................................73  
Service Menu......................................................................................................74  
Built In Test (BIT) ......................................................................................................75  
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Table of Contents (cont)  
Chapter 3 Maintenance (cont)  
Firmware/Software Upgrades....................................................................................76  
Internal Cabling and Signal Flow Diagram ................................................................77  
Chapter 4 Troubleshooting................................................................... 79  
Introduction ...............................................................................................................79  
No Power ..................................................................................................................79  
Media Does Not Move...............................................................................................80  
Carrier Axis Failure ...................................................................................................81  
Does Not Print...........................................................................................................82  
Ink Cartridge Misfiring ...............................................................................................82  
Paper Skewing ..........................................................................................................83  
Printer Output is Banding ..........................................................................................84  
Fan Does Not Power Up ...........................................................................................85  
Chapter 5 Assembly\Disassembly ....................................................... 87  
Introduction ...............................................................................................................87  
Remove the Left, Middle (Lid), and Right Covers ......................................................88  
Install the Left, Middle, and Right Covers ..................................................................89  
Remove the MPCB (Main Printed Circuit Board) and Actuator Assembly .................90  
Install the MPCB and Actuator Assembly ..................................................................91  
Remove Servo Motor ................................................................................................92  
Install Servo Motor ....................................................................................................94  
Remove the Carrier Assembly, Carrier Belt, and the Frame Tensioner .....................95  
Install the Carrier Assembly, Carrier Belt, and the Frame Tensioner ........................98  
Remove the Carrier PCB ........................................................................................100  
Install the Carrier PCB ............................................................................................102  
Remove the Paper Sensor or the Encoder Sensor .................................................102  
Install the Paper Sensor or the Encoder Sensor .....................................................104  
Remove the Trailing Cable Cover Assembly ...........................................................105  
Install the Trailing Cable Cover Assembly ...............................................................107  
Replacing the Carrier Bushings...............................................................................108  
Remove the Service Station, Seals, and Wipers ..................................................... 110  
Install the Service Station, Seals, and Wipers ......................................................... 111  
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Table of Contents (cont)  
Chapter 5 Assembly\Disassembly (cont)  
Remove the Lower Roller Assembly and Stepper Motor ......................................... 112  
Install the Lower Roller Assembly and Stepper Motor ............................................. 115  
Remove the Power Supply and AC Entry Module ................................................... 117  
Install the Power Supply and AC Entry Module .......................................................120  
Chapter 6 Parts List ............................................................................ 123  
Index ..................................................................................................... 131  
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List of Illustrations  
Figure  
Page  
Chapter 1 General Description  
Chapter 2 Theory of Operation  
2-1. General Block Diagram ...................................................................................26  
2-2. Paper (Media) Axis Drive.................................................................................27  
2-3. Carrier Axis Drive ............................................................................................28  
2-4. Main Printed Circuit Board ...............................................................................29  
2-5. Gate Array .......................................................................................................30  
2-6. Stepper Motor Controller .................................................................................33  
2-7. Servo Motor Controller ....................................................................................34  
2-8. Quadrature Signal Generation .........................................................................35  
2-9. Interface Circuits .............................................................................................36  
2-10. Carrier Assembly Circuits ................................................................................37  
2-11. Croma24 System Ground Network (Left Side) ................................................39  
2-12. Croma24 System Ground Network (Right Side) ..............................................40  
2-13. Front Key Controls...........................................................................................40  
Chapter 3 Maintenance  
3-1. Encoder Strip Cleaning....................................................................................46  
3-2. Cartridge Dimple Region .................................................................................47  
3-3. Flex Cable Contacts ........................................................................................48  
3-4. MPCB Connection Locations...........................................................................50  
3-5. Carrier PCB Connection Locations ..................................................................51  
3-6. Ribbon Connector Locking Mechanism ...........................................................51  
3-7. Servo Motor .....................................................................................................52  
3-8. Stepper Motor..................................................................................................53  
3-9. Examples of Banding ......................................................................................54  
3-10. Color Calibration ..............................................................................................55  
3-11. Deadband Fast/Slow .......................................................................................56  
3-12. Upper Roller Support Description ....................................................................57  
3-13. Upper Roller Mounting.....................................................................................59  
3-14. Gap of Pinch Roller .........................................................................................59  
3-15. Upper Roller Adjustment .................................................................................60  
3-16. Carrier Head Height Tolerance ........................................................................61  
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List of Illustrations (cont)  
Figure  
Page  
Chapter 3 Maintenance (cont)  
3-17. Setting Up Tools from Height Gauge Kit ..........................................................61  
3-18. Zeroing the Micrometer Gauge........................................................................62  
3-19. Test Cartridge Installed ....................................................................................62  
3-20. Carrier Positions for Head Height Adjustment .................................................63  
3-21. Maintenance Menu ..........................................................................................66  
3-22. Manufacturing Menu........................................................................................66  
3-23. Deadband Options Menu.................................................................................67  
3-24. Deadband Slow/Fast Display...........................................................................68  
3-25. Diagnostics Menu ............................................................................................68  
3-26. Paper Sensor Reported Data Dialog Box ........................................................69  
3-27. Fan Test Menu Panels.....................................................................................69  
3-28. Color Test ........................................................................................................70  
3-29. Keypad Test.....................................................................................................71  
3-30. LED Test..........................................................................................................72  
3-31. Servo Motor Test .............................................................................................72  
3-32. Paper Motor Test .............................................................................................73  
3-33. Service Menu ..................................................................................................74  
3-34. ROM Info .........................................................................................................74  
3-35. Service Special Information .............................................................................75  
3-36. Signal Wiring Diagram.....................................................................................78  
Chapter 4 Troubleshooting  
Chapter 5 Assembly/Disassembly  
5-1. Cover Removal/Installation..............................................................................89  
5-2. Frame Tensioner .............................................................................................92  
5-3. Electronics Cover Removal .............................................................................95  
5-4. Strain Relief Removal/Installation from Carrier ................................................96  
5-5. Carrier Belt Clamp ...........................................................................................97  
5-6. Installation of Frame Tensioner .......................................................................99  
5-7. Carrier PCB Removal/Installation ..................................................................101  
5-8. Paper and Encoder Sensor Removal ............................................................103  
5-9. Paper and Encoder Sensor Installation .........................................................104  
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List of Illustrations (cont)  
Figure  
Page  
Chapter 5 Assembly/Disassembly (cont)  
5-10. Trailing Cable Assembly Removal/Installation ...............................................106  
5-11. Carrier Bushing Removal ..............................................................................108  
5-12. Carrier Bushing Installation............................................................................109  
5-13. Service Station, Exploded View ..................................................................... 110  
5-14. C-Bracket Assembly and Platen Removal ..................................................... 113  
5-15. Stepper Motor Removal/Installation............................................................... 114  
5-16. Installing Lower Roller Assembly ................................................................... 116  
5-17. Ground Stud with Ground Lugs Attached ...................................................... 118  
5-18. Power Supply Assembly ................................................................................ 119  
Chapter 6 Parts List  
6-1. Croma24 Assembly Parts (Platen and Above)...............................................125  
6-2. Croma24 Assembly Parts (Below Platen) ......................................................126  
6-3. Carrier Assembly Breakdown ........................................................................127  
6-4. C-Bracket Assembly Breakdown ...................................................................128  
6-5. Lower Roller Assembly Breakdown ...............................................................129  
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List of Tables  
Table  
Page  
Chapter 1 General Description  
Chapter 2 Theory of Operation  
2-1. Front Key Control LED Codes .........................................................................41  
Chapter 3 Maintenance  
3-1. Pinch Roller Adjustments ................................................................................58  
3-2. Keypad Test Indications...................................................................................71  
Chapter 4 Troubleshooting  
4-1. Troubleshooting Table .....................................................................................79  
Chapter 5 Assembly/Disassembly  
Chapter 6 Parts List  
6-1. Parts List .......................................................................................................123  
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General Description  
1
Introduction  
This manual provides service information for the ENCAD, In c.  
Cr om a 24 Color Inkjet Printer.  
There are three versions to the Cr om a 24 Color Inkjet Printer  
family:  
CAD version  
CAD market  
parallel  
GA & CAD version  
GA & CAD  
serial & parallel  
GA version  
GA  
serial & parallel  
for :  
I/O:  
includes:  
ENCAD software RIP  
All versions will have an ADI Windows driver and print utility.  
This manual is written for service personnel who possess analog  
and digital circuitry experience. Chapter 2, Theory of Operation,  
should be read and thoroughly understood before troubleshooting/  
calibrating the printers.  
The printers support pre-cut and roll media. Media size is auto-  
matically determined and hardclip limits are set accordingly. Pre-  
cut media uses different maximum plotting areas than roll media.  
See the Printer Specifications for more details.  
Both RS-422 serial and Centronics parallel connections are pro-  
vided to interface with the host computer on the GA (Graphic Arts)  
compatable versions. Only the Centronics parallel connection  
exists on the CAD only version. Commands sent from the host  
computer are in En ca d RTL format.  
Drivers are supplied to support Windows-based PC’s (3.XX, 95, and  
NT) as well as Macintosh and Power PC computers.  
These printers expand upon ENCAD’s tradition of delivering fast,  
high-quality color or monochrome graphics for a variety of applica-  
tions. ENCAD has made significant advances in designing these  
17  
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Croma24 Service Manual  
plotters to respond to and anticipate our customers’ needs. Principal  
features are summarized below.  
Three Versions: CAD, GA (Graphic Arts), GA & CAD  
ENCAD’s software RIP supplied with the GA (Graphic Arts) version  
Remotely Configured via Host Computer  
25" (63.6 cm) Maximum Media Width  
600 x 600 dpi (mono) addressable  
300 x 300 dpi (color)  
Overview  
Printers draw according to instructions issued from a “host” com-  
puter. Every printer is engineered to understand a specific set of  
instructions and to execute each instruction in a precise manner.  
In addition, most printers are designed to execute predetermined  
characters automatically without a specific line-by-line instruction  
from the program. These characters are part of the printer’s  
permanent memory.  
Rela ted P u blica tion s  
The following publication contains additional information which may  
be useful in servicing the ENCAD, In c. Cr om a 24 Color Inkjet  
Printers:  
•
ENCAD, In c. Cr om a 24 User Guide, P/N 207103  
Copies of this and other ENCAD, In c. publications may be obtained  
by contacting your nearest authorized ENCAD, In c. dealer or by  
contacting ENCAD’s Technical Support and Service Department.  
Electrostatic Discharge (ESD) Sensitivity  
All PCBs (Printed Circuit Boards) associated with the Cr om a 24  
printers have components sensitive to ESD (electrostatic dis-  
charge). Care must be taken to avoid damage to any of the compo-  
nents by following current ESD handling procedures and practices.  
Always use an approved ESD grounding strap when handling or  
working with PCBs.  
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General Description  
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Warnings, Cautions, and Notes  
Warnings, cautions, and notes are used when additional informa-  
tion, instructions, or care should be observed. In this manual,  
warnings cautions, and notes precede the text to which each ap-  
plies. The definition of each is provided below.  
WARNINGS - Warnings are used to stress that the following steps  
or procedure has the potential to cause serious harm or death to  
service personnel. Extreme care should be observed when following  
the procedures and to exercise standard safety procedures. They  
are indicated by:  
Followed by a paragraph describing the concern.  
CAUTION - Cautions depict that the following steps or procedures  
can cause damage to the equipment if not properly followed. Ex-  
treme care should be observed when following the procedures and  
to exercise standard safety procedures. They are indicated by:  
Followed by a paragraph describing the concern.  
NOTE - Notes are placed before a procedure to inform the service  
personnel of specific details to improve quality, to give reminders of  
interrelated parts, and to provide other helpful information. They  
are indicated by:  
NOTE  
Followed by a paragraph describing the concern.  
General Description  
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Printer Specifications  
The specifications and performance characteristics of the Cr om a 24  
Color Inkjet Printers are as follows:  
Ma x P r in tin g Ar ea :  
Accu r a cy:  
0.2% line length (with  
ROLL mode off)  
Norm  
23.8”  
60.9cm  
62.9cm  
Extend 24.6”  
La n gu a ge Em u la tion :  
In t er fa ce:  
ENCAD RTL  
Centronics parallel  
RS-422 serial  
Bu ffe r :  
(GA and GA/CAD  
versions only)  
E n vir on m en t :  
Operating:  
2 MB permanently  
installed  
(not upgradable)  
41° to 104° F  
P ow er R eq u ir em en t s:  
Input Voltage:  
90 - 246 VAC  
(5° to 40° C)  
10% to 70% RH  
non-condensing  
47 - 63 Hz  
Storage:  
Output Power:  
24 W typical  
-40° to 140° F  
(-40° to 60° C)  
5% to 80% RH  
non-condensing  
63 W maximum  
Ba u d Ra tes:  
38400  
Dim en sion s:  
1MByte High Speed  
Serial (MAC only)  
Height 12” (305mm)  
Width 43.5”(1105mm)  
Depth 14” (356mm)  
R esolu t ion :  
Mono 600x600 dpi  
addressable  
Color 300x300 dpi  
20  
General Description  
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Contents of this Service Manual  
Figures are used in this manual to clarify procedures. They are  
for illustrative purposes only and may not necessarily be drawn to  
scale.  
Material in this manual may be repeated in various sections so  
that each section can “stand alone”. This allows information to be  
located without having to refer back and forth between sections.  
