Kodak 800 SERIES manual

NovaJet ® 8-Head Family Service Manual NovaJet 800 Series[...]

NOV AJET® 800 Series Color Inkjet Printer Service Manual Part Number 216520-01 ®[...]

iii NovaJet 800 Series Service Manual Copyright Eastman Kodak Company, 2002 KODAK, ENCAD ® , VinylJet ® , VinylJet ® , CADJET ® , Extreme Color Printing™, and Graphic Outdoor Matched System™ (GO) are trademarks of Eastman Kodak Company . Other trademarks and registered trademarks are the property of their respective owners. No part of this [...]

iv NovaJet 800 Series 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 NOVAJET 800 series printers. FEDERAL COMMUNICATIONS COMMISION RADIO AND TELEVISION INTERFERENCE FOR CLASS B DEVICE This equipment has been tested and f[...]

v NovaJet 800 Series Service Manual 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. − Increas[...]

vi NovaJet 800 Series Service Manual VDE Statement Hiermit wird bescheinigt, daß die NOVAJET 800 Serie von Drucker 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 [...]

vii NovaJet 800 Series Service Manual Material Safety Data Sheet ENCAD QIS (Quality Imaging Supplies) ink is nonhazard- ous, 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 92121-373[...]

viii NovaJet 800 Series Service Manual Warranty or Damage Claims United States ENCAD ® , Inc., warrants its printers ("P RODUCT ") 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 (858) 452-4350. ENCAD reserv[...]

ix NovaJet 800 Series Service Manual Table of Contents Chapter 1 General Description ....................................... 1-1 Introduction .................................................................................. 1-1 Overview ....................................................................................... 1-3 Related Publications[...]

x NovaJet 800 Series Service Manual Table of Contents (cont) Chapter 3 Maintenance ................................................... 3-1 Introduction .................................................................................. 3-1 Scheduled Maintenance ................................................................ 3-1 Cleaning Procedures [...]

xi NovaJet 800 Series Service Manual Table of Contents (cont) Chapter 4 Troubleshooting ............................................. 4-1 Introduction .................................................................................. 4-1 No Power ............................................................................... 4-1 No Power ..........[...]

xii NovaJet 800 Series Service Manual Table of Contents (cont) Chapter 4 Troubleshooting (cont) Microbanding ............................................................. 4-28 Banding Differences ................................................... 4-30 Horizontal Banding .................................................... 4-31 Vertical Banding ...[...]

xiii NovaJet 800 Series Service Manual Table of Contents (cont) Chapter 5 AssemblyDisassembly ................................ 5-1 Introduction .................................................................................. 5-1 Remove the Left, Top, and Right Covers ......................................... 5-2 Remove the E-Connect Network Asse[...]

xiv NovaJet 800 Series Service Manual Table of Contents (cont) Chapter 5 AssemblyDisassembly (cont) Remove the Lower Roller Assembly, Stepper Motor and Vacuum Fan (NovaJet 850) .......................................................... 5-48 Install the Lower Roller Assembly, Stepper Motor and Vacuum Fan (NovaJet 850) ..............................[...]

xv NovaJet 800 Series Service Manual Chapter 5 AssemblyDisassembly (cont) Remove the Carriage Assembly, Carriage Belt, and the Frame Tensioner .................................................................................... 5-23 Install the Carriage Assembly, Carriage Belt, and the Frame Tensioner ..............................................[...]

xvi NovaJet 800 Series Service Manual Chapter 6 Parts List ........................................................ 6-1 Table of Contents (cont)[...]

xvii NovaJet 800 Series Service Manual List of Illustrations Figure Page Chapter 1 General Description 1-1. NovaJet 800 Series Inkjet Printer ................................................. 1-1 Chapter 2 Theory of Operation 2-1. General Block Diagram. .............................................................. 2-3 2-2. Paper (Media) Axis Drive[...]

xviii NovaJet 800 Series Service Manual List of Illustrations (cont) Figure Page Chapter 3 Maintenance (cont.) 3-20. Color Calib Menu. .................................................................... 3-33 3-21. Vertical Options Menu. ............................................................ 3-34 3-22. Slow Deadband. .........................[...]

xix NovaJet 800 Series Service Manual List of Illustrations (cont) Figure Page Chapter 4 Troubleshooting (cont) 4-26. Unseated or Defective Trailing Cables. ...................................... 4-33 4-27. ESD Problems. ........................................................................ 4-34 4-28. Defective Carriage PWAs. ....................[...]

xx NovaJet 800 Series Service Manual List of Illustrations (cont) Figure Page Chapter 4 Troubleshooting (cont) 4-63. Normal Color Test (3 Pass). ..................................................... 4-61 4-64. Abnormal Test Examples. ........................................................ 4-61 4-65. Cartridge Tubing Needle and Septum. ............[...]

xxi NovaJet 800 Series Service Manual List of Illustrations (cont) Figure Page Chapter 4 Troubleshooting (cont) 4-98. Probable Defective Carriage PWA. .......................................... 4-92 4-99. Defective Main PWA. ............................................................. 4-92 4-100. Corrupted Code - Main PWA. ........................[...]

xxii NovaJet 800 Series Service Manual List of Illustrations (cont) Figure Page Chapter 5 Assembly/Disassembly (cont.) 5-18. Carriage Coupler Installation. ................................................... 5-28 5-19. Left Carriage Installation. ......................................................... 5-29 5-20. Carriage PWA Removal/Installation.[...]

xxiii NovaJet 800 Series Service Manual List of Tables Table Page Chapter 3 Maintenance 3-1. Main PWA Connections. ............................................................ 3-10 3-2. Carriage PWA Connections. ....................................................... 3-11 Chapter 4 Troubleshooting 4-1. Troubleshooting T able. ......................[...]

General Description 1-1 NovaJet 800 Series Service Manual General Description 1 Figure 1-1. NovaJet 800 Series Inkjet Printer. Introduction This manual provides service information for the ENCAD ® , Inc. NovaJet ® 800 Series Color Inkjet Printers. The NovaJet 850 printer is available in two sizes: a 42 inch model and a 60 inch model. The NovaJet [...]

General Description 1-2 NovaJet 800 Series Service Manual A Centronics parallel connection is provided to interface with the host computer. Commands sent from the host computer can be in several forms including HP-GL/2, HP-RTL and Encad RTL formats. Drivers are supplied to support Windows ® -based PCs (95, 98, ME, NT and 2000) as well as Macintosh[...]

General Description 1-3 NovaJet 800 Series Service Manual Overview Printers draw according to instructions issued from a “host” computer. 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 automa[...]

General Description 1-4 NovaJet 800 Series Service Manual Warnings, Cautions and Notes Warnings, cautions and notes are used when additional information, instructions or care should be observed. In this manual warnings, cautions and notes precede the text to which each applies. The definition of each is provided below. WARNINGS - Warnings are used [...]

General Description 1-5 NovaJet 800 Series Service Manual Printer Specifications The specifications and performance characteristics of the NovaJet 800 Series Color Inkjet Printers are as follows: Max Printing Area: 42 inch 60 inch Norm 40.8” 58.8” 1.04m 1.49m Extend 41.61” 59.61” 1.06m 1.51m Language Emulation: HP-RTL ENCAD RTL HP GL/2 Buff[...]

General Description 1-6 NovaJet 800 Series Service Manual 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 chapters so that each chapter can “stand alone”. This allows inform[...]

General Description 1-7 NovaJet 800 Series Service Manual 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. Chapter 4 TROUBLESHOOTING - A table containing problems that could occur and pos[...]

General Description 1-8 NovaJet 800 Series Service Manual Technical Support ENCAD offers full technical support and service for its various prod- ucts. If you are unable to find the answer to your question in either the User’s Guide, Service Manual, or other related publications, check out ENCAD’s Knowledge Base located on ENCAD’s website sup[...]

2 2-1 Introduction This chapter explains the mechanical and electrical theory of operation of the ENCAD NovaJet 800 Series Color Inkjet printers. The NovaJet 800 Series V-8 print engine has eight ink cartridges, eight 500-milliliter ink reservoirs and 12 independent ink lines. The cartridges are housed in a torque-free floating carriage assembly th[...]

Theory of Operation 2-2 NovaJet 800 Series Service Manual NovaJet 800 Series Printers General Block Diagram Figure 2-1 illustrates the major functional areas of the printers. The NovaJet 800 Series printers consist of three mechanical assem- blies: 1. Paper (Media) Axis Drive 2. Carriage Axis Drive 3. Media Feed and Take-Up System and five main ele[...]

Theory of Operation 2-3 NovaJet 800 Series Service Manual Figure 2-1. General Block Diagram.[...]

Theory of Operation 2-4 NovaJet 800 Series Service Manual Paper (Media) Axis Drive Figure 2-2. Paper (Media) Axis Drive. The Paper (Media) Axis Drive moves the plotting media in a direction 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 d[...]

Theory of Operation 2-5 NovaJet 800 Series Service Manual The Carriage Axis Drive CARTRIDGE 1 CARTRIDGE 2 CARTRIDGE 3 CARTRIDGE 4 OPTICAL ENCODER OPTICAL SENSOR PAPER SENSOR CARRIAGE PWA TRAILING CABLE CONNECTION FROM MAIN PWA TRAILING CABLE INKJET DRIVERS LEFT AND RIGHT CARRIAGE ASSEMBLY RIGHT CARRIAGE ASSEMBLY ONLY Figure 2-3. Carriage Axis Drive[...]

Theory of Operation 2-6 NovaJet 800 Series Service Manual Media Feed and Take-Up System REFLECTOR REFLECTOR SENSORS Figure 2-4. Power Feed and Take-Up System. The media feed and take-up system comprises of two optical sensors, two dc motors and a dryer assembly. See Figure 2-4. Motors are used to advance the media feed roll and the media take-up ro[...]

