POWER JET Plotter Reference Manual

4 Printheads Carriage

4.1 CARRIAGE MOTOR M642

The printheads carriage motor is a permanent magnet, 60 volt DC servomotor. The
motor drives the carriage through a 4 pulley ratio. An encoder is mounted on the motor
to monitor carriage position. Refer to the next section for encoder specifications.

4.2 QUICK REFERENCE MOTOR SPECIFICATIONS:

• Permanent Magnet DC servomotors

• Ball Bearing Movement

• Direction of Rotation = Bi-polarity

• Die-cast Endshield

• Maximum operating temperature:

40°C

• Minimum operating temperature: 0°C

M542 M642
MAE - 60 VOLT DC SERVOMOTORS
1100 1340
Caratteristiche operative / Operating specifications
Nm 0,66
Coppia continuativa a rotore bloccato / Continuous Stall torque
Picco di coppia a rotore bloccato / Peak Stall torque Nm 3,3
Corrente alla coppia continuativa a rotore bloccato/Continuous Stall Current A 5,2
Corrente massima di picco / Maximum Pulse Current A 25,9
Massima tensione applicabile ai morsetti/ Maximum terminal voltage V 60
Velocità massima / Maximum speed RPM 4000
Caratteristiche meccaniche / Mechanical data
kg m2 1,2-104
Momento d’inerzia del rotore / Rotor moment of inertia
Costante di tempo meccanica / Mechanical time constant ms 8,1
Massa del motore / Motor mass kg 2,3
Caratteristiche termiche /Thermal data
°C/W 2,7
Resistenza termica (arm/ambiente) 2 / Thermal resistance (arm/ambient) 2
Temperatura massima dell’armatura / Maximum armature temperature °C 155
Caratteristiche elettriche / Winding specifications
Nm/A 0,130
Costante di coppia (3) Kt / Torque constant (3) Kt
Costante di tensione (f.c.e.) (3) / Voltage constant (back emf) (3) V/RPM 13,4
Resistenza di armatura (4) / Armature resistance (4) Ω 0,94
Resistenza ai morsetti (4) / Terminal resistance (4) Ω 1,1
Induttanza di armatura / Armature inductance mH 0,86
Costante di tempo elettrica / Electrical time constant ms 1,1
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4.3 MOTOR SUBSTITUTION

Algotex recommends substituting the entire motor block in the event of either a
malfunctioning motor or encoder. Substitution instructions follow below.

1) Remove the original motor with encoder from the plotter:

- disconnect the 6 encoder leads;
(observe color sequence from left to right as illustrated in section 4.5).
- disconnect the 2 motor leads;
(observe color sequence: 1 black, 2 red).
- partially loosen the 4 support screws (3mm alen wrench).
- slide the AT5-340 timing belt off the motor pulley.
- remove the 4 support screws and extract the motor from the plotter.

2) Install the substitute motor:

- insert the pulley end of the motor through the support hole.
- before securing the 4 support screws;
- while tilting the motor higher at the left (encoder) end, slide the timing
belt onto the motor pulley.
- re-tighten the 4 support screws while pressing down on the left (encoder)
end of the motor to maintain the timing belt in tension.
- re-connect the 2 motor leads (respect color sequence).
- re-connect the 6 encoder leads (respect color sequence).

4.3.1 ‘Offset Trimmer’ regulation on the carriage motor power amplifier

After substituting either the printheads carriage motor, the carriage motor encoder,
or componants on the onboard electronic rack, follow the instructions below for
regulating the ‘Offset Trimmer’ on the carriage motor power amplifier to insure that
the printheads carriage does not move or ‘slip’ either towards the right or towards
the left side of the plotter.

1) Before turning the plotter ON, manually move the printheads carriage to the
center of the print area.
2) Switch the plotter ON, and double click the desktop icon ‘Shortcut to
AlgoPlotter.exe’.
3) On the ‘Algotex Plotter Driver’
menu, move the cursor above the
‘Plotter Settings’ button.
4) To open the Power Jet plotter ‘Tests and Advanced Settings’, use the following
keyboard/mouse sequence simultaneously:
[Shift]+[Ctrl]+[click and hold down the left mouse button]+[click and hold down the
right mouse button]. Then release ALL.

5) Then click the ‘Command’ heading to view the following menu.

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Command Settings

6) Click the ‘Offset’ button. If the printheads

carriage moves even slightly towards the left or
towards the right side of the plotter follow
instructions below.