Figures and tables are easily located and cross-referenced, and are  
listed in the front of the manual under List of Illustrations and  
List of Tables.  
This manual is divided into six chapters as:  
Chapter 1 GENERAL DESCRIPTION - Contains a general  
description of the ENCAD Cr om a 24 printer. This  
includes printer specifications, and related materials.  
Also included is a description of the use of Warnings,  
Cautions and Notes as used in this manual and chapter  
contents.  
Chapter 2 THEORY OF OPERATION - Functional  
descriptions of the overall printer and major assemblies  
are contained in this chapter.  
Chapter 3 MAINTENANCE - This chapter covers the  
scheduled maintenance, cleaning procedures and  
alignment/adjustments recommended to perform on the  
printers. Diagnostics and a signal flow diagram are also  
listed.  
General Description  
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Chapter 4 TROUBLESHOOTING - A table containing  
problems that could occur and possible causes and repairs  
is found in this chapter. This table is not intended to be a  
complete listing of troubleshooting procedures. It will  
isolate the problem down to the lowest replacable  
assembly. If the problem happens to be the wiring  
between assemblies, standard troubleshooting techniques  
will have to be implemented to correct the problem.  
Chapter 5 ASSEMBLY/DISASSEMBLY - Contains detailed  
procedures to remove and replace printer parts and  
assemblies.  
Chapter 6 PARTS LIST - Contains a complete listing of all  
field replacable parts and assemblies for the Cr om a 24  
Color Inkjet Printer. Illustrated parts breakdown  
drawings are included to help clarify and identify parts for  
ordering. Special kits and adjustment jigs may be  
required.  
ORIENTATION - Instructions in this manual are based on the  
assumption that the service person is facing the front of the  
printer. References to top view, back view, and so forth are consis-  
tent with this engineering standard. References to the X Axis and  
Y Axis (Paper Axis and Carrier Axis, respectively) follow the stan-  
dard of Au toCAD™ absolute coordinates: up and down for X, left  
to right for Y.  
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General Description  
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Croma24 Service Manual  
Technical Support  
ENCAD offers full technical support and service for its various  
products. If you are unable to find the answer to your question in  
either the User’s Guide, Service Manual, or other related publica-  
tions, check out ENCAD’s Technical Bulletins located on  
ENCAD’s bulletin board or the Internet:  
ENCAD BBS:  
(619) 452-2653 or  
(619) 452-3768  
ENCAD Web sit e:  
http://www.encad.com  
Additional information is available though our Technical Support  
and Service Department’s Help Desk.  
ENCAD, In c.  
Technical Support & Service Dept.  
6059 Cornerstone Court West  
San Diego, CA 92121  
Help Desk Telep h on e:  
Help Desk F AX:  
(619) 452-4350  
(619) 546-0659  
International Users contact your local ENCAD service provider.  
see details on your ENCAD registration card.  
General Description  
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This Page Intentionally Left Blank  
24  
General Description  
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2
Theory of Operation  
In tr od u ction  
This chapter explains the mechanical and electrical theory of opera-  
tion of the ENCAD Cr om a 24 D-Size Color Inkjet printer.  
The Cr om a 24 is a MC68322 microprocessor-based digital printer  
that receives plotting instructions from a host computer through  
either the RS-422 serial interface or the Centronics parallel inter-  
face.  
Cr om a 24 P r in ter Gen er a l Block Dia gr a m  
Figure 2-1 illustrates the major functional areas of the printer.  
The Croma24 printer consists of two mechanical drives:  
1. Paper (Media) Axis Drive  
2. Carrier Axis Drive  
and three main electrical assemblies:  
1. MPCB (Main Printed Circuit Board)  
2. Carrier Assembly  
3. Power Supply  
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F igu r e 2-1. Gen er a l Block Dia gr a m .  
26  
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P a p er (Med ia ) Axis Dr ive  
F igu r e 2-2. P a p er (Med ia ) Axis Dr ive.  
The Paper (Media) Axis Drive moves the plotting media in a direc-  
tion perpendicular to the length of the printer. This friction drive  
utilizes a micro-step drive technology and consists of a stepper  
motor, reduction gears, lower drive shaft assembly, and pinch  
wheels. This can be seen in Figure 2-2.  
The micro-step technology associated with the stepper motor gives  
the capability of a resolution up to 600 dpi.  
The reduction gear meshes the stepper motor to the lower drive  
shaft assembly which allows the media to advance or retract.  
The purpose of the pinch wheels is to apply pressure to the media  
onto the drive shaft assembly to reduce the chance of slipping.  
Misaligned pinch wheels is the main cause of skewing of the media.  
Theory of Operation  
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Th e Ca r r ier Axis Dr ive  
F igu r e 2-3. Ca r r ier Axis Dr ive.  
The Carrier Axis Drive moves the printer’s carrier assembly along  
the length of the printer. The drive consists of a servo motor, linear  
encoder strip, drive belt, and tension assembly. These items are  
illustrated in Figure 2-3.  
The servo motor, drive belt, and tension assembly are the compo-  
nents that actually drive the carrier assembly. The servo motor  
drives the belt back and forth allowing the attached carrier assembly  
to be repositioned as required. The tension assembly is spring  
controlled and allows the proper amount of tension on the belt.  
The linear optical encoder strip is used to obtain the printers accu-  
racy along the axis of the printer. It is made with 150 parallel lines  
per inch etched into it. By utilizing two optical encoder sensors that  
are slightly off set from each other, and reading the leading and  
trailing edges of the lines, a resolution of 600 dpi can be obtained.  
The stepper and servo motors are controlled from the main printed  
circuit assembly by the microprocessor.  
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Ma in P r in ted Cir cu it Boa r d (MP CB)  
F igu r e 2-4. Ma in P r in ted Cir cu it Boa r d .  
The Main Printed Circuit Board (MPCB) consists of six functional  
areas:  
1. Microprocessor (CPU)  
2. Gate Array  
3. Memory Circuits  
4. Stepper Motor Controller  
5. Servo Motor Controller  
6. Interface Circuits: Serial & Parallel  
Theory of Operation  
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Micr op r ocessor  
The microprocessor (a Motorola MC68322) is the central processor  
unit which supervises system functions, executes the printer firm-  
ware, manipulates data, and controls input/output data busses. It  
has a built-in parallel port, a two channel DMA (Direct Memory  
Access) controller, timer module, clock generator, and an on-board  
chip select generator. One DMA channel supplies data to the gate  
array for jet firing; the other DMA channel is used to receive data  
through the serial port via the gate array, or the serial port when  
using a high speed serial mode. One timer generates a servo inter-  
rupt every millisecond.  
The microprocessor halves the 40MHz crystal reference (X1) signal  
to create the 20MHz system clock that is used for timing of all  
internal circuitry.  
The chip select generator is programmed to generate chip selects at  
the appropriate addresses, with the appropriate data size (byte,  
word) and with the appropriate number of wait states.  
Ga te Ar r a y  
F igu r e 2-5. Ga te Ar r a y.  
30  
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The gate array contains the hardware logic for dot firing, monitor-  
ing changes in the Carrier Assembly position, controlling DMA for  
the serial port, and generating the PWM (Pulse Width Modulation)  
waveforms for the servo controller.  
The gate array is a Xilinx device. It is a static RAM-based field  
programmable gate array. This means that the logic that it imple-  
ments is determined by configuration information in internal RAM  
storage. Each time power is turned on, this information must be  
downloaded from the system ROM. This type of gate array allows  
for the flexibility of upgrading the logic by simply downloading the  
new system software.  
Mem or y Cir cu its  
Memory is used to retain large amounts of information. This  
information is stored in the device memory in the form of binary  
bits.  
Printer memory consists of Flash EEPROM, DRAM, and  
EEPROM.  
Maximum installable memory is as follows:  
DRAM = 2 MB  
Flash EEPROM = 1 MB  
Serial EEPROM = 1 KB  
F la sh EEP ROM  
Flash EEPROM is Electrically Erasable, Programmable, Read Only  
Memory used to store instructions and data constants which the  
microprocessor can access and interpret. This set of instructions  
and data constants is called the “firmware” of the plotter.  
The term “Flash” means that bytes cannot be individually erased.  
A block or the whole device is erased at the same time and the  
block or whole device is then reprogrammed. It can be erased and  
reprogrammed more than 10,000 times.  
Theory of Operation  
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The system firmware is stored in Flash EEPROM and can be up-  
graded by opening the Control Panel located on the host computer.  
Once the Control Panel has been executed, it first starts an initial-  
ization and status communication sequence with the printer. The  
Control Panel requires ink levels and deadband information to load  
correctly. At the same time, it checks the version of firmware that is  
loaded on the printer.  
The flash EEPROM is a volitile memory in that it will lose updated  
information after a loss of power and revert back to the firmware  
that was initially installed at the factory. If the Control Panel  
contains a newer version of the firmware than the printer is cur-  
rently loaded with, it automatically updates the firmware at the  
startup of the Control Panel.  
DRAM  
DRAM is Dynamic Random Access Memory which provides tempo-  
rary storage of the microprocessor calculation and input/output data.  
It is also a faster type of memory then the Flash EEPROM. Thats  
why the printer control program is also copied from the Flash  
EEPROM to RAM, where it can be executed faster.  
The printer is supplied with 2 Megabytes of DRAM permanently  
installed on the Main PC Board. Memory expansion is not available  
for this printer. Since it only supports EN-RTL language, additional  
memory is not required or beneficial.  
Ser ia l EEP ROM  
Serial EEPROM is an Electrically Erasable, Programmable, Read  
Only Memory which provides storage for calibration constants and  
user configuration data entered from the host computer.  
A 1K bit serial nonvolatile EEPROM stores calibration and configu-  
ration information. It retains data while the unit is off.  
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Step p er Motor Con tr oller  
F igu r e 2-6. Step p er Motor Con tr oller .  
The media is driven by a Stepper Motor, which drives the media in  
a direction perpendicular to the length of the printer. The media  
in the printer can advance forward and backward, depending upon  
the commands which the Stepper Motor receives from the micro-  
processor.  
The Stepper Motor Controller contains two identical circuits, one  
for each winding of the stepper motor. The circuit is a combination  
of two simpler types of circuits and can be thought of as a variation  
of either one.  
A digital-to-analog (D/A) converter receives digital data from the  
CPU and generates a sine wave output. This signal is fed into a  
comparator circuit that measures the current through the winding  
of the stepper motor. If the current is too low, a pulse of 24 V is  
generated. When the current goes above the output of the wave-  
form generator, the pulse turns off. Every time the output of the  
waveform generator is changed by the microprocessor, the motor  
moves 1 “micro-step”.  
Each circuit contains four main blocks (see Figure 2-6):  
1. Reference waveform generator  
The microprocessor uses a D/A (digital to analog) converter to  
set the desired level for the current in the stepper motor  
winding. The output of the D/A converter varies in time to  
create a reference waveform. This reference waveform is  
centered around 10 V.  
Theory of Operation  
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2. Motor current sense  
The voltage across a series current sense resistor is measured  
and level shifted so that it is centered around 5 V.  
3. Comparator  
This portion divides the output of the reference waveform gen-  
erator by two and compares it to the output of the motor current  
sensor. Logic inside the gate array generates the control signals  
for the power driver that applies voltage across the motor wind-  
ing in order to make the actual current match the reference  
waveform.  
4. Power driver  
An H-bridge allows the supply voltage to be applied across the  
winding in either polarity to drive the current to the desired  
value.  
Ser vo Motor Con tr oller  
F igu r e 2-7. Ser vo Motor Con tr oller .  
The Carrier Assembly is driven by the Servo Motor. The speed of the  
Carrier Assembly is controlled by varying the duty cycle of the power  
applied to the controller. The microprocessor checks the position of  
the Carrier Assembly approximately 1,000 times per second (during  
the servo interrupt). It then updates the PWM (pulse width modula-  
34  
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tor) register in the gate array which sets the duty cycle to make  
adjustments to the Carrier Assembly speed. A linear optical encoder  
is used to monitor the Carrier Assembly position.  
The optical encoder strip runs the length of the Stabilizer Bracket  
and contains 150 lines and spaces per inch. Thus there are 300  
edges per inch. The detector circuit actually consists of two optical  
edge detectors. They are separated from each other by one half the  
width of one of the optical lines on the encoder strip. This allows 4  
evenly spaced pulses to be developed for each line on the encoder  
strip. This is known as quadrature signals. It gives an effective  
resolution of 600 lines per inch. See Figure 2-8 for a graphical  
representation of quadrature signals.  
F igu r e 2-8. Qu a d r a tu r e Sign a l Gen er a tion .  
Theory of Operation  
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The direction that the Carrier Assembly is moving is known based  
upon the state of one detector’s output and the direction of the  
transition of the other detector’s output.  
A hardware counter in the gate array increments as the Carrier  
Assembly moves left and decrements as the Carrier Assembly moves  
right. The hardware counter is only eight bits wide, so it cannot  
store a value large enough to represent an absolute Carrier Assembly  
position. Instead, it is read during the servo interrupt and its value  
compared with that from the previous interrupt. This difference is  
used to update the absolute position value in the software.  
In ter fa ce Cir cu its: Ser ia l & P a r a llel  
F igu r e 2-9. In ter fa ce Cir cu its.  
Data from the host computer is received either through the  
Centronics parallel port or the serial port (on the GA/CAD or GA  
versions only). The gate array provides the control signals for DMA  
transfers from the serial port to DRAM.  