Theory of Operation 2-7 NovaJet 800 Series Service Manual Main PWA (Printed Wiring Assembly) Figure 2-5. Main PWA (Printed Wiring Assembly). The Main PWA (Printed Wiring Assembly) consists of seven functional areas: 1. Microprocessor (CPU) 2. Gate Array 3. Memory Circuits 4. Stepper Motor Controller 5. Servo Motor Controller 6. Interface Circuits: [...]

Theory of Operation 2-8 NovaJet 800 Series Service Manual Main PWA LED Status Indicators D1 - Normally flashes when the DSP is idle. Steady during print opera- tions. D8 - +24V available. D9 - Normally flashes when the Power PC processor is idle. Stops flashing when processor is busy (i.e. during paper sensing operations or printing). D10 - Normall[...]

Theory of Operation 2-9 NovaJet 800 Series Service Manual Gate Array Figure 2-6. Gate Array. The gate array contains the hardware logic for dot firing, monitoring changes in the Carriage Assemblies position, controlling DMA through the parallel port, and generating the PWM (Pulse Width Modulation) waveforms for the servo controller. It also control[...]

Theory of Operation 2-10 NovaJet 800 Series Service Manual Memory Circuits 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, SDRAM, and EEPROM. Maximum installable memory is as follows: SDRAM = 256 MB Flash EEPROM = 2 MB Serial [...]

Theory of Operation 2-11 NovaJet 800 Series Service Manual SDRAM SDRAM is Synchronous Dynamic Random Access Memory, which provides temporary storage of the microprocessor calculation and input/ output data. It is also a faster type of memory then the Flash EEPROM. That’s why the printer control program is also copied from the Flash EEPROM to RAM,[...]

Theory of Operation 2-12 NovaJet 800 Series Service Manual commands which the Stepper Motor receives from the microprocessor. 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 wav[...]

Theory of Operation 2-13 NovaJet 800 Series Service Manual Servo Motor Controller GATE ARRAY MOTOR DRIVER SERVO CONNECTOR CARRIAGE CONNECTOR SERVO MOTOR CARRIAGE ENCODER MAIN PWA Figure 2-8. Servo Motor Controller. The Carriage Assembly is driven by the Servo Motor. The speed of the Carriage Assembly is controlled by varying the duty cycle of the s[...]

Theory of Operation 2-14 NovaJet 800 Series Service Manual ENCODER STRIP OUTPUT OF DETECTOR 2 COMPOSITE TRANSITION-TRIGGERED OUTPUT OF BOTH DETECTORS OUTPUT OF DETECTOR 1 4 OUTPUT PULSES PER OPTICAL LINE DETECTOR 2 DETECTOR 1 Figure 2-9. Quadrature Signal Generation. The direction that the Carriage Assembly is moving is calculated based upon the st[...]

Theory of Operation 2-15 NovaJet 800 Series Service Manual A hardware counter in the gate array increments as the Carriage Assem- bly moves left and decrements as the Carriage Assembly moves right. The hardware counter is only eight bits wide, so it cannot store a value large enough to represent an absolute Carriage Assembly position. Instead, it i[...]

Theory of Operation 2-16 NovaJet 800 Series Service Manual Carriage Assembly Circuits CARTRIDGE 1 CARTRIDGE 2 CARTRIDGE 3 CARTRIDGE 4 OPTICAL ENCODER OPTICAL SENSOR PAPER SENSOR CARRIAGE PWA TRAILING CABLE CONNECTION FROM MAIN PWA TRAILING CABLE INKJET DRIVERS LEFT AND RIGHT CARRIAGE ASSEMBLY RIGHT CARRIAGE ASSEMBLY ONLY Figure 2-11. Carriage Assem[...]

Theory of Operation 2-17 NovaJet 800 Series Service Manual NOTE: The carriage housing has been modified from that of the Right Carriage Assembly. The belt strain relief has been removed and the encoder sensor clip has been removed. The Right Carriage PWA contains the logic and drive circuitry for the firing of the inkjet cartridges. It also establi[...]

Theory of Operation 2-18 NovaJet 800 Series Service Manual Control Panel The Control Panel is located on the right side of the printer and consists of 8 variable-action control buttons and an LCD graphics display. The control buttons are assigned to different functions and are dependant upon the selections that were previously selected. There are f[...]

Theory of Operation 2-19 NovaJet 800 Series Service Manual The power supply is fused using a 6.3A 250V fast blow type fuse. The outputs share a common ground which is isolated from earth ground with in the supply itself. Earth ground and DC ground are connected external of the power supply. The power supply will shut down under overload/short circu[...]

Theory of Operation 2-20 NovaJet 800 Series Service Manual The Main PWA has a humidity sensor and a temperature sensor mounted to the back side. The sensors monitor ambient room temperature and humidity. Prior to print operations the printer should be allowed to acclimate to the environment for at least 15 minutes. The plenum may be preheated using[...]

Theory of Operation 2-21 NovaJet 800 Series Service Manual Beeper and Fans The beeper contains built-in driver circuitry so that it beeps under firm- ware control. The beeper alerts the user to error conditions. There exists three types of fans that can be on these printers. A single fan, located below the power supply, is used for cooling the powe[...]

3 3-1 Maintenance Introduction This chapter contains general maintenance and cleaning instructions for the NovaJet 800 series printers. 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 main[...]

Maintenance 3-2 NovaJet 800 Series Service Manual Cleaning Procedures Always turn the printer OFF, remove the power cord and the inter- face cable before cleaning the printer. An electrical shock hazard may be present if these procedures are not followed. External Cleaning Do not use abrasive cleansers of any sort on the surfaces of the printer. Da[...]

Maintenance 3-3 NovaJet 800 Series Service Manual 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 carriage. Extreme drag results in a “carriage axis failure” fault and will stop the carriage motion. These problems may be eliminated by maintaining and[...]

Maintenance 3-4 NovaJet 800 Series Service Manual 7. If the service station is filling with ink or very dirty it can be removed and rinsed under warm water. To remove, pull the tab on the right side of the service station and lift out. Wash, dry thoroughly and replace by placing the left side in first then pushing down on the right side until the t[...]

Maintenance 3-5 NovaJet 800 Series Service Manual MAINTENANCE Trailing Cables Cleaning Clean the trailing cables bi- weekly or as necessary to remove any buildup of debris. Distilled water should be used. Do not pull too hard on the trailing cables or damage may occur. To clean the Trailing Cables: 1. Disconnect the power cord and interface cable. [...]

Main tena nce 3 -6 NovaJet 800 Series Service Manual Cartridge Dimples Cleaning CARTRIDGE DIMPLE AREA Figure 3-2. Cartridge Dimple 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 o[...]

Maintenance 3-7 NovaJet 800 Series Service Manual MAINTENANCE Be sure to clean the yellow cartridge because it is not readily apparent that it is dirty. The yellow ink is hard to see and could be overlooked. Flex Cable Contact Cleaning Flex Cable Contacts Figure 3-3. Flex Cable Contacts. Cleaning the flex cable contact area is very important due to[...]

Maintenance 3-8 NovaJet 800 Series Service Manual Clean and Inspect Stepper Motor Gears The stepper motor gears can become dirty after time (typically after 4-5 years of operation) if not cleaned. Dirty gears can cause microbanding in the print. This will reduce the quality of the output. Clean the motor gears with a stiff brush to knock off any de[...]

Maintenance 3-9 NovaJet 800 Series Service Manual MAINTENANCE Dryer Cleaning To clean ink and debris from the dryer, use a lint-free cloth dampened with water. Clean all external surfaces with the exception of the underside of the dryer. Reseat Connectors on Main PWA and Carriage Boards Integrated circuits may become weakened or damaged by electri-[...]

Maintenance 3-10 NovaJet 800 Series Service Manual J11 J5 J18 J17 J4 J15 J13 J6 J2 J1 J8 J10 J9 J7 U24 J12 Figure 3-4. Main PWA Connection Locations. Table 3-1. Main PWA Connections. J1 Trailing Cable A J10 Display J2 Trailing Cable B J11 Serial Port J3 not used J12 Servo Motor J4 Vacuum Fan #2 J13 AutoLoad Sensor J5 Parallel Port J14 not used J6 L[...]

Maintenance 3-11 NovaJet 800 Series Service Manual MAINTENANCE J7 J6 J4 J5 J3 J2 J1 Figure 3-5. Carriage PWA Connection Locations. Table 3-2. Carriage PWA Connections. J1 Trailing Cable J5 Cyan/Slot 2 Drivers J2 Paper Sensor J6 Magenta/Slot 3 Drivers J3 Encoder Sensor J7 Yellow/Slot 4 Drivers J4 Black/Slot 1 Drivers Figures 3-4 and 3-5 show the loc[...]

Maintenance 3-12 NovaJet 800 Series Service Manual LOCKING MECHANISM CONNECTOR ASSEMBLY RIBBON UNLOCKED LOCKED Figure 3-6. Ribbon Connector Locking Mechanism. Replace Trailing Cables Before replacing the trailing cables from the printer always remove power from the printer. The trailing cables (2 total) are rated for approximately 2000 hours of ope[...]

Maintenance 3-13 NovaJet 800 Series Service Manual MAINTENANCE Replace Carriage Cover/Carriage Bushings The carriage cover bushings (2 total) are rated for approximately 2000 hours of operational usage while the carriage assembly bushings (4 total) are rated for approximately 4000 hours of opera- tional usage. Many factors including, but not limite[...]

Maintenance 3-14 NovaJet 800 Series Service Manual Servo Motor Winding Resistance Check Figure 3-7. Servo Motor. 1. Disconnect the servo motor connection from J12 on the Main PWA. 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 [...]