View of right side onboard electronics Use a mini screwdriver to regulate the ‘Offset
A = Printheads Carriage Motor Amplifier Trimmer Screw’ (lowest of 4 screws)
If the printheads carriage moves towards the RIGHT side of the plotter:
- turn the Offset Trimmer Screw CLOCKWISE, ¼ turn.
- Again click the ‘Offset’ button. If the carriage still moves to the right,
- again turn the ‘Offset Trimmer Screw’ clockwise, ¼ turn.
- Repeat this sequence until the printheads carriage remains still.

If the printheads carriage moves towards the LEFT side of the plotter:
- turn the Offset Trimmer Screw COUNTER CLOCKWISE, ¼ turn.
- Again click the ‘Offset’ button. If the carriage still moves to the left,
- again turn the ‘Offset Trimmer Screw’ counter clockwise, ¼ turn.
- Repeat this sequence until the printheads carriage remains still.

7) After verifying that the printheads carriage does not move to the left or right when
clicking the ‘Offset’ button:
REPEAT the ‘Offset Trimmer Regulation’ procedure ONE HOUR AFTER the plotter has
been turned on to insure that the carriage remains still.
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The printheads carriage will remain in a fixed position at the state of 0 volts:

+ 10 volts: Carriage movement in one direction

0 volts: Carriage remains in fixed position

- 10 volts: Carriage movement in opposite direction

4.4 CARRIAGE MOTOR CABLE SEQUENCE

4.5 PRINTHEADS CARRIAGE MOTOR ENCODER

One revolution of the encoder is equivalent to 1000 pulse revolutions which are equal
to 2.50 cm of lateral displacement of the printheads carriage.

Encoder Cable Sequence

 POWER JET Plotter Reference Manual

4.6 PRINTHEADS CARRIAGE ENCODER SUBSTITUTION

Algotex recommends substituting the entire motor/encoder block in the event of a
malfunctioning encoder. If only an encoder is available, substitution instructions follow
below.

1) Remove the entire motor/encoder block (refer to preceeding section).

2) Remove the original encoder from the carriage motor:
- Remove the encoder cover.
- Loosen but do not remove the two mounting screws (use small flat blade
screwdriver) that fix the encoder to the base of the motor.
- Loosen the two set screws (ball end 0.050“ hex wrench) in the hub of the encoder.
- Pull the slide-lock mechanism to the extended OUT position.
- Remove the two mounting screws.
- Remove the encoder from the motor shaft by pulling UP.
- Remove the bronze jacket from the motor shaft.
3) Install the substitute encoder on the carriage motor:
4) Position the motor with the shaft for the encoder pointing up.
5) Apply a light film of grease on the motor shaft.
6) Pull out the slide/lock mechanism located at the side of the encoder.
7) Verify that the setscrews in the encoder hub are completely within the encoder bore.
8) Position the bottom of the bronze jacket with the top of the encoder hub so that the
holes in the jacket are aligned with the set screws in the hub.

9) Align the encoder hub with the motor shaft and

10) Tighten the 2 setscrews in the hub until they make
gently push the hub onto the shaft until the top rim of
contact with the motor shaft. Do NOT overtighten the
the bronze jacket is flush with the rim of the shaft.
screws. (ball end 0.05” hex wrench).

12) Push the slide lock mechanism in. While rotating

11) Secure the two mounting screws to fix the encoder the motor unit, verify that the middle disk within the
to the base of the motor. encoder does not scrape the base.
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13) If a scraping noise is audible while rotating the motor unit, or if there is no gap
between the disk and the mask on the underside of the PC board, remove the encoder
and re-install.
- Pull out the slide/lock mechanism.
- Unscrew the two mounting screws.
- Loosen the two hub setscrews.
- Push the encoder slightly lower on the motor shaft.
- Re-tighten the two setscrews and the two mounting screws.
- Push the slide/lock mechanism in completely.
- Audibly verify that the middle disk does not scrape on the base of the encoder.
14) Install the cover by sliding it over the encoder body until the tabs on the base of the
encoder engage with the locking feature in the cover.
15) Re-install the motor (refer to preceeding section).

4.7 CARRIAGE MOTOR PULLEY POSITIONING

The positions of the pulleys on the carriage motor block may be adjusted laterally to
center the belts. Adjust pulley positions by loosening the set screws (SS) with a 2.0 mm
hex wrench.