The serial port is designed primarily to interface to a Macintosh  
printer port. It has an eight pin Mini-DIN connector. The data  
(TXD, RXD) signals meet RS-422 electrical specifications, and the  
control signal (DTRCLK) meets the RS-423 electrical specifications.  
The control signal can be configured as a 1 MHz clock for high speed  
serial communications with a Macintosh.  
The serial port is compatible with RS-422 devices when an appropri-  
ate adapter cable is used. This cable is available from ENCAD.  
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Ca r r ier Assem bly Cir cu its  
F igu r e 2-10. Ca r r ier Assem bly Cir cu its.  
The Carrier Assembly contains:  
1) Carrier PCB  
2) Optical Sensors  
3) Paper Sensor  
4) Inkjet Cartridges  
The Carrier PCB contains the logic and drive circuitry for the firing  
of the inkjet cartridges. It also establishes an interface path for the  
optical sensor and paper sensor to communicate with the MPCB.  
The optical sensors receive their inputs from the optical encoder strip  
and sends this data to the MPCB. The MPCB uses this information  
to determine the horizontal position of the carrier assembly so that  
accurate printing can be established.  
The paper sensor circuitry senses for the presence of loaded media.  
It does this automatically during the start-up and load sequences. It  
Theory of Operation  
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also constantly monitors the media during printing to determine if  
the media has run out.  
If no paper is sensed, the paper sensor sends this information to the  
MPCB, which immediately begins an ‘out of paper’ subroutine. This  
subroutine starts the LEDS on the printer to blink (green blinks slow  
while yellow blinks faster.) It also informs the host computer of the  
situation and stops the printer from printing until more media is  
loaded.  
The sensor also checks for the size of the media loaded so it can  
determine the proper printing parameters.  
P ow er Su p p ly  
An internal UL recognized switching power module supplies power  
for the Cr om a 24 printer. It provides a constant 5 VDC and 24 VDC  
output from input voltage in the range of 90-264 VAC. The 24 V  
supply is used for: the stepper controller (which advances the  
paper); the servo controller (which moves the Carrier); and power to  
fire the inkjets. The 5V supplies power to the logic circuits.  
The power supply is fused using a 2 A 250 V fast blow type fuse.  
The outputs share a common ground which is isolated from earth  
ground within the supply itself. Earth ground and DC ground are  
connected external to the power supply.  
The power supply will shut down under overload/short circuit condi-  
tions on any output over the full range of input voltage. Overvoltage  
protection is 20%-30% above nominal for the 5 V and 24 V outputs.  
System Gr ou n d in g  
Due to the amount of plastics used in the manufacturing of the  
printer, a system of grounding the metal assemblies to each other is  
required. If no common ground was in place, the potential of electric  
shock could exist due to static voltage buildup on the individual  
assemblies. The system grounding network ensures that all metallic  
assemblies have the same ground potential. Figures 2-11 and 2-12  
show how the ground straps are implemented on the printers.  
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F igu r e 2-11. Cr om a 24 System Gr ou n d Netw or k (Left Sid e).  
Theory of Operation  
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F igu r e 2-12. Cr om a 24 System Gr ou n d Netw or k (Righ t Sid e).  
F r on t Key Con tr ols  
The Control Panel (see Figure 2-13) is located on the lower right side  
of the printer and consists of five controls and two LED indicators.  
The controls are (from left to right): Backward, Load, Forward, Cut,  
and Power. Table 2-1 lists all possible indications allowed using the  
LEDs and the conditions that generated that indication.  
F igu r e 2-13. F r on t Key Con tr ols.  
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Ta ble 2-1. F r on t Key Con tr ol LED Cod es.  
Theory of Operation  
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Maintenance  
3
Introduction  
This chapter contains general maintenance and cleaning instruc-  
tions for the Cr om a 24 printer.  
Scheduled Maintenance  
Scheduled maintenance consists of a list of checks that are planned  
to be performed on a regular basis or when conditions warrant it.  
Scheduled maintenance can be thought of as preventive mainte-  
nance since its purpose is to prolong the life of the printer. It is not  
intended to repair or isolate an existing problem, though it can  
sometimes be helpful in detecting a condition due to a weakened  
component that has not yet completely failed.  
Below is a list of scheduled maintenance checks and their periodic-  
ity.  
Clean external areas:  
weekly, or  
as required  
monthly  
Clean slide shaft:  
Clean service station:  
Clean encoder strip:  
Clean cartridge dimples:  
Clean flex cable contacts:  
biweekly  
monthly  
if prime fails  
if prime fails,  
or cartridge  
is replaced  
annually  
Clean and inspect motor gears:  
Clean and inspect MPCB:  
annually  
Clean and inspect carrier assembly:  
Reseat connectors on MPCB:  
Reseat connectors on carrier board:  
Replace carrier bushings:  
annually  
annually  
annually  
biannually  
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Clea n in g P r oced u r es  
Always turn the printer OFF, remove the power cord  
and the interface cable before cleaning the printer. An  
electrical shock hazard may be present if these proce-  
dures are not followed.  
Exter n a l Clea n in g  
Do not use abrasive cleansers of any sort on the sur-  
faces of the printer. Damage to the surface may result.  
The exterior surfaces of the printer may be cleaned with a soft cloth  
which has been dampened. For more persistent stains, a small  
amount of liquid detergent may be used. Cleaning intervals are  
determined by the environment in which the printer is used.  
Slid e Sh a ft Clea n in g  
Use only isopropyl alcohol on the slide shaft of the  
printer. Damage to the stainless steel slide shaft may  
result if cleaned with water and not completely dried  
off.  
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Maintenance  
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Printer problems can be caused by an accumulation of dirt or other  
contamination on the slide shaft. This contamination may lead to  
drag on the carrier. Extreme drag results in a “carrier axis failure”  
fault and will stop the carrier motion. These problems may be  
eliminated by maintaining and cleaning the slide shaft at intervals  
determined by the environmental conditions. Do n ot u se a n y  
lu b r ica t ion .  
To clean the slide shaft:  
1. Remove the power cord.  
2. Raise the middle cover.  
3. Moisten a clean cloth or paper wipe with isopropyl alcohol.  
4. Wipe the length of the slide shaft with the moistened cloth  
or wipe.  
5. Manually move the carrier assembly from side to side.  
6. Wipe the shaft again to remove any deposits left from the  
carrier.  
7. Lower the cover and reconnect the power cord, perform the  
PRIME plot. Be sure that the carrier moves freely over the  
slide shaft.  
Ser vice Sta tion Clea n in g  
Ink and dust may build up on the service station, resulting in  
contamination which may smear the prints. The service station is  
cleaned as follows:  
1. Disconnect the power cord and interface cable.  
2. Raise the middle cover.  
3. Carefully move the carrier toward the center of the printer.  
Maintenance  
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4. Using a cotton swab dampened with distilled water, wipe the  
seals and the rubber wiper in the service station until no  
more ink residue or dust can be removed.  
5. With a dry swab, wipe all moisture from the seals and  
wipers.  
6. Close the cover and reconnect the power cord and interface  
cable.  
Lin ea r En cod er Str ip Clea n in g  
Clean the linear encoder strip monthly, or as necessary, to remove  
any buildup of debris. Distilled water or isopropyl alcohol may be  
used. You may notice that it tends to fog the encoder strip; however,  
no detrimental effect has been observed in the field.  
To clean the Encoder Strip:  
1. Disconnect the power cord and interface cable.  
2. Slightly dampen a cotton swab with distilled water or  
isopropyl alcohol and wipe along the length of the encoder  
strip on both sides.  
3. Reconnect the power cord and interface cable.  
F igu r e 3-1. En cod er Str ip Clea n in g.  
46  
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Ca r tr id ge Dim p le Clea n in g  
F igu r e 3-2. Ca r tr id ge Dim p le Region .  
The cartridge dimple area can easily be contaminated by oils and  
dirt on fingers and hands or ink spilled onto them. This causes the  
cartridges to not receive some of the electrical signals for a proper  
firing of the jets. This can be seen as a misfiring of the cartridge.  
NOTE  
Care should be used when handling the cartridges.  
Avoid touching the cartridges on the dimple area or  
on the inkjet holes on the bottom. The oils and dirt on  
fingers and hands can contaminate the area and re-  
sult in misfiring of the inkjets.  
Clean the cartridge dimple area by gently dabbing the area with a  
lint free cloth or cotton swab saturated with isopropyl alcohol.  
Maintenance  
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F lex Ca ble Con ta ct Clea n in g  
F igu r e 3-3. F lex Ca ble Con ta cts.  
Cleaning the flex cable contact area is very important due to the ease  
of which this area can become dirty. This also causes the cartridges  
to not receive all of the electrical signals for a proper firing of the  
jets. This can be seen as a misfiring of the cartridge.  
NOTE  
Care should be used when handling the flex cable con-  
tact area. Avoid touching the contact area because the  
oils on your skin can contaminate the area and result  
in misfiring of the inkjets.  
Clean the flex cable contacts by gently dabbing the area with a  
cotton swab soaked with isopropyl alcohol.  
Clea n a n d In sp ect Step p er Motor Gea r s  
The stepper motor gears can become dirty and after time if not  
cleaned, could cause wide banding in the print or paper skewing.  
This will reduce the quality of the intended output. Clean the motor  
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Maintenance  
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gears with a stiff brush to knock off any debris. A cotton swab  
soaked with isopropyl alcohol can be used to remove any ink that  
may have accumulated on the gears.  
Clea n a n d In sp ect MP CB  
Foreign material on the MPCB could short out electrical signals  
being developed on the MPCB and cause erroneous prints or even  
damage to the MPCB. All electrical circuits should be free of foreign  
material, especially those with conductive properties.  
Clean the MPCB by blowing the objects away or gently brush them  
aside with a soft brush if required.  
Inspect the MPCB for any damage to the board, connections, or any  
of the components on the board. Replace board if inspection reveals  
any damage or flaws that could effect the function of the MPCB.  
Clea n a n d In sp ect Ca r r ier Assem bly  
Foreign material on the carrier assembly could short out signals  
being developed on the carrier assembly and cause erroneous prints  
or even damage to the carrier assembly. A very common problem is  
where ink has been spilled onto the carrier assembly. All electrical  
circuits should be free of foreign material, especially those with  
conductive properties.  
Clean the carrier assembly by blowing the objects away or gently  
brush them aside with a soft brush if required. Be careful not to let  
anything to fall into the printer as you clean or it could cause a new  
problem later.  
Inspect the carrier assembly for any damage to the boards, connec-  
tions, or any of the components on the assembly.  
Maintenance  
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Resea t Con n ector s on MP CB a n d Ca r r ier Boa r d  
Integrated circuits may become weakened or damaged  
by electrical discharge. Do not touch or work near in-  
tegrated circuits without wearing an ESD wrist strap.  
Ribbon connectors can be easily damaged if incorrectly  
handled. Observe extreme caution when handling the  
ribbon connectors to avoid damage.  
Many problems can be corrected simply by removing and reseating  
connections found in circuit assemblies. This process helps to clean  
the contacts and can dissipate any static electrical charges that  
might have developed.  
F igu r e 3-4. MP CB Con n ection Loca tion s.  
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F igu r e 3-5. Ca r r ier P CB Con n ection Loca tion s.  
Figures 3-4 and 3-5 shows the locations of all the connectors on the  
MPCB and carrier board respectively. To remove the ribbon cables  
from their connectors, lift the connector’s ribbon locking mechanism  
as shown in Figure 3-6. To reattach, depress the locking mechanism  
back into the locking position after inserting the ribbon cable end.  
F igu r e 3-6. Ribbon Con n ector Lock in g Mech a n ism .  
Maintenance  
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Rep la ce Ca r r ier Bu sh in gs  
The carrier bushings are rated for approximately 1500 hours of  
operational usage. Given an average of about 3 hours a day of  
printing for 104 weeks, results in 1560 hours. Therefore, it is safe to  
approximate 1500 hours into 2 years of continuous service.  
If not replaced, the wear on the bushings can result in erratic carrier  
motion and/or carrier axis failures. It can even cause cartridge  
headheight to become uneven.  
To replace the carrier bushings, follow the Replacing the Carrier  
Bushing procedures in Chapter 5.  
Servo Motor Winding Resistance Check  
F igu r e 3-7. Ser vo Motor .  
1. Disconnect the servo motor connection from the MPCB.  
2. Using a standard ohmmeter or multimeter, connect the  
meter leads to the two wires going to the motor.  
3. While manually rotating the servo motor, monitor the  
readings on the meter. The acceptable range is 10-20 ohms.  
Typically, the reading is 12-16 ohms.  
5. If the measurement is found to be unsatisfactory, replace the  
servo motor.  
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Stepper Motor Winding Resistance Check  
F igu r e 3-8. Step p er Motor .  
1. Disconnect the stepper motor connection from the MPCB.  
2. Using a standard ohmmeter or multimeter, measure  
between pins 1 (yellow wire) and 3.  
3. The reading should indicate 7.2 - 8.0 ohms.  
4. Continue by measuring between pins 4 and 6.  
5. Reading should also indicate 7.2 - 8.0 ohms.  
6. If either measurement is out of tolerance, replace the  
stepper motor.  
Banding: Hardware vs Software  
The technician must be able to identify whether the banding that  
is being observed is related to either a hardware or a software  
problem. The two examples in Figure 3-9 represent classic types of  
hardware and software banding errors.  
Maintenance  
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F igu r e 3-9. Exa m p les of Ba n d in g.  