Maintenance 3-15 NovaJet 800 Series Service Manual MAINTENANCE Stepper Motor Winding Resistance Check * B A Figure 3-8. Stepper Motor. 1. Disconnect the stepper motor connection from J7 on the Main PWA. 2. Using a standard ohmmeter or multimeter, measure between pins 1 (red wire) and 3. Point A in Figure 3-8. The asterisk in Figure 3-8 identifies t[...]

Maintenance 3-16 NovaJet 800 Series Service Manual Power Feed and Take-Up Motor Winding Resistance Check Figure 3-9. Power Feed and Take-Up Motor. 1. Remove the feed and/or take-up roll from the printer. 2. Using Phillips screwdriver, remove the four screws that secure the cradle idler from the right leg. 3. Ease the cradle idler off of the leg eno[...]

Maintenance 3-17 NovaJet 800 Series Service Manual MAINTENANCE Banding Differences Consistent horizontal banding is usually hardware related. Normally horizontal microbanding is caused by improper color deadband or color calibrations, dirty cartridges or service station. Inconsistent banding is usually software related. However, electrostatic disch[...]

Maintenance 3-18 NovaJet 800 Series Service Manual banding lines are generated by the software when the application incorrectly interprets the media advancing/ink firing sequence of the expected print file or when text an error occurs within the host application. Errors can also be caused by insufficient host workstation or RIP memory or processing[...]

Maintenance 3-19 NovaJet 800 Series Service Manual MAINTENANCE Banding Causes & Quick Analysis Horizontal Banding Problems 1. Check the print mode for the type of image being printed. Refer to Printer Calibrations - 'Checking Print Mode'. Is the high pass mode (5 pass for 2x4 configuration, 10 pass for 1x4, 1x6, and 1x8 cartridge set [...]

Maintenance 3-20 NovaJet 800 Series Service Manual 5. Clean the cartridge electrical and carriage flex driver cable contacts with isopropyl alcohol. Refer to Scheduled Maintenance. Reseat the flex driver cable connection for print images which contain vertical bar patterns along the right edge of print. If more than one color (represented by the ve[...]

Maintenance 3-21 NovaJet 800 Series Service Manual MAINTENANCE Menu, Service Menu, Test Print) may be used, but this test is a compressed vector based file and may exhibit certain dithering properties different from that of another rasterized print. 12. Refer to 'Cartridge Misfires' and 'Ink Dropout' to ensure all other troubles[...]

Maintenance 3-22 NovaJet 800 Series Service Manual 18. Clean or replace encoder strip for image skewing (image walking or skipping). Whether the image skews slights or off the page the encoder strip is at fault. Typically characterized as horizontal banding, often a walking image can also create vertical bands to appear in the print. Refer to &apos[...]

Maintenance 3-23 NovaJet 800 Series Service Manual MAINTENANCE create vertical bands to appear in the print. Refer to 'Scheduled Maintenance' for cleaning or 'Disassembly' for encoder strip replacement. Line Quality Problems (Overspray) 1. Check the print mode, normally quality is achieved in the draft, normal or best mode. The [...]

Maintenance 3-24 NovaJet 800 Series Service Manual Images CD and refer to 'Demonstration Print' for proper procedures. Alignments/Adjustments The ENCAD NovaJet 850 printers are designed with a minimum of maintenance requirements in mind. Calibrations include: color calibration, deadband alignment, and X-axis calibration. The mechanical ad[...]

Maintenance 3-25 NovaJet 800 Series Service Manual MAINTENANCE Calibration Jo Block (1.434”) - Not used Plastic Gauge Card (0.011”) - Not used There are two basic measurements that are to be made using this kit (ensure power is off prior to performing these proceures): 1. Slide Shaft Profile Adjustment 2. Carriage (Cartridge) Head Height Settin[...]

Maintenance 3-26 NovaJet 800 Series Service Manual MEASURE SECOND MEASURE FIRST MEASURE LAST ADJUST IF NECESSARY Figure 3-12. Measurement Positions for Slide Shaft. 3. Measure the right side (next to media alignment mark) and note the difference. Divide this amount by two. 4. Measure just off the center of the slide shaft and adjust the center turn[...]

Maintenance 3-27 NovaJet 800 Series Service Manual MAINTENANCE THIS IS THE INNER SCREW . POSITION GAUGE DIRECTL Y IN FRONT OF IT . THESE ARE THE TURNBUCKLE SCREWS. POSITION GAUGE IN BETWEEN THE SCREWS AND AS CLOSE TO CENTER AS POSSIBLE. Figure 3-13. Slide Shaft Profile Adjustment. For example: If the Left = 0, Right = +0.004”, then the center sho[...]

Maintenance 3-28 NovaJet 800 Series Service Manual HEAD HEIGHT CARTRIDGE JET PLATE PLATEN Figure 3-14. Carriage Head Height Tolerance. 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. Obtain the Hea[...]

Maintenance 3-29 NovaJet 800 Series Service Manual MAINTENANCE 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 3-16. ZERO GAUGE ENSURE PRESSURE IS PLACED ON THE REAR OF THE CART[...]

Maintenance 3-30 NovaJet 800 Series Service Manual Damage may occur to the micrometer gauge if the Carriage is moved without lifting up on the mea- suring tip. This action could also take the microme- ter out of alignment and foul the results of the align- ment. 6. While lifting up the measuring tip of the micrometer, slide the Carriage to the left[...]

Maintenance 3-31 NovaJet 800 Series Service Manual MAINTENANCE 12. To adjust the far right screw obtain the head height plate and install into the service station access hole (service station must be removed). Move the carriage assembly over the service station access hole so the Micrometer measuring tip extends to the head height plate surface. Ad[...]

Maintenance 3-32 NovaJet 800 Series Service Manual -6 -5 -4 -3 -2 -1 0 1 234 5 6 COLOR VERTICAL HEAD-TO-HEAD CALIBRATION Y M C COLOR HORIZONTAL HEAD-TO-HEAD CALIBRATION C M Y Current Heads (Y, M, C) Figure 3-18. Vert. and Horiz. Color Calibration. The “Current Heads (Y, M, C, 1, 2, 3, 4)” view represents the alignment of the heads as they are c[...]

Maintenance 3-33 NovaJet 800 Series Service Manual MAINTENANCE Prime Access Menu Color Calib Menu Calibration Menu Display Settings Print Settings Service Menu Exit * Figure 3-19. Utility Menu. 2. From the Utility Menu, select “Color Calib Menu”. This brings up the color calibration menu and it looks like Figure 3-20. Vertical Horizontal Vert. [...]

Maintenance 3-34 NovaJet 800 Series Service Manual 4 Vertical Next Option <> Prev Option selected Cancel Ok * Figure 3-21. 4 Vertical Options Menu. 5. Observe the plot and using either “Prev Option” or “Next Option”, rotate through the selections until the one that best aligns the cartridge in slot 4 on the plot is selected. Press “[...]

Maintenance 3-35 NovaJet 800 Series Service Manual MAINTENANCE Figure 3-22. Slow Deadband. Figure 3-22 shows what the display will look like when printing the slow deadband 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 top and bottom set of l[...]

Maintenance 3-36 NovaJet 800 Series Service Manual Calibration Menu Diagnostics Menu About Cartridge Info. Test Print Exit * Figure 3-23. Service Menu. 3. Select the “Calibration Menu” from the Service Menu. 4. The Calibration Menu shown in Figure 3-24 is where the deadband tests are performed. Select “Slow Db Test” to run the slow deadband[...]

Maintenance 3-37 NovaJet 800 Series Service Manual MAINTENANCE 7. Continue performing steps 4 through 6 until the slow deadband adjustment is correct. Color Deadband Alignment The color deadband alignments are necessary to ensure that the output images are being produced with the highest quality standards available while using the ENCAD printer in [...]

Maintenance 3-38 NovaJet 800 Series Service Manual 4. The Color Db Menu is shown in Figure 3-26 and is where the color deadband test is performed. Left Right Color Db Test Exit * Figure 3-26. Color Db Menu. Select “Color Db Test” to run the color deadband test. The test consists of 12 default calibration settings. When the test is run it will p[...]

Maintenance 3-39 NovaJet 800 Series Service Manual MAINTENANCE 6. Observe the plot and using either “Prev Option” or “Next Option”, rotate through the selections until one that seems closer to the correct value is selected. Press “Ok” to accept the selection and return to the Left Carriage Cartridge Slot Selection Menu. 7. Continue perf[...]

Maintenance 3-40 NovaJet 800 Series Service Manual 33" or 83.82 cm Figure 3-27. Paper Axis Test. 5. With a precision drafters measuring stick, measure the exact distance from each of the “ T ” intersections. 6. Select “Paper Axis” at the Calibration Menu. This brings up the options menu for the paper axis adjustment. This menu is simil[...]

Maintenance 3-41 NovaJet 800 Series Service Manual MAINTENANCE Servo PWM Test Servo Cycle Test Accessory Menu Carriage Test Color Test Menu Continuous Test Exit * Figure 3-28. Diagnostics Menu. All tests under the Diagnostics Menu should be performed by competent technicians only. The types of tests that can be performed are: Servo PWM Test, Servo [...]

Maintenance 3-42 NovaJet 800 Series Service Manual Servo Cycle Test - Tests the servo motor by moving the carriage back and forth across the slide shaft. The number of cycles is selectable and the available options are: 10 100 1,000 10,000 100,000 1,000,000. Carriage Test - Prints 5 sets of 3 parallel lines to test the vibration characteristics of [...]