Carriage Motor Pulleys

4.8 LUBRICATION
Lubrication will reduce plotter movement noise and improve print quality. Periodically
apply a few drops of synthetic, Teflon based lubricant on:
- the teeth of the carriage motor pulleys,
- the stainless steel carriage rail.
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4.9 PRINTHEADS CARRIAGE MOTOR AMPLIFIER

View of right side onboard electronics Close-up view of the Motor Amplifier
A = Printheads Carriage Motor Amplifier

Loop Gain Trimmer: regulation may be required after substituting;

- the carriage motor, the power amplifier, or the printhead control board.
‘Loop Gain Trimmer’ regulation instructions follow below.
1) Open the Printhead Settings menu.
2) Begin printing vertical lines.
3) Use a mini screwdriver to slowly turn the ‘Loop Gain Trimmer’ screw clockwise until
the motor begins to vibrate and emits a high pitched sound.
4) Turn the trimmer screw counter-clockwise two complete revolutions.
5) Verify that the carriage motor no longer vibrates and that the printhead carriage does
not ‘slip’ slightly at the ‘turn around’ points (the points where the carriage inverts
direction from left to right, or from right to left).

Current Limit Trimmer: DO NOT CHANGE FACTORY SETTINGS.

This trimmer is used to adjust the continuous and peak current to the carriage motor.
- Power plotters have an ‘Omni directional sensor’ for paper jams:
- contact with paper = open circuit (cut current)

Reference Gain Trimmer: DO NOT CHANGE FACTORY SETTINGS.

This trimmer is used to adjust the ratio between the input signal and the output variables
(voltage, current, and velocity).

Offset Trimmer: regulation may be required after substituting;

- the carriage motor, the power amplifier, or the printhead control board.
- Refer to section 4.3.1 in the Power Jet Plotter Reference Manual for regulation
instructions of the ‘Offset Trimmer’.
 POWER JET Plotter Reference Manual

4. 10 SUBSTITUTION OF THE CARRIAGE MOTOR BEARING RINGS

1) Decrease the carriage belt tension by loosening the blocking nuts at the right side of
the plotter.
2) Remove the carriage belt from the 30 pitch pulley.
3) Loosen the set screw on the 30 pitch pulley and slide pulley off the carriage motor
axle.
4) Slide the A5 closed loop belt off of the 16 pitch pulley.
5) Loosen the set screw on the 48 pitch pulley and slide the pulley off the carriage motor
axle.
1 3-5

30 Pitch Pulley Set Screw

(2mm alen wrench)

48 Pitch Pulley Set Screw

(2mm alen wrench)

6) Remove the seeger spring lock at the LEFT end of the pulley axle.
7) Remove the axle from the support by tapping it on the LEFT end with a rubber
headed mallet and a flat bladed screwdriver while at the same time pulling it out from
RIGHT side.
8) Remove the two bearing rings by tapping them from the inside towards the exterior of
the support with the mallet and a flat bladed screwdriver.
9) Install the new bearings by first tapping them into place with the rubber hammer. Use
an alluminum block to protect the rings while tapping them into position within the
support.
6 7 9

10) Install the new axle by tapping it through the bearing rings with the mallet. Place an
aluminum block between the end of the axle and the mallet to protect the axle while
tapping it into position. The seeger spring lock on the axle should be positioned flush
against the bearing ring on the right.
11) Install the seeger at LEFT end of the axle, flush against left bearing ring.
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12) Reinstall the 48 pitch pulley. The key on the axle should be matched up with the
pulley notch.
13) Use a straight edge to help align the 48 pitch pulley vertically with the 16 pitch
pulley.
14) Tighten the set-screw on the 48 pitch pulley.

12 13 14

15) When repositioning the 30 pitch pulley, move the printhead carriage completely to
the left. Position the pulley so that the belt is centered and then tighten the set-screw.
16) Re-adjust carriage belt tension by tightening the blocking nuts equally on the left
and right.

A = Left side seeger spring lock E = Pulley/bearing axle

B = Left side bearing ring F = 48 pitch pulley
C = Right side bearing ring G = 30 pitch pulley
D = Right side seeger spring lock H = 16 pitch pulley
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4.11 PRINTHEADS CARRIAGE ‘PAPER JAM’ SENSOR

The printheads carriage is equipped with an ‘Omni-Directional’ sensor that will cut
current to the printheads carriage motor should the antennae come into contact with
paper or any extraneous objects in the path of the carriage.

Printheads Carriage Front View

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PRINTHEADS CARRIAGE UPGRADE INSTALLATION

1) Remove the original printheads

configuration from the carriage.
2) Then disconnect the printheads cable-
chainlink unit from the support as shown
above, and remove the support from the 3) Thread the drill-holes on the base of the new
carriage. printheads configuration (recommended size 3mm).

4) After installing the new printhead configuration on the carriage, connect the printheads cable-
chainlink unit to the carriage. Then manually move the carriage to the extreme left side of the plotter.
Verify that the chainlink unit will pass through the recess on the left side of the plotter.
Eventually, reverse the cable CLAMP, so that the screw faces the rear of the plotter, as illustrated.