Hardware banding is usually characterized by consistent banding  
strips as shown. It signifies a slippage in the media’s normal move-  
ment that is possibly due to the stepper motor, lower drive shaft  
assembly, or the rollguides on the back of the printer. All these  
possible faulty areas deal with a rotational movement that, if faulty,  
will generate a consistent banding pattern. The MPCB and Carrier  
PCB can also cause this type of error to incur.  
Software banding is characterized by inconsistent banding lines.  
These banding lines are generated by the software when incorrectly  
interpreting the paper advancing/ink firing sequence of the expected  
print file. Because it is not directly tied to a mechanical movement,  
the bands become inconsistent in both frequency and duration. The  
possible causes are the printer driver, the original software package,  
or the RIP, if used. To eliminate the chance that it is the printer  
driver:  
1) Remove any RIP or network systems and connect the printer  
directly to the computer.  
2) Print a test file approved by ENCAD that uses only the  
printer driver software and the ENCAD printer.  
If the test file prints correctly, the problem lies in either the software  
package that generated the print or the RIP, if used.  
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Alignments/Adjustments  
The ENCAD Cr om a 24 printers are designed with a minimum of  
maintenance requirements in mind. Most of the adjustments are  
controlled and performed via software/firmware interaction that  
require you to run a subroutine and enter values on the computer.  
Programmed calibrations include: color calibration, deadband  
alignment, and X-axis calibration. The mechanical adjustment  
requirements include the pinch roller adjustments and the encoder  
strip height adjustments. No electrical alignments are required.  
Color Ca libr a tion  
This procedure describes how to check that the cartridges are  
properly aligned for color plotting & should be followed each time  
the ink cartridges are installed. Figure 3-10 is a representation of  
how a color calibration looks when printed.  
F igu r e 3-10. Color Ca libr a tion .  
Maintenance  
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The “Current Heads (Y, M, C)” view represents the alignment of the  
heads as they are currently entered. This is just an overview of all  
heads and how they are aligned. Do not attempt to align the heads  
using this view.  
The “Color Horizontal Head-to-Head Calibration” checks the align-  
ment of the nozzles horizontally and allows corrections when re-  
quired. J ust enter the value below the set of lines that are correctly  
aligned. Be careful that you are aligning the correct color by observ-  
ing the C (cyan), M (magenta), and Y (yellow) on the right side of the  
plot.  
The “Color Vertical Head-to-Head Calibration” checks the alignment  
of the nozzles vertically and allows corrections when required. J ust  
enter the value below the set of lines that are correctly aligned. Be  
careful that you are aligning the correct color by observing the C  
(cyan), M (magenta), and Y (yellow) on the right side of the plot.  
Dea d ba n d Align m en t  
Deadband calibration compensates for minute differences created  
when bidirectional printing is used. Unidirectional printing is not  
affected by deadband. There are four types of deadband tests: slow  
deadband, fast deadband, fast deadband; vertical lines (all), and fast  
deadband; vertical lines (one).  
F igu r e 3-11. Dea d ba n d Slow /F a st.  
Figure 3-11 shows what the display will look like when printing  
either the fast or slow test if it is out of alignment. A correctly  
aligned printer will appear as if there is only a series of vertical lines  
printed. No difference between the three segments of lines would be  
apparent.  
The SLOW DEADBAND calibration is a precision test that checks  
the firing time of the jets as related to the forward and reverse  
direction.  
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X-Axis Ca libr a tion  
The X-axis calibration procedure ensures that the processing that  
drives the stepper motor is correct to minimize line length accuracy  
errors.  
P in ch Roller Ad ju stm en t P r oced u r e  
The purpose of the Paper Skew Adjustment is to make certain that  
the Pinch Roller in the Upper Roller Support stays centered on its  
shaft and/or has a gap when the Lower Roller is rotated forward  
for approximately two full revolutions. In other words, the Pinch  
Roller should not drift rapidly to the left or to the right when the  
Lower Roller is rotated forward for two full revolutions. (Slow  
drifting is acceptable.)  
Use the torque screwdriver with the P0 bit to adjust the Pinch  
Roller mounting screws. The maximum torque requirement is  
1 in-lbs ± 0.5.  
F igu r e 3-12. Up p er Roller Su p p or t Descr ip tion .  
1. Figure 3-12 shows the Upper Roller Support and the  
mounting screws. Stand behind the printer in order to  
adjust the mounting screws on the Upper Roller Supports.  
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2. Become familiar with the actions and results shown in  
Table 3-1. Note that these actions are performed from  
behind the printer.  
Ta ble 3-1. P in ch Roller Ad ju stm en ts.  
ACTION  
RESULT  
1. Turn mounting screw  
counterclockwise (ccw).  
1. Screw is loosened.  
2. Turn mounting screw  
clockwise (cw).  
2. Screw is tightened.  
3. Loosen left mounting screw  
(turn ccw).  
3. Roller moves to the right.  
4. Roller moves to the left.  
5. Roller moves to the left.  
6. Roller moves to the right.  
4. Tighten left monting screw  
(turn cw).  
5. Loosen right mounting screw  
(turn ccw).  
6. Tighten right mounting screw  
(cw).  
7. Not maintaining downward  
pressure (towards the floor) on  
the head of each mounting screw  
7. The upper roller support  
will not be perfectly level and  
will not perform its function  
at the same time as you loosen or properly.  
tighten the screw.  
Each mounting screw must be  
completely at the bottom  
edge of its hole in the back  
of the C-bracket as you  
loosen or tighten the screw.  
See Figure 3-13.  
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F igu r e 3-13. Up p er Roller Mou n tin g.  
3. If you loosen one of the mounting screws and the roller  
moves in one direction, and you need to move the roller in  
the opposite direction, tighten the screw that was loosened  
to its maximum torque (1 in.-Lbs. ± 0.5) BEFORE loosening  
the other screw to move the roller in the opposite direction.  
NEVER LOOSEN OR TIGHTEN BOTH MOUNTING  
SCREWS AT THE SAME TIME ON THE SAME UPPER  
ROLLER SUPPORT.  
4. Following all of the above information precisely will ensure  
that the Upper Roller Support springs are deflected and the  
lower tail of the springs will always be pressed against the  
C-bracket’s vertical wall (without a gap) as shown in  
Figure  
3-13.  
F igu r e 3-14. Ga p of P in ch Roller .  
Maintenance  
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F igu r e 3-15. Up p er Roller Ad ju stm en t.  
Figure 3-15 shows how the motion (rapid drifting to the right or to  
the left) of the roller determines which mounting screw should be  
tightened in order to eliminate the motion of the roller so that the  
roller stays in the center of the shaft and/or there is a gap when the  
Lower Roller is rotated forward.  
Hea d Heigh t Align m en t P r oced u r e  
Perform this procedure only when the encoder strip stabilizer has  
been removed from the C-Bracket or whenever the alignment is in  
question. The head height alignment procedure is to ensure that a  
0.065” +/- 0.003” difference exists between the cartridge jet plate and  
the Platen. See Figure 3-16.  
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F igu r e 3-16. Ca r r ier Hea d Heigh t Toler a n ce.  
1. Remove the lid and the right cover of the printer. See  
Chapter 5 for procedures.  
2. Obtain the 3 tools (Micrometer Dial Gauge, Test Cartridge,  
and Measuring Tip Extender) from the Height Gauge Kit.  
Assemble the tools as shown in Figure 3-17.  
F igu r e 3-17. Settin g Up Tools fr om Heigh t Ga u ge Kit.  
Maintenance  
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3. Place the test cartridge upright on a flat surface and ‘zero’  
the gauge by loosening the knob near the top and turning the  
dial until the needle is at the ‘0’ position on the dial. Tighten  
the knob. See Figure 3-18.  
F igu r e 3-18. Zer oin g th e Micr om eter Ga u ge.  
4. Remove the Cyan ink cartridge. Snap the test cartridge with  
the micrometer gauge into the position vacated by the Cyan  
ink cartridge. See Figure 3-19. Ensure that the micrometer  
can be read from the BACK of the printer.  
F igu r e 3-19. Test Ca r tr id ge In sta lled .  
5. Remove the trailing cable assembly.  
6. Loosen the three screws located on the back of the C-bracket  
that secures the stabilizer to the C-bracket.  
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Damage may occur to the micrometer  
gauge if the Carrier is moved without  
lifting up on the measuring tip. This  
action could also take the micrometer  
out of alignment and foul the results of  
the alignment.  
7. While lifting up the measuring tip of the micrometer, slide  
the Carrier to the center of the stabilizer as shown in Figure  
3-20. Position it as close to the screw as possible and drop the  
measuring tip onto the platen. Do this a couple of times to  
ensure an accurate reading.  
F igu r e 3-20. Ca r r ier P osition s for Hea d Heigh t Ad ju stm en t.  
8. Move the left and right ends of the stabilizer bracket until a  
reading of 0.075 +/- 0.003” is observed. Read only the RED  
numbers on the micrometer gauge. The measurement of  
0.075 +/-0.003” is used because the test cartridge being used  
does not have a print head attached. A 0.010” difference had  
to be added to compensate for the lack of a print head.  
9. Tighten the screw on the center of the stabilizer.  
Maintenance  
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10. While lifting up the measuring tip of the micrometer, slide  
the Carrier to the left of the stabilizer as shown in Figure 3-  
20. Position it as close to the screw as possible and drop the  
measuring tip onto the platen. Do this a couple of times to  
ensure an accurate reading.  
11. Move the left end of the stabilizer bracket until a reading of  
0.075” +/- 0.003” is observed. Read only the RED numbers on  
the micrometer gauge.  
12. Tighten the screw on the left end of the stabilizer.  
13. While lifting up the measuring tip of the micrometer, slide  
the Carrier to the right of the stabilizer as shown in Figure 3-  
20. Position it as close to the screw as possible and drop the  
measuring tip onto the platen. Do this a couple of times to  
ensure an accurate reading.  
14. Move the right end of the stabilizer bracket until a reading of  
0.075” +/- 0.003” is observed. Read only the RED numbers on  
the micrometer gauge.  
15. Tighten the screw on the right end of the stabilizer.  
16. Repeat these steps as many times as necessary to ensure an  
accurate alignment.  
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Croma24 Control Panel  
During the installation procedures for the Cr om a 24 , a software  
Control Panel for this printer is installed onto the computer. This  
control panel provides a means to monitor and adjust certain vari-  
ables utilized by the printer. These variables include:  
ink levels in the cartridges  
color calibration adjustments  
Other items that can be accomplished at the control panel are:  
media movement (forward/backward)  
media standard selections  
cutting the media  
priming the cartridges  
access cartridge (moves the Carrier to the middle of the Platen  
for changing cartridges, etc.)  
The printer control panel also has a hidden maintenance menu that  
has been developed with subroutines to aide the technician in  
troubleshooting and to assure the quality of the printed output  
products.  
All menus depicted in this section have been derived from the Win-  
dows95™ Control Panel version. Other versions of the Control Panel  
may look slightly different but have the same functionality.  
The maintenance subroutines are hidden and should be performed  
by competent technicians only. To make the Maintenance Menu  
appear:  
1. Open (or execute) the Croma24’s Control Panel program.  
2. At the “About Croma24” menu, simultaneously type ‘S’ while  
holding down the ‘Alt’ key.  
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This brings up the Maintenance Menu as seen in Figure 3-21.  
F igu r e 3-21. Ma in ten a n ce Men u .  
Figure 3-21 shows that the Maintenance Menu for the Cr om a 24 is  
divided into 3 submenus:  
Manufacturing  
Diagnostics  
Service Options  
Ma n u fa ctu r in g Men u  
F igu r e 3-22. Ma n u fa ctu r in g Men u .  
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The Manufacturing Submenu (Figure 3-22) consists of two proce-  
dures:  
Print Quality Test  
Deadband  
The procedures are primarily used in the manufacturing process  
and is adjusted correctly before it leaves the plant. They are also  
available to the field technician in case such adjustments are  
required to be performed again.  
P r in t Qu a lity Test  
The Print Quality Test prints an imbedded 24” RTL graphic that  
allows the technician to get a general idea how well the printer is  
operating. The graphic depicts a series of triangles of different  
colors. This test is primarily used to identify if banding is present.  
Dea d ba n d  
F igu r e 3-23. Dea d ba n d Op tion s Men u .  
The Deadband calibration (Figure 3-23) consists of four tests:  
Slow Deadband Test  
Fast Deadband Test  
Single Line Test  
All Line Test  
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F igu r e 3-24. Dea d ba n d Slow /F a st Disp la y.  
Figure 3-24 shows what the display will look like when printing  
either the fast or slow test if it is out of alignment. A correctly  
aligned printer will appear as if there is only a series of vertical lines  
printed. No differences will be apparent between the segments in  
each set of lines .  
The SLOW DEADBAND calibration is a precision test that checks  
the firing time of the jets as related to the forward and reverse  
direction.  
Allowable values for the Slow Deadband is -1, 0 and 1, and from 0 to  
164 in increments of one for the Fast Deadband.  
The Single Line Test and All Line Test are variations of the Slow and  
Fast Tests except they print longer lines so that long time integra-  
tion of the deadband calibration can be observed. The Single Line  
Test prints only one line at a time while the All Line Test prints all  
lines at the same time.  
Dia gn ostics Men u  
F igu r e 3-25. Dia gn ostics Men u .  