Maintenance 3-43 NovaJet 800 Series Service Manual MAINTENANCE Fan #1 and Fan #2 Tests - Tests the operation of the fans on the printer. Fan #1 Test (while depressed) turns on the power supply cooling fan and the suction fan inside the platen on the right side of the printer. Fan #2 Test (while depressed) turns on the suction fan inside the platen [...]

Maintenance 3-44 NovaJet 800 Series Service Manual 4. Select the firmware file in the Files section of the dialog box and press the Print button. The firmware file is sent to the printer as a normal print job. Approxi- mately 20 - 40 seconds later a single beep should be heard indicating the update was successful. After a one second delay, the prin[...]

Maintenance 3-45 NovaJet 800 Series Service Manual MAINTENANCE Wait approximately 20 to 40 seconds later until you hear a SINGLE beep, indicating the download was successful. You may encounter a set of double beeps shortly after sending the firmware file, but you must wait until you hear the SINGLE beep. 5. After hearing the single beep, remove pow[...]

Maintenance 3-46 NovaJet 800 Series Service Manual 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 J7 J1 CARRIAGE A OR B PWA 1 2 3 4 +5V EXB GND EXA J2 1 2 3 4 J1 OPTICAL ENCODER SENSOR YELLOW/4 MAGENTA/3 CYAN/2 CARTRIDGE DRIVERS BLACK/1 J4 J5 J6 J7 TXOU T 0- (A/B) TXOUT(A/B)0+ TXOUT(A/B)1+ TXOU[...]

Maintenance 3-47 NovaJet 800 Series Service Manual MAINTENANCE Figure 3-32. Leg Harness Connections Diagram. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 J6 SUPPLY SENSOR MAIN PRINTED WIRING ASSEMBLY 21 22 [...]

Troubleshooting 4-1 NovaJet 800 Series Service Manual Troubleshooting 4 No Power • printer not ON depress power switch • faulty power replace power cord cord • AC input not replace AC entry Introduction Chapter 4, Troubleshooting consists of a table that is intended to aide the technician in troubleshooting the NovaJet 800 series printers. Th[...]

Troubleshooting 4-2 NovaJet 800 Series Service Manual Symptoms Possible cause Solution Table 4-1. Troubleshooting Table (cont). No Power • printer not ON depress power switch • faulty power replace power cord cord • AC input not replace AC entry present at power module supply • DC output replace power voltage not supply present (see Figure [...]

Troubleshooting 4-3 NovaJet 800 Series Service Manual Symptoms Possible cause Solution Table 4-1. Troubleshooting Table (cont). • trailing cable replace trailing defective cable Media Does Not Move • perform Stepper replace stepper Motor Winding motor if out of Resistance check tolerance • rough motion bad bearings - while spinning replace st[...]

Troubleshooting 4-4 NovaJet 800 Series Service Manual Symptoms Possible cause Solution Table 4-1. Troubleshooting Table (cont). Internal ERROR “Carriage Axis Failure” • dirty (or perform Slide Shaft lubricated) slide Cleaning procedure shaft • perform Servo replace servo motor Motor Winding Resistance check • check servo bad bearings - mo[...]

Troubleshooting 4-5 NovaJet 800 Series Service Manual Symptoms Possible cause Solution Table 4-1. Troubleshooting Table (cont). • worn carriage replace carriage bushings bushings • loose trailing remove power and cable connections reseat trailing cable connections at the MPWA and the carriage assemblies • cutter assembly replace cutter malfun[...]

Troubleshooting 4-6 NovaJet 800 Series Service Manual Symptoms Possible cause Solution Table 4-1. Troubleshooting Table (cont). Internal ERROR “Paper Sensor Failure” • servo motor reattach connections and vaccuum fan correctly (use Figure connections to 3-4 for reference) MPWA are switched • paper sensor reseat paper cable unseated sensor c[...]

Troubleshooting 4-7 NovaJet 800 Series Service Manual Symptoms Possible cause Solution Table 4-1. Troubleshooting Table (cont). Internal ERROR “MPCB Failure” • bad MPWA replace MPWA Unrecognized Cartridges Error • faulty connection check cartridges of cartridge ID chip to flex cable • wrong cartridges check cartridges installed • incorr[...]

Troubleshooting 4-8 NovaJet 800 Series Service Manual Symptoms Possible cause Solution Table 4-1. Troubleshooting Table (cont). Media Sen Ref. Pts Not Initialized (NJ880 only) • reference points reset all eleven refer- were accidentally ence p9oints by per- cleared forming the Media Ref Pts. Alignment Image Skews or Moves • dirty encoder clean [...]

Troubleshooting 4-9 NovaJet 800 Series Service Manual Symptoms Possible cause Solution Table 4-1. Troubleshooting Table (cont). • bad MPWA replace MPWA Ink Cartridge Misfiring • cartridge low on refill or replace ink cartridge • defective septum replace cartridge needle tubing needle/ septum assy. • ink drop out lower ink pre-heat (ink star[...]

Troubleshooting 4-10 NovaJet 800 Series Service Manual Symptoms Possible cause Solution Table 4-1. Troubleshooting Table (cont). Ink Cartridge • service station 1) perform Service Misfiring (cont) dirty or not Station Cleaning properly sealing procedures cartridge jet area 2) replace seal on service station • bad carriage replace carriage PWA P[...]

Troubleshooting 4-11 NovaJet 800 Series Service Manual Symptoms Possible cause Solution Table 4-1. Troubleshooting Table (cont). Printer Output is 2) inspect and/or Banding (Horz.) replace stepper (cont) motor gears and/or lower roller assembly 3) replace MPWA • insufficient replace or refill ink in cartridges cartridges (normally 1/3 full) • c[...]

Troubleshooting 4-12 NovaJet 800 Series Service Manual Symptoms Possible cause Solution Table 4-1. Troubleshooting Table (cont). Printer Output is 2) replace carriage Banding (Horizontal) quad flex cable (cont) • carriage check carriage assembly assembly for proper obstructed movement along Y-arm • carriage belt is reinstall, check loose, too t[...]

Troubleshooting 4-13 NovaJet 800 Series Service Manual Symptoms Possible cause Solution Table 4-1. Troubleshooting Table (cont). • defective encoder clean encoder strip strip • bad MPWA replace MPWA Keypad Locked-Up or Not Functioning Properly • firmware 1) reset printer problem 2) refresh or up- grade firmware (while in continuous run state)[...]

Troubleshooting 4-14 NovaJet 800 Series Service Manual Symptoms Possible cause Solution Table 4-1. Troubleshooting Table (cont). • carriage replace carriage bushings worn bushings (4) • debris or clean fan assembly obstruction in fan • drive belt replace frame slipping on idler tensioner, spring, or idler • hardware or tighten hardware asse[...]

Troubleshooting 4-15 NovaJet 800 Series Service Manual Symptoms Possible cause Solution Table 4-1. Troubleshooting Table (cont). • color calibration perform Color needed Calibration • deadband perform Deadband calibration needed Calibration (in bidirectional printing mode) • debris or clean slide shaft lubrication on slide shaft • leaks or [...]

Troubleshooting 4-16 NovaJet 800 Series Service Manual Symptoms Possible cause Solution Table 4-1. Troubleshooting Table (cont). Fan Does Not Power Up • MPWA has 1) reseat connection 24 VDC at J3 at MPWA to fan pins 1-2 2) replace fan • power not being 1) reload firmware applied to fan 2) replace MPWA Media Take-Up Motor Not Operat- ing, Sensor[...]

Troubleshooting 4-17 NovaJet 800 Series Service Manual Symptoms Possible cause Solution Table 4-1. Troubleshooting Table (cont). Media Feed Motor Not Operating, Sensor Works • bad connection reconnect Feed to the motor motor • bad Feed motor replace Feed motor • faulty wiring leg reseat or replace harness leg harness • bad MPWA replace MPWA[...]

Troubleshooting 4-18 NovaJet 800 Series Service Manual Symptoms Possible cause Solution Table 4-1. Troubleshooting Table (cont). • reflective decal replace reflective missing decal • sensor not replace or reshape aligned correctly sensor bracket (sensor bracket bent or misaligned)[...]

Troubleshooting 4-19 NovaJet 800 Series Service Manual Print Quality Issues Cartridge Misfires (Intermittent Banding) Cartridge or print head misfires (clogged jets or misfiring jets) lead to microbanding in prints and can cause operational downtime. The Prime pattern tests all cartridge jets. Activate the Prime pattern several times to verify the [...]

Troubleshooting 4-20 NovaJet 800 Series Service Manual Failure Analysis - Print Misfires 1. Ensure ink is in supply to cartridge jets? Are the ink lines full of ink at the reservoir tubing needles (connected to reservoir) and at the cartridge tubing/septum needles (connected to cartridges)? 2. Are the ink cartridges /contact points (flex contacts) [...]

Troubleshooting 4-21 NovaJet 800 Series Service Manual Figure 4-3. Dirty Service Station. 5. Are there any signs of leaking ink on or below the inkjet carrier assembly? This would indicate an air leak is in the ink delivery system. Ensure the septum connector fittings (3 parts make up the septum connector) are tight. Check all fittings. Replace car[...]

Troubleshooting 4-22 NovaJet 800 Series Service Manual PWA? Reseat either the Right or Left Carriage PWA flex driver cable connections. The floating carriage cover must be removed first. Refer to Disassembly. Figure 4-5. Unseated Flex Driver Cable. 8. Is the trailing cable damaged? Look for black runs or brown freckles in the cable. Brown freckles [...]

Troubleshooting 4-23 NovaJet 800 Series Service Manual Figure 4-7. Damaged Flex Driver Cable. 11. Inspect flex driver cables (on carriage). Has damage/ink attack occurred? Look at electrical dimples for charring or burn marks. Replace cable if damaged. Refer to Disassembly. 12. Reseat flex driver cable connection at the appropriate Carriage PWA For[...]

Troubleshooting 4-24 NovaJet 800 Series Service Manual Figure 4-9. Unseated or Defective Trailing Cable. 13. Replace both trailing cables for vertical white gaps or spaces in the Prime pattern, jumps in color, or for irregular patterns with horizontal lines. Also refer to Microbanding. Refer to Disassembly for trailing cable replacement procedures.[...]

Troubleshooting 4-25 NovaJet 800 Series Service Manual Figure 4-11. Stall Configuration. Ensure the left or right Carriage PWA is tested properly. 15. Replace the Main PWA only if a specific test pattern, calibration, or jet sequence fails to print. Magnetic tipped screwdrivers are known to have caused these types of Main PWA failures in the past. [...]

Troubleshooting 4-26 NovaJet 800 Series Service Manual Clearing Cartridge Misfires - Press lightly against jets with a water/alcohol moistened lint-free cloth. Blot gold jet plate area, do not wipe. - Insert cartridge and initiate a Color Test @ 100% in the 2-pass mode. Note: running the color test in the single pass mode severely reduces printhead[...]

Troubleshooting 4-27 NovaJet 800 Series Service Manual Figure 4-14. Service Station. If failures are occurring within 40 ml of ink throughput, improper cleaning of electrical contacts on carrier or a connectivity problem probably exists. Driver chips on the carriage PCB are known to have blown multiple cartridges in a row and vice versa. Some cartr[...]

Troubleshooting 4-28 NovaJet 800 Series Service Manual Some types of address line and power line failures are below: Figure 4-16. Catastrophic Jet Failure. Figure 4-17. Power Line Failure. Figure 4-18. Address Line Failure. Figure 4-19. Multiple Address Line Failure. Microbanding Minimal microbanding normally occurs in the production modes (1, 2, a[...]

Troubleshooting 4-29 NovaJet 800 Series Service Manual Figure 4-20. Microbanding. Refer to the following table for the differences between quality modes in the 1x4 and 2x4 configurations. Note: 6 pass, speed 10 is the true photo mode in 1x4 operations. Figure 4-21. Quality Print Modes.[...]

Troubleshooting 4-30 NovaJet 800 Series Service Manual Banding Differences Consistent horizontal banding is usually hardware related. Normally, horizontal microbanding is caused by improper color deadband or color calibrations, dirty cartridges or service station. Inconsistent banding is usually software related. However, electrostatic discharge (E[...]

Troubleshooting 4-31 NovaJet 800 Series Service Manual Horizontal Banding 1. Check the print mode for the type of image being printed. Is the enhanced print pass mode printing OK? Note: photo pass mode may microband in some of the 2 tone color ranges including blue, gray, orange, and purple hues. Enhanced modes should not microband. Check to see if[...]

Troubleshooting 4-32 NovaJet 800 Series Service Manual Figure 4-24. AutoWipe Interference. 4. Ensure the Auto-Wipe feature is turned off. To gain access select SetUp Menu, Paper Option Menu, Auto-Wipe, select off. Auto-Wipe of the carriage head (occurs every 2 minutes when activated) can cause a dry band to appear on the print. This feature is norm[...]

Troubleshooting 4-33 NovaJet 800 Series Service Manual Figure 4-26. Unseated or Defective Trailing Cables. 6. Clean the cartridge electrical and carriage flex driver cable contacts with isopropyl alcohol. Refer to Routine Maintenance. Reseat the flex driver cable connection for print images which contain vertical bar patterns along the right edge o[...]

Troubleshooting 4-34 NovaJet 800 Series Service Manual Figure 4-27. ESD Problems. Figure 4-28. Defective Carriage PWAs. 8. Change media to see if electrostatic discharge from media is causing the banding to occur. Add 3rd party static eliminator protection if required.[...]

Troubleshooting 4-35 NovaJet 800 Series Service Manual Figure 4-29. Carriage Head Strike. 9. Ensure the vacuum fan or fans are providing adequate suction for media. If the exhaust grill (s) are installed incorrectly then carriage head scraping will occur on the media causing streaking or inconsistent banding. This could also be due to thick media ([...]

Troubleshooting 4-36 NovaJet 800 Series Service Manual 12. Print a test RTL file to verify banding, if banding is absent, then check software. Obtain the service or support CD or Customer’s Demo Images CD and refer to ‘Demonstration Print’ for proper procedure. Print at least 50% of the test print before deciding the next course of action. Th[...]

Troubleshooting 4-37 NovaJet 800 Series Service Manual Figure 4-34. Defective Carriage PWA (Color Test). 15. Inspect and clean stepper motor and lower roller drive gears if printer is older than 5 years. (Every two years if printer is used for textile printing.) Other unique microbanding causes include synchronization errors from the stepper drive [...]

Troubleshooting 4-38 NovaJet 800 Series Service Manual Figure 4-36. Defective Stepper Motor. 17. Check carriage head height when jet plate scrapes appear on media. The Banding will have jagged or slightly angled lines at the termination points or may even appear as light cuts in the media (like a utility knife cut the surface of a print). The norma[...]

Troubleshooting 4-39 NovaJet 800 Series Service Manual Figure 4-37. Servo System Synchronization Failure. 18. Replace the servo motor for horizontal bands (thicker than 2 mm) which extend beyond the page layout from .5 mm to 20 mm. The servo motor bearings may be faulty which cause excessive drag and ‘carriage axis errors’. The normal servo mot[...]

Troubleshooting 4-40 NovaJet 800 Series Service Manual Figure 4-39. Connectivity Problem . 19. Horizontal bands (0.2 mm to 1 mm) which extend beyond the page layout are usually caused by the RIP or workstation memory or the driver not having sufficient work space or other network data flow related problems. Ensure 1GB is free on hard drive at all t[...]

Troubleshooting 4-41 NovaJet 800 Series Service Manual create vertical bands to appear in the print. Refer to ‘Routine Maintenance’ for cleaning or ‘Disassembly’ for encoder strip replacement. Figure 4-41. Main PWA Failures. 21. Replace Main PWA for severe horizontal and vertical banding patterns. Also replace Main PWA or for specific inter[...]

Troubleshooting 4-42 NovaJet 800 Series Service Manual If the color in an output image tends to vertically shift in color (over 1 meter slowly) then the Main PWA is suspect of having a problem. Figure 4-42. RIP Problem. Figure 4-4. Bent Servo Motor Pulley. 22. For phantom images in output, verify RIP is not causing the problem by performing a demon[...]

Troubleshooting 4-43 NovaJet 800 Series Service Manual 23. Diagonal banding is often RIP related. Lines protruding from text on vertical bands in text are typically errors within the applications text field. Vertical Banding Figure 4-44. Dirty or Worn Carriage Bushings. Figure 4-45. Worn Bushings or Bushing Pads. 1. For vertical banding check carri[...]

Troubleshooting 4-44 NovaJet 800 Series Service Manual 2. Rotate image in software 90 degrees and/or print a test RTL file to verify banding. Obtain the Sample Images CD and refer to ‘Demonstration Print’ for proper procedures. Figure 4-46. Defective Trailing Cable Examples. 3. Replace the trailing cable assembly prior to any circuit assembly r[...]

Troubleshooting 4-45 NovaJet 800 Series Service Manual multiple sets of vertical bars appear along the right edge of the print, usually containing CMYK colors. The image may also be ‘pushed’ slightly to the left side of the printing area. Refer to Disassembly. Figure 4-47. Dirty Encoder Strip. 4. Clean and/or replace encoder strip for image ske[...]

Troubleshooting 4-46 NovaJet 800 Series Service Manual 5. Check pinch roller for proper height and encoder stabilizer bracket teflon strip for bubbles. Replace teflon strip/encode stabilizer bracket assembly if problems persist. Line Quality Problems (Overspray) 1. Check the print mode. The enhanced modes should not exhibit any overspray problems. [...]

Troubleshooting 4-47 NovaJet 800 Series Service Manual Figure 4-50. ESD Problem. 7. Change media to see if electrostatic discharge from media is causing the banding or ink over-spray to occur. Add 3rd party ESD protection if required (static eliminator strip). 8. Perform the carriage vibration test under ‘Diagnostics’ Menu, the lines should pri[...]

Troubleshooting 4-48 NovaJet 800 Series Service Manual Perform ‘Cartridge Maintenance & Testing’ before calling technical support or your service representative. These steps must be performed before cartridges will be replaced in any event. Cartridge Maintenance & Testing ENCAD cartridges are engineered for optimum reliability and compa[...]

Troubleshooting 4-49 NovaJet 800 Series Service Manual than 2 weeks apply hot water towel to jet plate area for 15 to 30 seconds. If cleaning the jet plate thoroughly and re-priming the cartridge does not improve print quality, go to Step 4. 4. Run a prime and inspect the printed lines. If the photo mode is not supported as indicated by the Prime P[...]

Troubleshooting 4-50 NovaJet 800 Series Service Manual Figure 4-52. Cartridge Cleaning. Cartridge Misfires - Press lightly against jets with a water/alcohol moistened lint-free cloth. Blot. Do not wipe. - Insert cartridge and initiate a Color Test @ 100% density in a 2-pass print mode. For severe jet clogs use ultrasonic cleaner (30-40 sec) or warm[...]

Troubleshooting 4-51 NovaJet 800 Series Service Manual Figure 4-53. Service Station Cleaning. - If failures are occurring within 40ml ink throughput, improper cleaning of electrical contacts on carriage or a connectivity problem probably exists. - Initially cartridges should be replaced, but further investigation is required. - Check ink lot codes [...]