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The Diagnostics Menu as seen in Figure 3-25 consists of eight  
tests:  
Paper Sensor Test  
Fan Test  
Carrier Vibration Test  
Color Test  
Keypad Test  
LED Test  
Servo Motor Test  
Paper Motor Test  
P a p er Sen sor Test  
The Paper Sensor Test checks the operation of the optical paper  
sensor. Once activated, a pop-up dialog box (Figure 3-26) appears  
that displays the widthof the media loaded in inches, centimeters,  
and millimeters.  
F igu r e 3-26. P a p er Sen sor Rep or ted Da ta Dia log Box.  
F a n Test  
F igu r e 3-27. F a n Test Men u P a n els.  
The Fan Test toggles the fan on and off each time the control  
button is activated.  
Maintenance  
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Ca r r ia ge Vibr a tion Test  
The Carriage Vibration Test prints 5 sets of 3 parallel lines to test  
the vibration characteristics of the carrier assembly.  
Color Test  
F igu r e 3-28. Color Test.  
The Color Test prints a 1 inch swath of each color (total of 4) to test  
for banding. The test is selectable in the amount of ink that is  
printed to 10%, 25%, 35%, 50%, 65%, 75%, or 100%.  
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Keyp a d Test  
F igu r e 3-29. Keyp a d Test.  
The Keypad Test checks the keypads on the MPCB. The keypads  
are the microswitches that are activated whenever one of the tabs  
on the actuator is depressed.  
Each time a switch is activated and hold for a few seconds, a LED  
(or both LEDs) becomes illuminated. The indications to be observed  
is listed in Table 3-2.  
Ta ble 3-2. Keyp a d Test In d ica tion s.  
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The test is selectable in duration. The available time selections are:  
5, 10, 20, 30, 40, 50, 60, 90, 120, 180, 240, or 300 seconds, 10 or 30  
minutes, or 1 hour.  
LED Test  
F igu r e 3-30. LED Test.  
The LED Test lights both LEDs on the printer. The test is selectable  
in duration. The available time selections are: 5, 10, 20, 30, 40, 50,  
60, 90, 120, 180, 240, or 300 seconds, 10 or 30 minutes, or 1 hour.  
Ser vo Motor Test  
F igu r e 3-31. Ser vo Motor Test.  
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The Servo Motor Test tests the servo motor by moving the carrier  
back and forth across the slide shaft. Speed is selectable to either  
slow or fast. The number of cycles the carrier does is selectable  
between 0 and 10,000 cycles.  
P a p er Motor Test  
F igu r e 3-32. P a p er Motor Test.  
The Paper Motor Test tests the stepper (media) motor by moving  
the paper forward by a selected number of steps. The number of  
steps is selectable between 0 and 300 steps. At 0 steps, the media  
will not advance at all.  
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Ser vice Men u  
F igu r e 3-33. Ser vice Men u .  
The Service Menu consists of ROM Information.  
F igu r e 3-34. ROM In fo.  
The ROM Info screen displays the current firmware version, and  
date and time of development. This information helps the technician  
by providing a means of identifying the firmware loaded on the  
printer.  
Additional information can be obtained by revealing the Service  
Special Information Menu as shown in Figure 3-35. To display the  
Service Special Information Menu, at the Maintenance Menu,  
simultaneously type ‘S’ while holding down the ‘Alt’ key and then  
type in “bali.”  
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F igu r e 3-35. Ser vice Sp ecia l In for m a tion .  
The Service Special Information Menu displays information about  
the printers plot and ON time (in seconds) as well as the Maximum  
PWM/Position and Carriage Shut Down Position.  
Built In Test (BIT)  
The Croma24 printer has a built in test mode which is used as an  
additional tool for the technician in troubleshooting. The BIT mode  
is a way of checking the performance of the printer while removing  
any interferance or conditions that may be caused by the computer  
or network. It is considered as a stand-alone test.  
To perform the BIT test, a loopback cable is required and needs to be  
installed into the I/O ports before powering up the printer. If the  
printer is a GA or GA & CAD version, insert both the parallel and  
serial ends of the loopback cable before powering up.  
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To enter the BIT mode, apply power to the printer while simulta-  
neously depressing the ‘soft on’ button. Continue to hold onto the  
‘soft on’ button until the carrier assembly has traveled halfway  
across the length of the platen. Release the ‘soft on’ button.  
The printer will go through its normal start-up routine. Once the  
start-up routine is completed, it will perform and print out a series of  
tests. First thing it will do is prime the cartridges.  
The prime is followed by a serial port test (GA or GA & CAD ver-  
sions). The loopback cable is required to pass this test.  
Then it will print a fast deadband display and a color calibration  
display.  
It will then test the parallel port test. The loopback cable is required  
to pass this test.  
After completing the parallel port test, the BIT test begins again  
with a prime. It will continue to perform the BIT test until the BIT  
mode is exited. To exit the BIT mode, turn the printer off and on  
again in the normal power-up mode.  
The deadband and color calibration displays are for visual inspection  
of the condition of the printer only, no adjustments can be performed  
while in the BIT mode.  
Firmware/Software Upgrades  
The Croma24 Control Panel, Printer Driver, and embedded firmware  
are all upgraded onto the computer at the same time by installing  
the latest Croma24 software bundle. The latest version can be found  
on ENCAD’s bbs or website, the phone numbers are located in  
Chapter One.  
The installation procedure will upgrade the Control Panel and the  
Printer Driver simultaneously. Verify that the upgrade was success-  
ful by checking in the “about” panel in both the Control Panel and  
the Driver for version specs.  
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The latest firmware version was included and installed onto the  
computer during the installation process. To upgrade the firm-  
ware on the printer, open the Control Panel with the printer  
online. During the initial start up of the Control Panel, it commu-  
nicates with the printer’s firmware. The Control Panel is collect-  
ing information stored on the printer such as current ink levels  
and the firmware version. If the Control Panel finds an older  
version of firmware, it automatically installs the latest version  
that is stored on the computer.  
This communication between the Control Panel and the printer  
happens every time that the Control panel is opened.  
NOTE  
The printer’s firmware will revert back to version 1  
(the original version) if power is removed from the  
printer for any reason.  
To assure that the latest version is loaded onto the printer, it is a  
good practice to run a “Prime” every morning that the printer is to  
be used. This forces the user to open the Control Panel, which  
verifies that the latest version of firmware is loaded.  
It also helps the cartridges to purge any possible obtructions  
within the jets before clogging begins by firing all the jets for a  
period of time.  
Internal Cabling and Signal Flow Diagram  
Figure 3-36 is a schematic of the major components and the  
cabling associated between them. The diagram depicts component  
boards or assemblies, jack connections, cables, and signal flow. It  
is to be used by the technician as an additional aid in trouble-  
shooting and improve understanding of the printer theory of  
operation.  
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F igu r e 3-36. Sign a l Wir in g Dia gr a m .  
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Troubleshooting  
4
Introduction  
Chapter 4, Troubleshooting consists of a table that is intended to  
aide the technician in troubleshooting the Cr om a 24 printer. This  
table addresses symptoms with their possible causes and solutions.  
Basic troubleshooting skills will be required to perform the symptom  
identification, troubleshooting, fault isolation, and repair of the  
printer when using this table.  
Ensure that all applicable software diagnostic tests have been  
properly executed, all visual indications (including LED status) have  
been observed, and all applicable pushbuttons have been depressed  
to obtain a complete list of symptoms to be applied to the table below.  
Use the table in conjunction with Chapter 3, Maintenance, whenever  
the table prompts you for additional information. This information  
may be in the form of an illustration, additional data, or a procedure  
that needs to be performed.  
Table 4-1. Troubleshooting Table.  
Symptoms  
No P ow er  
Possible cause  
Solution  
• faulty power  
cord  
replace power cord  
• AC input not  
present at power  
supply  
replace AC entry  
module  
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Table 4-1. Troubleshooting Table (cont).  
Symptoms  
No Power (cont)  
Possible cause  
Solution  
• all DC output  
voltages not  
present (see  
Figure 3-18 for  
voltages)  
1) check fuse on  
power supply  
2) replace power  
supply  
• all DC voltages  
present at MPCB  
replace MPCB  
Med ia Does Not  
Move  
• perform Stepper replace stepper  
Motor Winding  
motor  
Resistance check  
• rough motion  
while spinning  
stepper motor  
bad bearings -  
replace stepper  
motor  
• pinch rollers  
not adjusted  
correctly  
adjust pinch rollers  
• paper sensor  
not responding  
replace paper  
sensor  
• media control  
switches on  
printer are  
Croma24 Control  
Panel corrupted -  
reinstall Control  
operating correctly Panel  
• bad MPCB replace MPCB  
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Table 4-1. Troubleshooting Table (cont).  
Symptoms  
Possible cause  
Solution  
Ca r r ier Axis  
F a ilu r e  
• dirty (or  
lubricated) slide  
shaft  
perform Slide Shaft  
Cleaning procedure  
• perform Servo  
Motor Winding  
Resistance check  
replace servo motor  
• check servo  
motor for smooth  
movement  
bad bearings -  
replace servo motor  
• obstruction in  
path of carrier  
(may or may not  
be visible)  
remove obstruction  
• dirty encoder  
strip  
perform Encoder  
Strip Cleaning  
procedure  
• damaged  
encoder strip  
replace encoder  
strip  
• bad encoder  
sensor  
replace encoder  
sensor  
• worn carrier  
bushings  
replace carrier  
bushings  
• loose trailing  
cable connections  
reseat trailing cable  
connections at the  
MPCB and the  
carrier assembly  
Troubleshooting  
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Table 4-1. Troubleshooting Table (cont).  
Symptoms  
Possible cause  
Solution  
Carrier Axis Failure • cutter assembly  
replace cutter  
assembly  
(cont)  
malfunction  
• damaged carrier 1) check idler/  
drive belt system  
tension assembly  
2) check carrier belt  
Does Not P r in t  
• bad connection  
reseat cable  
between computer connections on  
and printer  
computer and  
printer  
• firmware is  
corrupted  
refresh EEPROM  
firmware with new  
download  
• bad MPCB  
replace MPCB  
In k Ca r tr id ge  
Misfir in g  
• cartridge low on  
ink  
refill or replace  
cartridge  
• flex contacts  
dirty or damaged  
1) perform Flex  
Cable Contact  
Cleaning  
procedures  
2) replace carrier  
assembly  
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Table 4-1. Troubleshooting Table (cont).  
Symptoms  
Possible cause  
Solution  
Ink Cartridge  
• cartridge dimple 1) perform  
Misfiring (cont)  
area dirty or  
damaged  
Cartridge Dimple  
Cleaning procedure  
2) replace cartridge  
reseat cartridge  
• cartridge not  
seated correctly  
• bad cartridge  
replace cartridge  
• service station  
dirty or not  
properly sealing  
cartridge jet area  
1) perform Service  
Station Cleaning  
procedures  
2) replace seal on  
service station  
• bad carrier  
assembly  
replace carrier  
assembly  
• bad MPCB  
replace MPCB  
P a p er Sk ew in g  
• pinch rollers not perform Pinch  
aligned correctly  
Roller Adjustment  
Procedure  
• stepper motor  
gearing dirty or  
damaged  
perform Clean and  
Inspect Stepper  
Motor Gears  
procedure  
Troubleshooting  
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Table 4-1. Troubleshooting Table (cont).  
Symptoms  
P r in ter Ou tp u t is  
Possible cause  
Solution  
Ba n d in g  
• if banding is  
consistent  
1) inspect and/or  
replace stepper  
motor (perform  
Stepper Motor  
Winding Resistance  
Check )  
2) inspect and/or  
replace stepper  
motor gears and/or  
lower roller  
assembly  
3) replace MPCB  
replace or refill  
• check amount  
of ink in cartridges cartridges  
• cartridges need  
to be primed  
perform Prime  
• color calibration  
required  
perform Color  
Calibration  
• X-axis  
calibration  
required  
perform X-axis  
Calibration  
• cartridge dimple 1) perform  
area dirty or  
damaged  
Cartridge Dimple  
Cleaning procedure  
2) replace cartridge  
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Table 4-1. Troubleshooting Table (cont).  
Symptoms  
Possible cause  
Solution  
• flex cable  
contacts dirty or  
damaged  
1) perform Flex  
Cable Contact  
Cleaning  
2) replace carrier  
assembly  
• carrier belt is  
loose, too tight,  
worn, or damaged  
reinstall, check  
tension assembly,  
and/or replace belt  
• carrier bushings replace bushings  
worn or damaged  
F a n Does Not  
P ow er Up  
• MPCB has  
24 VDC at J 3  
pins 1-2  
1) reseat connection  
at MPCB to fan  
2) replace fan  
replace MPCB  
• power not being  
applied to fan  
Troubleshooting  
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Assembly\Disassembly  
5
Introduction  
Chapter 5 contains the procedures for removal and replacement of  
the Croma24 printer assemblies and mechanisms. Illustrations are  
provided for clarity. Steps for each replaceable part may depend  
on parts already removed in previous disassembly directions. It is  
recommended that you read through each procedure before begin-  
ning the removal and replacement of any assemblies or mecha-  
nisms.  