Troubleshooting 4-52 NovaJet 800 Series Service Manual Inkjet Nozzle Problems - Resistor burnout - no firing (175 million firings average per resistor). Severe clogging may be cleared using ultrasonic cleaner (30-40 sec) or hot water (10-15 sec). Ink Starvation Ink starvation of one or more colors can occur between 10 minutes and 3 hours of operati[...]

Troubleshooting 4-53 NovaJet 800 Series Service Manual Ink System Pressure Theory The ink system works on less than 1/10 psi pressure. The reservoir caps should remain loose to allow for atmospheric pressure to push down on the ink to provide adequate pressure on the ink. The purpose of the cartridge priming procedure is to establish -2 to -5 inch [...]

Troubleshooting 4-54 NovaJet 800 Series Service Manual Failure Analysis: 1. Ensure the cartridge is properly primed and pressure has been established inside the cartridge (see SetUp procedures) Note: When priming the cartridge it is important to ensure the suction end of the EasyPrime or NovaPrime assembly is flush against the cartridge jet plate. [...]

Troubleshooting 4-55 NovaJet 800 Series Service Manual Figure 4-57. 208 Jet Cartridge. 5. Replace the cartridge with a new cartridge (print head). Re-prime the ink delivery line. Figure 4-58. EasyPrime Operation. 6. If ink cannot be pulled through the line using the EasyPrime device ensure the device is functioning correctly by verifying suction an[...]

Troubleshooting 4-56 NovaJet 800 Series Service Manual 7. Always run a color test @100% in the 2 pass print mode to verify the proper pressure levels have been achieved within the cartridge. 8. Replace the septum connector and attached cartridge tubing needle. 9. Replace reservoir tubing needle. 10. Replace the blue or gray valve in the floating ca[...]

Troubleshooting 4-57 NovaJet 800 Series Service Manual Figure 4-60. Excessive Ink Pressure. Caution: overfilling the cartridges with ink (greater than 35 ml) can cause pressure regulating problems in the ink delivery system where large ink droplets can fall from cartridges, thus damaging the prints. High humidity in the printing environment and a d[...]

Troubleshooting 4-58 NovaJet 800 Series Service Manual Figure 4-61. Excessive Ink PreHeat Settings. The preheat settings are factory set to default settings of 0 (zero) and are dependent upon the installed ink set. These settings are to aid in the minimization of ghosting and or ink density issues. The preset heater settings in conjunction with the[...]

Troubleshooting 4-59 NovaJet 800 Series Service Manual As mentioned above the ambient or surrounding temperature does have an effect on the heating of the ink. ENCAD has established that these settings will be adequate for most installations. However, if the printer is in an environment that is hot or that the temperature changes a lot throughout t[...]

Troubleshooting 4-60 NovaJet 800 Series Service Manual is downloaded and can only be corrected with a reinitialization of the printer. The reinitialization can be performed prior to or immediately after a firmware download. Figure 4-62. Dirty Service Station Problem. NOTE 2: The symptoms of this problem could be easily confused with dirty service s[...]

Troubleshooting 4-61 NovaJet 800 Series Service Manual Figure 4-63. Normal Color Test (3 Pass). Normal Color Test. Some microbanding or banding will be seen in the bar patterns – the purpose of the test is to check for ink pressure and not the quality of the printed pattern. Verify all bars print at 100% ink saturation. Abnormal Color Tests: Figu[...]

Troubleshooting 4-62 NovaJet 800 Series Service Manual 2. Ensure the reservoirs are attached to female valves properly at left end of printer or this may cause ink starvation in the ink delivery system after 10 minutes of print operations. Figure 4-65. Cartridge Tubing Needle and Septum. 3. Ensure the septum connector assembly is tightly secure. Th[...]

Troubleshooting 4-63 NovaJet 800 Series Service Manual Figure 4-66. Ink Starvation. 8. Refer to ‘Ink Starvation’ procedures for any printed output which resembles the following image where one color stops printing completely. “Unrecognized Cartridge” Error Message For an ‘Unrecognized Cartridge error’ message first ensure the 2 electri-[...]

Troubleshooting 4-64 NovaJet 800 Series Service Manual Figure 4-67. Cartridge Identification Chip. 3. It is possible the ID chip on the rear of the cartridge may have slipped from its original position. Verify the double dimples (2 small circles on flex cable) have been penetrated at or near the center of each circle. If not the chip is out of posi[...]

Troubleshooting 4-65 NovaJet 800 Series Service Manual Figure 4-68. Flex Driver Cable. 6. Test dc voltage across the 2 IC (integrated circuit) identification dimples on carriage flex driver cable using a DVM (digital multimeter). In the DC scale verify that the voltage is jumping from 0 to +5Vdc. If the voltage is fairly steady at +5V then the resp[...]

Troubleshooting 4-66 NovaJet 800 Series Service Manual Figure 4-69. Paper Sensor. Initialization Failure One symptom of a defective paper sensor is when the carriage assembly suddenly stops at left end of unit during initialization - initialization does not complete (dim or blank control panel display). This could also be due to a faulty power supp[...]

Troubleshooting 4-67 NovaJet 800 Series Service Manual Loading Media Failure The carriage paper sensor (infrared sensor) will first obtain a reference at right side of media surface after load media is selected (or during autoload), then measure for media front edge detection (roll 1, roll 2, and sheet modes only), then measure media left edge dete[...]

Troubleshooting 4-68 NovaJet 800 Series Service Manual Figure 4-70. Paper Sensor Location. 5. Ink on Paper Sensor (most common failure). 6. Trailing cable connections (reseat/replace cable – outer cable). Encoder Sensor Error The encoder sensor error typically happens when a break in continuity occurs in the flexible printed circuit (FPC) line at[...]

Troubleshooting 4-69 NovaJet 800 Series Service Manual Initialization Failure One symptom of a defective encoder sensor is when the carriage heads fail to move during printer initialization - initialization does not complete and a ‘Carriage Axis Error’ results. Replace paper sensor PWA on carriage in this situation, unless the servo motor or tr[...]

Troubleshooting 4-70 NovaJet 800 Series Service Manual Figure 4-72. AutoLoad Paper Sensor. A symptom of failure includes when media is loaded and the printer rejects the media and spits it out the rear of the printer. First ensure the entire platen surface has been thoroughly cleaned using distilled water on a lint-free cloth. One quick solution fo[...]

Troubleshooting 4-71 NovaJet 800 Series Service Manual Figure 4-73. Carriage Head Assembly. Carriage Test Perform a Servo Cycle Test (10 cycles is sufficient) to verify carriage bushings are defective. Ensure Halt time does not exceed 90. Left to Right resistances are normally higher than Right to Left due to carriage heads pushing against ink deli[...]

Troubleshooting 4-72 NovaJet 800 Series Service Manual Failure Analysis 1. Is the Encoder Strip clean? Has any image skewing occurred prior to the carriage axis error? If skewing resumes following a cleaning within a day or two then the encoder strip is damaged and must be replaced. Normally the encoder strip cleanings should carry the unit through[...]

Troubleshooting 4-73 NovaJet 800 Series Service Manual 4. Is the Media Cutter malfunctioning? Remove the cutter and service station to ensure the assemblies are not inhibiting carriage assembly travel. Also ensure the cutter groove is free of debris. 5. Is the Carriage Belt tight? Is the carriage belt frayed? Check the frame tensioner and idler for[...]

Troubleshooting 4-74 NovaJet 800 Series Service Manual Figure 4-76. Main PWA Trailing Cable Connection. 9. For erratic carriage movement at power up reseat the trailing cables and encoder sensor cable connections at the right carriage PWA. Reseat trailing cables at the Main PWA jacks. Ensure all ZIF (zero insertion force) connections are locked. 10[...]

Troubleshooting 4-75 NovaJet 800 Series Service Manual or less at power up and results with a ‘carriage axis error’ or if operation is intermittent with failures. Servo motor power can be checked by assisting carriage head movement with one hand (gently help push the carriage assembly along; if successful, the servo motor is defective. Refer to[...]

Troubleshooting 4-76 NovaJet 800 Series Service Manual Figure 4-78. Main PWA LED Operation. Ensure Main PWA LEDs (light emitting diodes) are properly functioning: D1 – Normally flashes; DSP is not active. Steady during print operations. D9 – Normally flashes; Power PC processor is idle. Stops flashing when processor is active (i.e. during paper[...]

Troubleshooting 4-77 NovaJet 800 Series Service Manual 3. Remove power from the printer. Ensure the memory module (DIMM - dual-in-line memory module) at the Main PWA is seated properly. There must be installed memory for the printer to initialize. The top and right cover assemblies must be removed to access the Main PWA (remove 5 screws to gain acc[...]

Troubleshooting 4-78 NovaJet 800 Series Service Manual Figure 4-80. Paper Sensor. 8. If the carriage assembly suddenly stops at left end of unit during initialization - initialization does not complete (dim or blank control panel display), this could be the symptom of a defective paper sensor. This could also be due to a faulty power supply. The pa[...]

Troubleshooting 4-79 NovaJet 800 Series Service Manual Media Sensor Reference Points Not Initialized Hardware Failures/Diagnostic Tests Quick Troubleshooting List 1. Send a test image (PRT or RTL) directly to printer to verify a hardware failure. 2. If the carriage stops during normal travel clean encoder strip/slide shaft/bushing/belt; reseat trai[...]

Troubleshooting 4-80 NovaJet 800 Series Service Manual 7. Replace failed subassemblies. Inconsistent Operations ¨ Reinitialize unit. Select Init Settings to re-initialize printer, 1 beep should sound. Functional Problems Figure 4-82. Functional Problem. Verify proper grounds from power source exist; plug both the computer and printer into the same[...]

Troubleshooting 4-81 NovaJet 800 Series Service Manual ESD Problems Figure 4-84. ESD Problem. 1. Intermittent Banding - jet failures. 2. OverSpray 3. Severe color loss in either 1x4 right or the 1x4 left print mode. Verify media is not causing the problem. Change to a different media type. Dryer Failure/Sensor Error From the top-level menu of the p[...]

Troubleshooting 4-82 NovaJet 800 Series Service Manual Figure 4-85. Main PWA Humidity Sensor. The Dryer Mode: (cccccccc) indicates the current dryer setting. Opera- tional modes are “OFF”, “ON”, “AUTO”, or “DISABLED”. Plenum T . and MBoard T. (main-board T.) indicate temperature and are displayed in degrees C. MBoard H. (main-board [...]

Troubleshooting 4-83 NovaJet 800 Series Service Manual firmware is unable to read the plenum temperature, main-board tempera- ture, or main-board humidity, the corresponding equals sign (=) will change to a tilde (~). This error condition signifies an internal bus commu- nication failure only. It does not indicate sensor connection or perfor- mance[...]

Troubleshooting 4-84 NovaJet 800 Series Service Manual reading that was sampled when the detected error occurred. Failure Analysis 1. Ensure all logic cable and power cable connections are intact. 2. Check lower leg harness cable plug connections between right stand leg and platen plug, and connection between upper leg harness cable and Main PWA. P[...]

Troubleshooting 4-85 NovaJet 800 Series Service Manual At this point the printer must be turned OFF and then ON to clear this condition. When this condition occurs simply leave the printer on for a period of a minute or two while the heating elements are cooled. Figure 4-86. Dryer LEDs. Figure 4-87. Dryer Connectivity.[...]

Troubleshooting 4-86 NovaJet 800 Series Service Manual Intermittent Problems/Continuity If the printer experiences intermittent print problems or reboots then ensure all connections at Main PWA are good, platen is thoroughly cleaned of ink, verify the DIMM module is seated correctly and check for foreign debris in rollers. Failure Analysis 1. Reini[...]

Troubleshooting 4-87 NovaJet 800 Series Service Manual SEH Blue test button IP ADDRESS 192.168.2.10 Figure 4-89. SEH Activated Test Pattern. Figure 4-90. E-Connect LEDs. 4. For data or communications problems to the printer check parallel port interface by running a E-Connect Test (quickly depress Test Button at rear of printer at E-Connect Box) or[...]

Troubleshooting 4-88 NovaJet 800 Series Service Manual Figure 4-91. Driver/RIP Problem. Figure 4-92. Inadaquate Network Data Transfer Rate. 5. Check with the RIP or Print Driver vendor for the latest software upgrades to ensure no conflicts exist with currently loaded firmware. To check current firmware version from Main Menu select Utility Menu, s[...]

Troubleshooting 4-89 NovaJet 800 Series Service Manual Figure 4-93. ESD Problems. 6. Ensure media does not generate large amounts of electrostatic discharge as this may interfere with normal printing operations including microbanding, over-spray, and ink drop out. Add 3 rd party ESD protection (static eliminator strip). 7. Reseat the memory module [...]

Troubleshooting 4-90 NovaJet 800 Series Service Manual Figure 4-94. Servo Cycle/PWM Menu. 8. Run the PWM test (3 default cycles) or Servo Cycle test (set for 100 cycles) under Diagnostics; if the tests were successful (without error or Halt time does not exceed 60) then check the firmware version. If the carriage assembly moves only 1- 3" (2 t[...]

Troubleshooting 4-91 NovaJet 800 Series Service Manual Figure 4-96. Servo System Synchronization Error. 11. Verify the servo motor resistance values with an ohmmeter or multimeter - should be 2-8 ohms (1.5-30 ohms acceptable). Replace servo motor if values are out of tolerance. Check outrigger bushings followed by the carriage bushings. 12. Replace[...]

Troubleshooting 4-92 NovaJet 800 Series Service Manual Figure 4-98. Probable Defective Carriage PWA. 13. For inconsistent color output (color changes randomly or changes slowly down the print within the same color space), color print failures in all colors or prints, or no color print output then replace the appropriate carriage assembly (defective[...]

Troubleshooting 4-93 NovaJet 800 Series Service Manual Figure 4-100. Corrupted Code - Main PWA. Figure 4-101. Microbanding. 15. Corrupted Flash ROM First reload Firmware (direct connect a PC via a 6 foot/2 meter IEEE 1284 compliant parallel printer cable), then reload Boot Code, and finally replace the Main PWA (to check the Flash ROM) for the foll[...]

Troubleshooting 4-94 NovaJet 800 Series Service Manual Figure 4-102. Apparent Ink Overspray. Figure 4-103. True Type Font Problem. 18. For ink overspray or rough appearance of text edges ensure Adobe fonts are being used and that embedded text is not scaled via a compression plug-in. Figure 4-104. Print Settings Not Printing in Black. 19. If the pr[...]

Troubleshooting 4-95 NovaJet 800 Series Service Manual Figure 4-105. Text Field Problem. 20. Diagonal banding within text or lines adjacent to text indicates a text field problem. Figure 4-106. Dirty or Defective Encoder Strip. 21. If color deadband appears correct on both edges of the printer but is off at the center then the encoder strip is eith[...]

Troubleshooting 4-96 NovaJet 800 Series Service Manual Figure 4-107. Initialization Menu Location. Printer Hesitation/Networking Problems Hesitation of the printer carriage is normally caused by the parallel port data rate not being optimized. Ensure the ECP parallel port mode is utilized, or better, network the printer. Data Starvation ‘Data Sta[...]

Troubleshooting 4-97 NovaJet 800 Series Service Manual worked environments) - E-Connect is improperly configured for high data transfer rate; redundant protocols turned on (900 kbyte optimum data rate normally required) - Network has high traffic (limit workstations on server) - Computer parallel port mode not set to ECP with DMA (for non-net- work[...]

Troubleshooting 4-98 NovaJet 800 Series Service Manual Suggest increasing memory to 256 MB for low pass print mode opera- tions. Typically this only affects CAD (computer aided design) users that send HP-GL/2 files (vector) to the printer. File format examples include .plt and hp2. Miscellaneous Notes Note: NT does not support ECP parallel port mod[...]

Troubleshooting 4-99 NovaJet 800 Series Service Manual be connected between the upper parallel centronics port and the lower (network box) parallel port. Figure 4-109. E-Connect LEDs. Figure 4-110. Semi-Circular Nook Test Pattern. To activate an E-Connect TEST: Quickly depress the test key with a pen tip or other small blunt tool. DO NOT DEPRESS LO[...]

Troubleshooting 4-100 NovaJet 800 Series Service Manual Parallel Port Test Attach the service loopback test cable to the printer’s parallel port (contact ENCAD Technical Support to obtain). Activate the ‘Continuous Test’ by selecting the Utility Menu, Service Menu, Diagnostics Menu, Continuous Test. The printer will activate several test patt[...]

Troubleshooting 4-101 NovaJet 800 Series Service Manual Figure 4-112. Demo Print. 2. Refresh printer firmware. Refer to the ‘Firmware Download’ proce- dure. Firmware Downloading Procedures NJ850 Printer 1. Power on the printer. Verify current firmware version on printer to see if a firmware upgrade is necessary. Select Utility Menu, Service Men[...]

Troubleshooting 4-102 NovaJet 800 Series Service Manual of the dialog box. Give the new folder a name and press OK . 7. Now press the Add button in the Files section of the dialog box. Find the firmware file that you downloaded from Encad’s website and press the Open button. This will add the firmware file to the folder you created. 8 . Select th[...]

Troubleshooting 4-103 NovaJet 800 Series Service Manual Figure 4-113. Firmware Download Procedures. NJ880 Printer 1. Place printer into continuous run mode (two-beep sequence) by holding down the top-left and the bottom-left keys on the keypad and powering on the printer until the two-beep sequence is heard after approximately 6 seconds. 2. Perform[...]

Troubleshooting 4-104 NovaJet 800 Series Service Manual INTERNET: http://www.encad.com (Downloads - Software) 5. Extract 2 files from the executable: xxxxxx.rom, and readme.txt. 6. If your printer is set up using a printer server, you can use the ENCAD File Print Utility (EFPU) to download the new firmware to your printer. The EFPU can be found on [...]

Troubleshooting 4-105 NovaJet 800 Series Service Manual Media Handling System Failure If the takeup or feed system fails first ensure the printer is in the proper media supply mode. Four modes are available. Sheet, Roll 1, Roll 2, and T akeUp. Roll 1 activates only the top roller to feed media while Roll 2 activates only the bottom roller to feed m[...]

5 5-1 AssemblyDisassembly Introduction Chapter 5 contains the procedures for removal and replacement of the NovaJet 800 series 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 ea[...]

AssemblyDisassembly 5-2 NovaJet 800 Series Service Manual A Hardware Kit is available for the printers. See Chapter 6 of this manual for the part number . W ARNING Always turn the printer OFF , remove the power cord and the interface cable before beginning any disassembly pro- cedures. An electrical shock hazard may be present if these precautions[...]

NovaJet 800 Series Service Manual AssemblyDisassembly 5 - 3 3. Lift up on the lef t side of the T op Cover until it clears the Left Cover while still depressing the retracting stop assembly , then slide the cover to the left to disengage it from the Right Cover . T o r emove the Right Cover Assembly: Figure 5-1. Right Cover Assembly Removal/Instal[...]

AssemblyDisassembly 5-4 NovaJet 800 Series Service Manual 8. Disconnect the Display data ribbon cable connector at the J10 location on the Main PWA. T o remove the Left Cover Assembly: 1. Disconnect and remove all ink reservoirs. Figure 5-2. Left Cover Removal/Installation. 2. Remove the two screws securing the Left Cover to the Left Frame. See th[...]