The following is a list of tools which are recommended to disassemble  
and reassemble the printer:  
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#1 Phillips Torque Screwdriver  
#2 Phillips Torque Screwdriver  
#1 Slotted Torque Screwdriver  
#2 Slotted Torque Screwdriver  
#1 Phillips Screwdriver  
#2 Phillips Screwdriver  
#1 Slotted Screwdriver  
#2 Slotted Screwdriver  
Torque Screwdriver, Allen Hex Driver (4mm)  
Torque Screwdriver, Socket Head (4mm)  
Wire Cutters  
Needle Nose Pliers  
X-ACTO Knife  
ESD Wrist Strap  
The following materials are also required:  
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Isopropyl Alcohol  
Cotton Swabs  
Lint Free Cloth or Tissue  
Double Sided Tape (1/16” thick, 3/4” wide)  
Loctite Blackmax, P/N 200172  
A Hardware Kit is available for the printers. See Chapter 6 of this  
manual for the part number.  
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Always turn the printer OFF, remove the power cord  
and the interface cable before beginning any disasembly  
procedures. An electrical shock hazard may be present  
if these precautions are not followed.  
Remove the Left, Middle (Lid), and Right Covers  
Removing the Left Cover allows immediate access to the left side of  
the Platen for removal of the Carrier Assembly, Carrier Drive Belt,  
Tension Assembly, and the Cutter Activator.  
Removing the Right Cover provides immediate access to the Main  
Printed Circuit Board (MPCB), Control Panel, Servo Motor, and the  
MPCB connections (to the Stepper and Servo Motors, Fan, Trailing  
Cable, and Power Supply.)  
The Middle Cover (Lid) needs to be removed before any of the  
other covers can be removed. It also gives access to the Carrier  
Assembly and the Service Station when in the open position.  
1. Remove Cover Retaining Clips (2) from the Middle (Lid) Cover.  
Insert a Needle Nose Pliers into the square openings near the  
back of the Lid and remove the Retaining Clip.  
2. Put the Middle Cover (Lid) in the open position by lifting the  
front of the Middle Cover to the full upward position.  
3. Remove the Middle Cover by pushing the Middle Cover  
backwards to disengage it from the Left Cover pin. Push back  
on the right side to disengage it from the Right Cover pin.  
4. Remove the Right Cover by using a flat head screwdriver to  
unhook the locking clasps located in Figure 5-1. All clasps can  
be accessed from under the Base. Carefully lift off the Cover.  
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F igu r e 5-1. Cover Rem ova l/In sta lla tion .  
5. Remove the Left Cover by using a flat head screwdriver to  
unhook the locking clasps located in Figure 5-1. All clasps but  
one can be accessed from under the Base. The clasp located  
near the AC input plug can be reached with a #1 flathead  
screwdriver inserted into the slot between the Base and the  
Cover above and to the left of the AC plug on the back of the  
printer. See insert on Figure 5-1. Carefully lift off the Cover.  
Install the Left, Middle, and Right Covers  
1. Align the locking mechanisms on the Left Cover with the holes  
in the Base. Carefully push the Cover down onto the Base until  
it locks into place.  
2. Align the locking mechanisms on the Right Cover with the holes  
in the Base. Carefully push the Cover down onto the Base until  
it locks into place.  
3. Reinsert the Middle Cover by pressing it back onto the left and  
right pins. Lower the Middle Cover into the ready position.  
4. Reinstall the Cover Retaining Clips (2) into the square openings  
in the Lid.  
Assembly\Disassembly  
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Remove the MPCB (Main Printed Circuit Board)  
and Actuator Assembly  
Integrated circuits may become weakened or damaged  
by electrical discharge. Do not touch or work near in-  
tegrated circuits without wearing an ESD wrist strap.  
1. Perform steps 1 through 4 of the Left, Middle, and Right Cover  
Removal procedures to remove the Middle and Right covers.  
2. Remove the three screws and washers securing the Actuator  
Assy and the MPCB.  
3. Lift out the Actuator Assy.  
4. Put on an ESD wrist strap.  
5. Disconnect the Trailing Cable connector at the J 6 location. Use  
the thumb and forefinger to pull up on the connector lock and  
remove the trailing cable from the connector.  
6. Disconnect the Fan connector (red and black wires) at the J 3  
location. Grasp the Fan connector with the thumb and  
forefinger and pull straight out.  
7. Disconnect the Stepper Motor connector at the J 7 location.  
Grasp the Stepper Motor connector with the thumb and  
forefinger and pull straight out.  
8. Disconnect the Power Supply connector at the J 5 location.  
Grasp the Power Supply connector with the thumb and  
forefinger and pull straight out.  
9. Disconnect the Servo Motor connector (red and blue wires) at  
the J 4 location. Grasp the Servo Motor connector with the  
thumb and forefinger and pull straight out.  
10. Remove the grounding strap for the Stepper Motor.  
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11. Using care, remove the MPCB by bringing it out the front of the  
printer.  
Failure to use an approved anti-static bag for storage  
or shipment may cause damage to the MPCB and af-  
fect the Warranty.  
12. Place the MPCB in an ESD bag (anti-static bag) in preparation  
for shipment to ENCAD for replacement or repair, or if it is to  
be stored at your facility for repair.  
Install the MPCB and Actuator Assembly  
Integrated circuits may become weakened or damaged  
by electrical discharge. Do not touch or work near in-  
tegrated circuits without wearing an ESD wrist strap.  
1. Put on an ESD wrist strap.  
2. Remove the MPCB from the ESD bag.  
3. Insert the MPCB through the area in the front of the printer.  
Align the MPCB so that the serial and parallel connections  
protrude out of the back of the printer and that the screw holes  
are aligned to the holes on the Base of the printer.  
4. Using a #2 Phillips Torque Screwdriver, fasten the Actuator  
Assy to the MPCB and the Base with 15 in-lb of torque.  
5. Attach the grounding strap for the Stepper Motor.  
Assembly\Disassembly  
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6. Connect the Servo Motor connector to J 4 on the MPCB.  
7. Connect the Power Supply connector to J 5 on the MPCB.  
8. Connect the Stepper Motor connector to J 7 on the MPCB.  
9. Connect the Fan connector to J 3 on the MPCB.  
10. Connect and lock the Trailing Cable connector to J 6 on the  
MPCB.  
11. Reinstall the Middle and Right Covers by performing steps 2  
through 4 of the Reinstall the Left, Middle, and Right Covers  
procedure.  
Remove Servo Motor  
1. Perform the Left, Middle, and Right Cover Removal procedures  
to remove the Left, Middle and Right Covers.  
2. Disconnect the Servo Motor connector (red and blue wires) at  
the J 4 location on the MPCB.  
F igu r e 5-2. F r a m e Ten sion er .  
3. Depress the back of the Frame Tensioner (see Figure 5-2) to  
create slack in the Carrier Belt and slip it off of the Servo  
Motor pulley.  
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4. Move the Carrier Belt to the left so it is out of the way of the  
Servo Motor pulley.  
5. Move the Carrier Assembly to the left end of the Slide Shaft.  
Integrated circuits may become weakened or dam-  
aged by electrical discharge. Do not touch or work  
near integrated circuits without wearing an ESD  
wrist strap.  
6. Put on an ESD wrist strap.  
7. In order to have access to the back screw on the Servo Motor,  
it is necessary to disconnect the Trailing Cable from the  
MPCB and lift up the right end of the Trailing Cable.  
Disconnect the Trailing Cable connector at the J 6 location on  
the MPCB.  
8. Lift up gently and hold the right end of the Trailing Cable.  
9. Using a #2 Phillips screwdriver, remove the back screw on the  
Servo Motor. The screwdriver will be at a slight angle. Be  
careful not to strip the head of the screw or to cause damage  
to the Encoder Strip.  
10. Lower the Trailing Cable back into place.  
11. While holding the Servo Motor, remove the front screw on the  
Servo Motor.  
12. Tilt the bottom of the Servo Motor towards the back of the  
Platen and carefully lower the motor through the opening and  
out of the back of the printer.  
Assembly\Disassembly  
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Install Servo Motor  
Integrated circuits may become weakened or damaged  
by electrical discharge. Do not touch or work near  
integrated circuits without wearing an ESD wrist strap.  
1. Put on an ESD wrist strap.  
2. Reinsert the Servo Motor under the Platen with the connector  
facing the FRONT side of the Platen. Guide the pulley up  
through the opening in the Platen.  
3. Once the Servo Motor pulley is through the Platen, push up on  
the Servo Motor and align the screw holes with the screw hole  
openings.  
4. Insert the front screw into the Servo Motor and tighten it  
almost all the way.  
5. Lift up gently and hold the right end of the Trailing Cable.  
6. Insert the back screw into the Servo Motor and tighten it.  
Make sure the screw does not go into the motor at an angle,  
and be careful not to strip the head of the screw or to cause  
damage to the Encoder Strip.  
7. Tighten both screws on the Servo Motor to 15 in-lb of torque.  
8. Push the right end of the Trailing Cable back down into the hole  
on the Platen and reconnect the end to J 6 on the MPCB.  
9. Depress the back of the Frame Tensioner and wrap the Carrier  
Belt over the Servo Motor pulley. Make sure that the guides on  
the inside of the belt are inserted in the pulley grooves and that  
the belt is not twisted.  
10. Move the Carrier Assembly back and forth to check the Carrier  
Belt tension.  
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11. Perform the Reinstall the Left, Middle, and Right Covers  
procedures to reinstall the Left, Middle and Right Covers.  
Remove the Carrier Assembly, Carrier Belt, and  
the Frame Tensioner  
F igu r e 5-3. Electr on ics Cover Rem ova l.  
1. Perform the Left, Middle, and Right Cover Removal  
procedures to remove the Left, Middle and Right Covers.  
2. Remove the Cutter Actuator by reaching under the Platen  
and releasing the actuator support tabs.  
3. Move the Carrier Assembly to the far left side of the Slide  
Shaft.  
Assembly\Disassembly  
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4. Lift up on the front left side of the Electronics Cover until it  
comes part way off of the Carrier Assembly. Then lift up on the  
front right side of the Electronics Cover and move the  
Electronics Cover slightly to the left so that the back of it clears  
the Trailing Cable Support Assembly. See Figure 5-3.  
5. Lift up on the connector lock to unlock the Trailing Cable  
connector (J 1) on the Carrier PCB and remove the end of the  
Trailing Cable.  
F igu r e 5-4. Str a in Relief Rem ova l/In sta lla tion fr om Ca r r ier .  
6. Remove the Trailing Cable and Strain Relief from the Carrier  
Assembly by releasing the latch on the left lower side of the  
Strain Relief and lifting it off of the Carrier Assembly. See  
Figure 5-4.  
7. Move the Carrier Assembly away from the left end of the Slide  
Shaft. Compress the back of the Frame Tensioner and use the  
end of a screwdriver to remove the Carrier Belt from the Servo  
Motor pulley. See Figure 5-2.  
8. Remove the Compression Spring from the Frame Tensioner and  
set it aside.  
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9. Push the Carrier Belt through the Frame Tensioner enough  
to remove the Idler Pulley Assembly from the Frame  
Tensioner, and then set aside the Idler Pulley Assembly and  
the Frame Tensioner. (See Figure 5-6 for part identification,  
if necessary.)  
10. Slide the Carrier Assembly and Drive Belt off the left side of  
the Slide Shaft.  
F igu r e 5-5. Ca r r ier Belt Cla m p .  
11. Once the Carrier Assembly is removed from the Slide Shaft,  
turn it over so that you can see the Belt Clamp. See  
Figure 5-5.  
12. To disengage the Carrier Belt from the Belt Clamp, push the  
Carrier Belt away from the left post of the Belt Clamp and  
gently lift up until the bottom edge of the Carrier Belt clears  
the top of the left post.  
13. Push the Carrier Belt away from the right post of the Belt  
Clamp and gently lift up to finish removing the Carrier Belt  
from the Belt Clamp.  
Assembly\Disassembly  
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Failure to use an approved anti-static bag for storage  
or shipment may cause damage to the MPCB and af-  
fect the Warranty.  
14. Place the Carrier Assembly in an ESD (anti-static) bag in  
preparation for shipment to ENCAD for replacement or repair,  
or if it is to be stored for repair at your facility.  
Install the Carrier Assembly, Carrier Belt, and the  
Frame Tensioner  
1. To install the Belt onto the Carrier Assembly, the “bumps” on  
the belt (where the ends of the belt are joined together to make  
the belt continuous) must be positioned between the left and  
right posts of the Belt Clamp. See Figure 5-5.  
2. Slide the Carrier Belt between the right post and the middle  
post and guide it down into the Belt Clamp. Then slide the  
Carrier Belt between the left post and the middle post and  
finish placing the Carrier Belt into the Belt Clamp.  
3. Check the position of the Carrier Belt to make sure it matches  
Figure 5-5.  
4. Make sure the left end of the Trailing Cable extends out beyond  
the left end of the Trailing Cable Support Assembly.  
5. Slide the Carrier Assembly onto the left end of the Slide Shaft,  
making sure that the Encoder Strip fits into the slot in the  
Slider and the Encoder on the Carrier PCB. Guide the belt  
while sliding the Carrier Assembly from left to right on the  
Slide Shaft.  
6. Move the Carrier Assembly to the left end of the Slide Shaft  
and align the left bushing on the Carrier Assembly with the left  
end of the Slide Shaft.  
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7. Insert the Strain Relief (with Trailing Cable) onto the Carrier  
Assembly by sliding it onto the Strain Relief Support until it  
snaps firmly into place. See Figure 5-4.  
8. Place the Trailing Cable into the J 1 connector lock on the  
Carrier PCB. Make sure the silver fingers on the Trailing Cable  
are fully inserted into the lock and slide both sides of the  
connector lock shut at the same time.  
9. Place the right side of the back of the Electronics Cover under  
the Trailing Cable Support Assembly and gently press down on  
the ends of the Electronics Cover until the latches snap into the  
Carrier Assembly.  
10. Slide the Carrier Assembly to about the middle of the Slide  
Shaft and stretch out the Carrier Belt.  
11. Insert the Carrier Belt into the Frame Tensioner so that the  
belt extends about an inch past the Frame Tensioner.  
F igu r e 5-6. In sta lla tion of F r a m e Ten sion er .  
12. Holding the Carrier Belt and Frame Tensioner, insert the Idler  
Pulley Assembly into the loop of the belt. Make sure that the  
side of the Idler Pulley Assembly with the thicker outer ring of  
plastic is facing up. See Figure 5-6.  
Assembly\Disassembly  
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13. Once the Idler Pulley Assembly is in position, pinch the belt to  
hold the Idler Pulley Assembly in place and pull it into the  
Frame Tensioner so that the axle rests in the V-shaped groove  
in the Frame Tensioner.  
14. Insert the Compression Spring into the opening in the back of  
the Frame Tensioner so that the end of the spring fits over the  
post inside the opening.  
15. Fit the Compression Spring over the post at the back of the C-  
Bracket.  
16. Fit the notch in the front end of the Frame Tensioner over the  
notch in the front of the C-Bracket.  
17. Depress the back of the Frame Tensioner and slip the Carrier  
Belt over the Servo Motor pulley. Make sure that the guides in  
the Carrier Belt are properly fitted over the Servo Motor  
pulley.  
18. Gently move the Carrier Assembly from end to end and make  
sure that the Carrier Belt is not rubbing against any other  
parts.  
Remove the Carrier PCB  
Integrated circuits may become weakened or damaged  
by electrical discharge. Do not touch or work near  
integrated circuits without wearing an ESD wrist strap.  
1. Perform the Carrier Assembly, Carrier Belt, and the Frame  
Tensioner Removal procedures to remove the Carrier Assembly  
from the Slide Shaft.  
2. Put on an ESD wrist strap.  
3. Unlock the connectors and remove all flex cables on the Carrier  
PCB. Ensure that the ferrite remains on the black cartridge  
flex cable.  
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F igu r e 5-7. Ca r r ier P CB Rem ova l/In sta lla tion .  
4. Unlock the latch on the right end of the Carrier Assembly and  
lift up the right end of the Carrier PCB. See Figure 5-7.  
5. Slide the Carrier PCB to the right to remove the tab on the  
left end of the Carrier PCB from the slot in the Carrier  
Assembly.  
Assembly\Disassembly  
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Failure to use an approved anti-static bag for storage  
or shipment may cause damage to the Carrier PCB  
and affect the Warranty.  
6. Place the Carrier PCB in an ESD bag (anti-static bag) in  
preparation for shipment to ENCAD for replacement or repair,  
or if it is to be stored at your facility for repair.  
Install the Carrier PCB  
1. Put the tab on the left end of the Carrier PCB into the slot in  
the left side of the Carrier Assembly. See Figure 5-7.  
2. Ensure that no flex cables are underneath the Carrier PCB.  
3. Push down the right end of the Carrier PCB until the latch  
snaps into place.  
4. Reattach all flex cables on the Carrier PCB. Ensure that the  
ferrite remains on the black cartridge flex cable.  
5. Perform the Carrier Assembly, Carrier Belt, and the Frame  
Tensioner Reinstallation procedures to reinstall the Carrier  
Assembly.  
Remove the Paper Sensor or the Encoder Sensor  
1. Perform the Carrier Assembly, Carrier Belt, and the Frame  
Tensioner Removal procedures to remove the Carrier Assembly  
from the Slide Shaft.  
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F igu r e 5-8. P a p er a n d En cod er Sen sor Rem ova l.  
2. To remove the Paper Sensor:  
a. Unlock the connector at J 3 and remove the flex cable.  
b. Turn the Carrier Assembly over and hold it while firmly  
grasping the Paper Sensor between thumb and index finger.  
See Figure 5-8.  
c. Pull straight up on the Paper Sensor and remove it from  
the Carrier Assembly.  
3. To remove the Encoder Sensor:  
a. Unlock the connector at J 2 and remove the flex cable.  
b. Turn the Carrier Assembly over and lay it with the top  
side facing down.  
c. Push down on the plastic clip and at the same time push  
down on the Encoder until the plastic pieces on each side of  
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the Encoder clear the ridges which hold it in place. Then pull it  
straight out. See Figure 5-8.  
Install the Paper Sensor or the Encoder Sensor  
F igu r e 5-9. P a p er a n d En cod er Sen sor In sta lla tion .  
1. To install the Paper Sensor:  
a. Turn the Carrier Assembly so that the bottom side of it is  
facing up.  
b. Route the flex on the Paper Sensor through the slot in the  
Carrier Assembly. Make sure the flex cable goes all the way  
through and does not curl under the Carrier PCB.  
c. Grasp the Paper Sensor between thumb and index finger  
and guide the sides of the board into the grooves on each side of  
the opening. See Figure 5-9.  
d. Push the Paper Sensor board down into the Carrier  
Assembly until it snaps firmly into place.  
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e. Turn the Carrier Assembly over and insert the Paper  
Sensor flex cable into the connector at J 3.  
f. Push both sides of the connector lock shut at the same  
time.  
2. To install the Encoder Sensor:  
a. Turn the Carrier Assembly so that the bottom side of it is  
facing up.  
b. Push down on the plastic clip and slide the back of the  
Encoder Sensor over it.  
c. Push the Encoder Sensor in past the ridges until the  
Encoder Sensor snaps into place.  
d. Turn the Carrier Assembly over and insert the Encoder  
flex cable into the connector at J 2.  
e. Push both sides of the connector lock shut at the same  
time.  
3. Perform the Carrier Assembly, Carrier Belt, and the Frame  
Tensioner Reinstallation procedures to reinstall the Carrier  
Assembly.  
Remove the Trailing Cable Cover Assembly  
1. Perform the Left, Middle, and Right Cover Removal  
procedures to remove the Left, Middle and Right Covers.  
2. If you have not already removed the Carrier Assembly from  
the Slide Shaft, you will need to perform Steps 3 through 7 of  
the Removing the Carrier Assembly, Carrier Belt, and the  
Frame Tensioner procedures in order to remove the  
Electronics Cover and release the left end of the Trailing  
Cable from the Carrier PCB.  
3. Disconnect the Ferrite and Ferrite Bracket from the Strain  
Relief by turning the Strain Relief over and pushing down on  
the Ferrite Bracket’s catch until it can pass under the Strain  
Relief. Pull the Ferrite Bracket clear from the Strain Relief.  
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4. Remove the Trailing Cable from the triangular portion of the  
Strain Relief.  
5. Lift up on the short end of the tape and unfold the bend in the  
Trailing Cable.  
6. Remove the Strain Relief by pushing the Trailing Cable down  
through the opening in the Strain Relief.  
7. Disconnect the Trailing Cable connector at the J 6 location on  
the MPCB. Use the thumb and forefinger to pull forward on  
the connector lock and remove the Trailing Cable from the  
connector. See Figure 3-6 if necessary.  
F igu r e 5-10. Tr a ilin g Ca ble Assem bly Rem ova l/In sta lla tion .  
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8. Using a #2 Phillips screwdriver, remove the three screws and  
washers securing the Trailing Cable Cover Assembly to the C-  
Bracket Assembly. See Figure 5-10.  
9. With the Carrier Assembly in the far right position (if still  
installed), carefully slide the Trailing Cable Cover left until it  
clears the back of the Carrier Assembly. Then lift the Trailing  
Cable Assembly out of the printer.  
Install the Trailing Cable Cover Assembly  
1. Ensure that the Carrier Assembly (if installed) is at the far  
right side of the Slide Shaft, position the Trailing Cable Support  
Assembly in front of the C-Bracket and offset to the left enough  
to clear the Carrier Assembly.  
2. Carefully slide the right side of the Trailing Cable Cover  
Assembly behind the Carrier Assembly until the screw holes on  
the Trailing Cable Cover Assembly lines up with the holes in the  
C-Bracket Assembly.  
3. Fasten the Trailing Cable Cover Assembly onto the C-Bracket  
Assembly with 3 screws with 15 in-lb of torque.  
4. Insert the right side of the Trailing Cable through the hole  
provided in the Platen and Secure to the J 6 connector on the  
MPCB.  
5. If the Carrier Assembly is not installed, perform steps 5  
through 18 of the Reinstalling the Carrier Assembly, Carrier  
Belt, and the Frame Tensioner procedures.  
6. Push the Trailing Cable up through the opening in the Strain  
Relief.  
7. Fold the Trailing Cable and press it down onto the tape.  
8. Slide the fold in the Trailing Cable under the triangular portion  
of the Strain Relief.  
9. Slide the Ferrite Bracket onto the Strain Relief until the catch  
is securely in place on the Strain Relief.  
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7. Insert the Strain Relief (with Trailing Cable) onto the Carrier  
Assembly by sliding it onto the Strain Relief Support until it  
snaps firmly into place. See Figure 5-4.  
Replacing the Carrier Bushings  
1. Perform the Carrier Assembly, Carrier Belt, and the Frame  
Tensioner Removal procedures to remove the Carrier  
Assembly from the Slide Shaft.  
F igu r e 5-11. Ca r r ier Bu sh in g Rem ova l.  
2. Use a flat tip screwdriver to push up on the latch which holds  
the Carrier Bushing in place. See Figure 5-11.  
3. Pull the Carrier Bushing out of the Carrier Assembly.  
4. Repeat Steps 2 and 3 for the other Carrier Bushing.  
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F igu r e 5-12. Ca r r ier Bu sh in g In sta lla tion .  
5. Orient the new Bushing as shown in Figure 5-12 so that the  
metal tab on top of the Bushing goes into the Carrier Assembly  
first.  
6. Push the Bushings in until they snap into place.  
7. Perform the Reinstall the Carrier Assembly, Carrier Belt, and  
the Frame Tensioner procedures to reinstall the Carrier  
Assembly.  
Assembly\Disassembly  
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Remove the Service Station, Seals, and Wipers  
F igu r e 5-13. Ser vice Sta tion , Exp lod ed View .  
1. Place the Middle Cover in the open position.  
2. Move the Carrier Assembly to the left side of the Slide Shaft.  
3. Reach into the Right Cover and pull back on the Service  
Station release tab located on the far side of the Service  
Station. See Figure 5-13.  
4. Raise the right side of the Service Station out of the Platen.  
5. Lift out the left side of the Service Station from the Platen  
and remove the Service Station. Moving the Service Station  
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farther to the right might be required to release the left side  
of the Service Station.  
6. To remove a Service Station Wiper, lift the Wiper up and off  
of the Wiper support.  
7. To remove a Service Station Seal:  
a. Disconnect the Sled spring from the post on the bottom of  
the Service Station Sled. See Figure 5-13.  
b. Slide the Service Station Sled to the right and up until it  
is removed from the Service Station Base.  
c. While pushing the Service Station Seal in, remove the  
retaining ring from the other side. This releases the Seal Post  
(with the Seal attached) and the Seal spring.  
d. Remove the Seal from the Seal Post by sliding the rubber  
Seal until it is released.  
Install the Service Station, Seals, and Wipers  
1. To install a Service Station Seal:  
a. Slide the new Seal over the Seal Post.  
b. Insert the Seal Post through the Seal spring.  
c. Align the Seal Post and spring into the hole on the Service  
Station Sled, it is keyed to only go in one way.  
d. Press the Seal Post in to give enough clearance on the  
other side to attach the retaining ring.  
e. Insert the Service Station Sled into the Service Station  
Base by sliding the Service Station Sled down and to the left  
into the Base. To seat the Sled completely into the Base it  
will be necessary to press down on the tab on the Actuator.  
f. Reattach the spring onto the post on the bottom of the  
Service Station Sled.  
2. To install a Service Station Wiper, press the new Wiper onto  
the wiper support.  
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3. Position the Service Station inside the Right Cover and place  
the left side of the Service Station into the Platen.  
4. Push down on the right side of the Service Station until the  
Service Station snaps into place.  
5. Slide the Carrier Assembly to the right and back into the  
home position.  
6. Lower the Middle Cover.  
Remove the Lower Roller Assembly and Stepper  
Motor  
1. Perform the Carrier Assembly, Carrier Belt, and the Frame  
Tensioner Removal procedures to remove the Carrier  
Assembly from the Slide Shaft.  
2. Perform the Trailing Cable Cover Assembly Removal  
procedures to remove the Trailing Cable Support Assembly.  
3. Disconnect the Servo Motor connector (red and blue wires) at  
the J 4 location on the MPCB.  
4. Using a #2 Phillips screwdriver, remove the back screw on the  
Servo Motor. The screwdriver will be at a slight angle. Be  
careful not to strip the head of the screw or to cause damage  
to the Encoder Strip.  
5. While holding the Servo Motor, remove the front screw on the  
Servo Motor.  
6. Tilt th e bottom of th e Ser vo Motor tow a r d s th e ba ck of  
th e P la ten a n d ca r efu lly low er th e m otor th r ou gh th e  
op en in g a n d ou t of th e ba ck of th e  
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.retnirp  
F igu r e 5-14. C-Br a ck et Assem bly a n d P la ten Rem ova l.  
Assembly\Disassembly  
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7. Remove the C-Bracket Assembly by removing the four  
attaching screws. See Figure 5-14.  
8. Using a #2 Phillips screwdriver, remove the grounding strap  
on the left side of the Slide Shaft.  
9. Remove the Slide Shaft using a 3mm hex head driver.  
10. Disconnect the Lower Drive Shaft Assembly from the Platen  
by removing the 4 attaching screws. See Figure 5-14.  
11. Remove the Platen by releasing the 4 securing tabs (2 on each  
side) and six screws. Gently lift the Platen off of the Base.  
12. Disconnect the Stepper Motor cable from J 7 on the MPCB.  
13. Disconnect the Stepper Motor ground strap from the MPCB.  
14. Raise the Lower Drive Shaft Assembly out of the Base.  
F igu r e 5-15. Step p er Motor Rem ova l/In sta lla tion .  
15. Remove the Stepper Motor Extension Spring from the  
Stepper Motor and the post on the Left Lower Drive Shaft  
Bracket. See Figure 5-15.  
16. Remove the hardware securing the Stepper Motor to the Left  
Lower Drive Shaft Bracket and remove the Stepper Motor.  
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Install the Lower Roller Assembly and Stepper  
Motor  
NOTE  
Ensure that the stepper motor wires are exiting the  
motor casing in the “down” direction when completely  
installed. The wires should be opposite from the holes  
that secure the bracket to the platen.  
1. Loosely attach the Stepper Motor to the Lower Roller bracket  
using Stepper Motor hardware as shown in Figure 5-15.  
2. Attach the Stepper Motor tension spring to the Stepper Motor  
and the Lower Roller Bracket. Tighten the Stepper Motor  
hardware to 8 in-lb of torque.  
Assembly\Disassembly  
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F igu r e 5-16. In sta llin g Low er Roller Assem bly.  
3. Lower the Lower Roller Assembly into the Base of the printer  
by aligning the bracket guides with the base guide tracks. See  
Figure 5-16.  
4. Slide the Lower Roller Assembly to the right until the left  
lower roller bracket is snug against the bracket stop guide.  
5. Route the Stepper Motor wires through the wire access area  
and to the wire clamp. Attach the connector to J 7 on the  
MPCB.  
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6. Route the Stepper Motor ground strap through the wire access  
area and to the wire clamp. Attach onto the back of the MPCB.  
7. Carefully snap the Platen onto the printer Base. Ensure that  
the ground straps for the Slide Shaft and C-Bracket are coming  
through the holes in the Platen.  
8. Secure the Lower Roller Assembly onto the Platen.  
9. Attach the C-Bracket Assembly and ground strap to the Platen  
by aligning the bracket onto the bracket guide pins and securing  
with attaching hardware to 15 in-lb of torque. See insert of  
Figure 5-14 for connection of ground strap onto the C-Bracket.  
Ensure that the Pinch Rollers are centered on the lower rollers  
and that tension is being applied the the lower rollers.  
10. Attach the Slide Shaft to the supports tightening to 15 in-lbs of  
torque using 3mm hex head torque screwdriver.  
11. Attach the ground strap to the left side of the Slide Shaft.  
12. Perform the Carrier Assembly, Carrier Belt, and the Frame  
Tensioner Reinstallation procedures to reinstall the Carrier  
Assembly.  
Remove the Power Supply and AC Entry Module  
1. Remove the Left, Middle, and Right covers by following the  
cover removal procedures.  
2. Remove the Cutter Actuator by reaching under the Platen and  
releasing the actuator tabs.  
3. Release the Carrier Belt from the servo Motor spindle by  
pressing the tension assembly inward to allow enough slack to  
lift off the belt from the servo motor.  
4. Disengage the Trailing Cable from the Carrier Assembly by  
disconnecting the cable from J 1 on the Carrier Board and  
pressing on the Trailing Cable Strain Relief latch (see Figure 5-  
4).  
5. Slide the Carrier Assembly, Belt and Tension Assembly off the  
left side of the Slide Shaft.  
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6. Disconnect the Trailing Cable from J 6 on the MPCB and  
remove the Trailing Cable Cover Assembly.  
7. Disconnect the Servo Motor cable from J 4 on the MPCB and  
remove the Servo Motor.  
8. Remove the C-Bracket Assembly.  
9. Using a #2 Phillips screwdriver, remove the grounding strap  
on the left side of the Slide Shaft.  
10. Remove the Slide Shaft using a 3mm hex head driver.  
11. Disconnect the Lower Drive Shaft Assembly from the Platen  
by removing the 4 attaching screws.  
12. Remove the Platen by releasing the 4 securing tabs (2 on each  
side) and six screws. Gently lift the Platen off of the Base.  
13. Disconnect the Power Supply cable from J 5 on the MPCB.  
Remove the cable from the cable supports on the Base.  
F igu r e 5-17. Gr ou n d Stu d With Gr ou n d Lu gs Atta ch ed .  
13. Disconnect the ground lug from the ground stud. See Figure  
5-17.  
14. Remove the Power Supply Assembly by unhooking it from the  
two plastic hooks securing it to the Base and sliding it out.  
15. Loosen the 4 screws and slip the Power Supply cover off of  
the Power Supply base. See Figure 5-18.  
16. Disconnect the cable from TB2 on the Power Supply Board.  
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17. Disconnect the AC Entry Module from the Power Supply Board  
by disconnecting cable from TB1.  
18. Remove 4 screws and washers securing power supply board and  
remove power supply board. Remove grounding wire to the AC  
Entry Module from the mounting screw on the power supply  
lower cover.  
19. Remove AC Entry Module by unsnapping from the power supply  
base.  
F igu r e 5-18. P ow er Su p p ly Assem bly.  
Assembly\Disassembly  
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Install the Power Supply and AC Entry Module  
1. Insert the AC Entry Module by snapping it into the Power  
Supply base.  
2. Install Power Supply board into the Power Supply base using  
four mounting screws and washers. Attach the ground wire  
from the AC Entry Module to the lower Power Supply cover  
mounting screw.  
3. Connect the AC Entry Module plug into TB1 on the Power  
Supply board.  
4. Attach the Power Supply cable to the TB2 connector on the  
Power Supply board.  
5. Place the Power Supply cover over the assembly and slide into  
place over the loosened screws on the Power Supply base.  
Ensure that the grounding strap is still attached to the screw  
on the Power Supply base.  
6. Insert the Power Supply Assembly into the printers Base.  
Orient the assembly so that the extensions on the back of the  
Power Supply base slip into the square holes in the Base of the  
printer and that the AC Entry Module extends through the  
back of the printer.  
7. Apply pressure downward on the Power Supply Assembly until  
it snaps firmly into place.  
8. Connect the ground lug to the grounding stud on the Base. See  
Figure 5-17.  
9. Position the Power Supply cable into the cable supports inside  
the front part of the Base until it reaches the MPCB.  
10. Connect the Power Supply cable to the J 5 connector on the  
MPCB.  
11. Carefully secure the Platen onto the printer Base. Ensure that  
the ground straps for the Slide Shaft and C-Bracket are coming  
through the holes in the Platen.  
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12. Secure the Lower Roller Assembly onto the Platen.  
13. Attach the C-Bracket Assembly to the Platen by aligning the  
bracket onto the bracket guide pins and securing with  
attaching hardware. Ensure that the Pinch Rollers are  
centered on the lower rollers and that tension is being applied  
the the lower rollers.  
14. Attach the Slide Shaft to the supports tightening to 15 in-lbs  
of torque using 3mm hex head torque screwdriver.  
15. Attach the ground strap to the left side of the Slide Shaft.  
16. Perform the Carrier Assembly, Carrier Belt, and the Frame  
Tensioner Reinstallation procedures to reinstall the Carrier  
Assembly.  
Assembly\Disassembly  
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Parts List  
6
This chapter lists the items and their associated numbers for the  
parts and assemblies of the Cr om a 24 printers that are field re-  
placeable. The list is in order of part name as identified in the  
assembly/disassembly chapter.  
This list is to be used in conjunction with the assembly/disassembly  
procedures to aquire the necessary parts and properly install them  
into the printer.  
The parts and asssemblies may be ordered through your local autho-  
rized dealer or ENCAD, In c.’s Technical Support and Service  
department.  
Ta ble 6-1. P a r ts List.  
F IGUR E ITE M  
P ART NAME  
P ART #  
6-1  
6-1  
6-1  
6-1  
6-1  
6-1  
6-1  
6-1  
6-1  
6-1  
6-1  
6-1  
6-1  
6-2  
6-2  
1
2
COVER, LID ............................................ 207027  
COVER, LEFT ......................................... 207028  
COVER, RIGHT ...................................... 207029  
TRAILING CABLE COVER ASSY ........ 208405  
TRAILING CABLE ASSEMBLY ........... 207068  
BELT ........................................................ 203037  
SPRING, COMPRESSION .................... 203999  
IDLER ASSY ........................................... 207185  
FRAME TENSIONER ............................ 207197  
SLIDE SHAFT ........................................ 206480  
SERVICE STATION ASSEMBLY ......... 204629  
CUTTER ACTUATOR ............................ 206812  
PLATEN .................................................. 206546  
SERVO MOTOR, METRIC .................... 207034  
LIGHT PIPE ............................................ 207031  
3
4
5
6
7
8
9
10  
11  
12  
13  
1
2
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F IGUR E ITE M  
P ART NAME  
P ART #  
6-2  
6-2  
6-2  
6-2  
6-2  
6-2  
6-2  
6-2  
6-2  
6-3  
6-3  
6-3  
6-3  
6-3  
6-3  
6-3  
6-4  
6-4  
6-5  
6-5  
3
4
ACTUATOR, MPCB ................................ 207030  
MAIN PRINTED CIRCUIT BOARD ..... 207047  
LOWER DRIVE SHAFT ASSY .............. 206479  
FAN ASSEMBLY.................................... 203443  
POWER SUPPLY ASSEMBLY .............. 207042  
ROLLGUIDE ASSY, RIGHT ................. 204969-5  
ROLLGUIDE ASSY, LEFT .................... 206828-4  
FEET ........................................................ 207041  
BASE ASSEMBLY.................................. 207040  
COVER, CARRIER ................................. 207038  
CARRIER PCB ........................................ 207088  
ENCODER SENSOR W/FLEX .............. 206823  
PAPER SENSOR W/FLEX..................... 207180  
STRAIN RELIEF .................................... 204694  
CARRIER BUSHING (SET OF 2) ......... 207961  
CARRIER FRAME ASSY ....................... 207077  
ENCODER STRIP .................................. 206384  
PINCH ROLLER ASSY ............................ 207071  
STEPPER MOTOR W/GEAR ................. 207173  
BRACKET, STEPPER MOTOR,  
5
6
7
8
9
10  
11  
1
2
3
4
5
6
7
1
2
1
2
RIGHT .................................................. 206854-1  
BRACKET, STEPPER MOTOR,  
6-5  
3
LEFT ..................................................... 206854-2  
HARDWARE KIT ................................... 208995  
124  
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F igu r e 6-1. Cr om a 24 Assem bly P a r ts (P la ten a n d Above).  
Parts List  
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F igu r e 6-2. Cr om a 24 Assem bly P a r ts (Below P la ten ).  
126  
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F igu r e 6-3. Ca r r ier Assem bly Br ea k d ow n .  
Parts List  
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F igu r e 6-4. C-Br a ck et Assem bly Br ea k d ow n .  
128  
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F igu r e 6-5. Low er Roller Assem bly Br ea k d ow n .  
Parts List  
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130  
Parts List  
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Index  
A
L
axis drive  
carrier . . 28  
language emulation . . 20  
line accuracy . . 20  
paper (media) . . 27  
linear encoder strip . . 46  
lower roller assembly . . 112  
B
M
banding . . 84  
hardware or software . . 53  
built in test (BIT) . . 75  
media does not move . . 80  
menus  
diagnostics . . 68  
C
manufactoring . . 66  
microprocessor . . 25  
mpcb . . 29, 49, 90  
cabling . . 77  
calibration  
color . . 55  
N
deadband . . 56, 67  
head height . . 60  
X-axis . . 57  
no power . . 79  
notes . . 19  
carrier assembly . . 95  
carrier axis failure . . 81  
carrier bushings . . 108  
cartridges . . 47, 55  
cautions . . 19  
O
optical encoder strip . . 28, 35  
P
control panel . . 40, 65  
paper skewing . . 83  
pinch roller . . 57  
E
power supply . . 38, 117  
printer does not print . . 82  
ESD . . 18  
F
R
features . . 18  
firmware . . 31  
related publications . . 18  
resistance check  
servo motor . . 52  
stepper motor . . 53  
resolution . . 20, 28, 35  
G
general block diagram . . 25  
I
ink cartridge misfiring . . 82  
131  
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Croma24 Service Manual  
S
V
scheduled maintenance . . 43  
service station . . 45, 110  
servo motor . . 92  
version  
CAD only . . 17  
GA & CAD . . 17  
signal flow . . 77  
GA (Graphic Arts) . . 17  
skewing . . 57  
stepper motor . . 112  
W
warnings . . 19  
T
technical specifications . . 20  
technical support  
ENCAD BBS . . 23  
ENCAD website . . 23  
help desk  
FAX # . . 23  
telephone # . . 23  
tests  
carriage vibration . . 70  
color . . 70  
fan . . 69  
keypad . . 71  
LED . . 72  
paper sensor . . 69  
print quality . . 67  
servo motor . . 72  
troubleshooting . . 79  
132  
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