NovaJet 800 Series Service Manual AssemblyDisassembly 5 - 5 Inst all the Lef t, T op, and Right Covers T o install the Left Cover: 1. Position the Left Cover over the Left Frame and while depressing the retracting stop assembly on the Support Bracket, lower the Left Cover into position onto the Left Frame. Release the retracting stop assembly . CA[...]

AssemblyDisassembly 5-6 NovaJet 800 Series Service Manual CAUTION Applying too much torque to the lower screws can cause the mounts for the standoffs on the cover to break, requir- ing a replacement of the cover . 4. Secure the Right Cover with two screws located on the left side (torque to 15 in-lbs) and three located under the baseplate (torque [...]

NovaJet 800 Series Service Manual AssemblyDisassembly 5 - 7 Figure 5-3. E-Connect Assembly Installation/Removal. 3. Put on an ESD wrist strap. 4. Slowly lower the E-Connector Assembly until you can disconnect the power cable from the connection located near the center of the circuit board. Inst all the E-Connect Network Assembly 1. Connect the pow[...]

AssemblyDisassembly 5-8 NovaJet 800 Series Service Manual Remove the Keypad and Display 1. Remove the T op and Right Covers following procedures outlined earlier in this chapter . 2. T urn the Right Cover Assembly over and with a 1/4” socket or wrench, remove the four kepnuts securing the ESD Shield and ground connections. See Figure 5-4. Remove[...]

NovaJet 800 Series Service Manual AssemblyDisassembly 5 - 9 4. Disconnect the grounding flex cable from the large standoff before removing the Keypad Assembly . See Figure 5-5 for location. Remove the Keypad Assembly . Figure 5-5. Keypad and Display Grounding Connections. Install the Keypad and Display 1. Route the Keypad flex data and ground cabl[...]

AssemblyDisassembly 5-10 NovaJet 800 Series Service Manual 4. Place the ESD Shield onto the Display standoffs using four kepnuts with a 1/4” socket or wrench. T orque to 2.5 in-lbs. 5. Attach ground connections to the Cover S tandoffs as shown in Figure 5-5. Apply a small drop of loctite into the Cover holes, attach S tandof fs and torque to 6 i[...]

NovaJet 800 Series Service Manual AssemblyDisassembly 5-11 Install Memory Module 1. Slowly push the Memory Module into place. Make sure the module is fully seated. 2. Push the side clips towards the Memory Module until they hold the module securely in place. 3. Install the T op and Right Covers following procedures outlined earlier in this chapter[...]

AssemblyDisassembly 5-12 NovaJet 800 Series Service Manual 7. Disconnect the Leg Harness connection at the J6 location by grasping the Leg Harness connector with thumb and forefinger and pulling straight out. 8. Disconnect the Trailing Cable B connection at the J2 location. Use the thumb and forefinger to pull up on the connector lock and remove t[...]

NovaJet 800 Series Service Manual AssemblyDisassembly 5-13 Figure 5-7. Main PW A Removal.[...]

AssemblyDisassembly 5-14 NovaJet 800 Series Service Manual CAUTION Failure to use an approved antistatic bag for storage or shipment may cause damage to the Main PW A and affect the W arranty . 17 . Place the Main PWA in an ESD bag (antistatic bag) in preparation for shipment to ENCAD for replacement or repair , or if it is to be stored at your fa[...]

NovaJet 800 Series Service Manual AssemblyDisassembly 5-15 8. Connect the V acuum Fan 1 connector to J15 on the Main PWA. 9. Connect the AutoLoad Sensor connector to J13 on the Main PW A. 10 . Connect and lock the T railing Cable A connector to J1 on the Main PWA. 1 1. Connect and lock the Trailing Cable B connector to J2 on the Main PWA. 12 . Con[...]

AssemblyDisassembly 5-16 NovaJet 800 Series Service Manual Figure 5-8. Power Supply Removal. T o remove the Cooling Fan and AC Entry Module: 1. Remove the four screws located below the Right Baseplate securing the Power Supply Bracket to the Right Baseplate. Remove the Power Supply Bracket. See Figure 5-9. 2. Using a Phillips screwdriver and a 1/4[...]

NovaJet 800 Series Service Manual AssemblyDisassembly 5-17 Figure 5-9. Cooling Fan/AC Entry Module Removal. Inst all the Power Supply , Cooling Fan, and AC Entry Module T o install the Cooling Fan and AC Entry Module: 1. Insert the AC Entry Module into the AC Entry Module hole on the Right Baseplate. Press in until it snaps securely into place. 2.[...]

AssemblyDisassembly 5-18 NovaJet 800 Series Service Manual 5. Insert and hold the Power Supply into place while securing it with four screws. T orque to 15 in-lbs. 6. Reconnect the Power Supply to the AC Entry Module by reattaching the quick disconnect connection. Push the quick disconnect assembly behind the Power Supply Bracket and out of sight.[...]

NovaJet 800 Series Service Manual AssemblyDisassembly 5-19 Figure 5-10. Using the Belt Removal T ool. 6. Turn the movable side so that the tool begins to expand and the Frame T ensioner S pring compresses. Continue to turn on the Belt Removal T ool until the belt can be lifted off of the Servo Motor pulley . 7. Move the Carriage Belt to the left s[...]

AssemblyDisassembly 5-20 NovaJet 800 Series Service Manual 1 1 . Lower the Trailing Cable back into place. 12 . While holding the Servo Motor , remove the front screw on the Servo Motor . 13 . Lower the motor to clear the platen and carefully bring the motor out of the printer . Install Servo Motor 1. Reinsert the Servo Motor under the Platen with[...]

NovaJet 800 Series Service Manual AssemblyDisassembly 5-21 10 . Route the E-Connect power cable through the grommet on the E- Connect Plate. Reinstall the E-Connect Plate under the Platen. T orque to 15 in-lbs. 1 1. Connect the Servo Motor connector to J12 on the Main PWA. 12 . Install the E-Connect Network Assembly and the T op, Left and Right Co[...]

AssemblyDisassembly 5-22 NovaJet 800 Series Service Manual A Figure 5-12. Left Side of Ink Delivery System. 5. Remove the remaining six screws securing the Fitting Mount Bracket (left portion of the Ink Delivery System) to the Left Frame. See Figure 5-12 6. Move the Carriage to the center of the Slide Shaft. Figure 5-13. Floating Carriage Cover Re[...]

NovaJet 800 Series Service Manual AssemblyDisassembly 5-23 7. Remove the Floating Carriage Cover from the Left and Right Support Brackets. The Floating Carriage Cover is part of the Ink Delivery System. See Figure 5-13. 8. Carefully slide the Ink Delivery System out of the left side of the printer . Install the Ink Delivery System 1. Carefully sli[...]

AssemblyDisassembly 5-24 NovaJet 800 Series Service Manual Figure 5-14. Using the Belt Removal T ool. 4. Turn the movable side so that the tool begins to expand and the Frame T ensioner S pring compresses. Continue to turn on the Belt Removal T ool until the belt can be lifted off of the Servo Motor pulley . 5. Turn the Belt Removal T ool in the o[...]

NovaJet 800 Series Service Manual AssemblyDisassembly 5-25 Figure 5-15. Electronics Covers Removal. 8. Remove the T railing Cables and S train Reliefs from both Carriages by releasing the latch on the left lower side of the S train Relief and lifting it off of the Carriages. See Figure 5-16.[...]

AssemblyDisassembly 5-26 NovaJet 800 Series Service Manual LA TCH Figure 5-16. Strain Relief Removal/Installation. 9. Slide the Carriage Assembly to the left edge of the Slide Shaf t while taking up the slack of the Belt at the same time. NOTE The Belt is connected to the right Carriage only . The left Carriage is directly connected to the right C[...]

NovaJet 800 Series Service Manual AssemblyDisassembly 5-27 CARRIAGE BEL T BEL T CLAMP RIGHT POST OF BEL T CLAMP LEFT POST OF BUMP Figure 5-17. Carriage Belt Clamp. 13 . T o disengage the Carriage Belt from the Belt Clamp, push the Carriage Belt away from the left post of the Belt Clamp and gently lift up until the bottom edge of the Carriage Belt [...]

AssemblyDisassembly 5-28 NovaJet 800 Series Service Manual Inst all the Carriage Assembly , Carriage Belt, and the Frame T ensioner 1. T o install the Belt onto the right Carriage, the “bump s” 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 Bel[...]

NovaJet 800 Series Service Manual AssemblyDisassembly 5-29 Encoder on the Carriage PWA. Ensure that the Carriage Coupler goes over the top of Slide Shaft. S tretch out the Belt towards the Servo Motor to ensure that there are no twists in it. Leave enough of the Belt loop overhanging the left side to ensure that the left Carriage will not bind in [...]

AssemblyDisassembly 5-30 NovaJet 800 Series Service Manual Carriage PWAs. 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. 1 1 . Position the Electronics Cover over the right Carriage and gently press down on the ends of the Electronics Cover until[...]

NovaJet 800 Series Service Manual AssemblyDisassembly 5-31 22 . T urn the Belt Removal T ool to tighten the belt around the Servo Motor pulley . 23 . Move the Carriage Assembly back and forth to check the Carriage Belt tension. Remove the Belt Removal T ool. 24 . Gently move the Carriage Assembly from end to end and make sure that the Carriage Bel[...]

AssemblyDisassembly 5-32 NovaJet 800 Series Service Manual TA B SL O T L ATC H Figure 5-20. Carriage PW A Removal/Inst allation.[...]

NovaJet 800 Series Service Manual AssemblyDisassembly 5-33 5. Unlock the latch on the right end of the Carriage and lift up the right end of the Carriage PWA. See Figure 5-20. 6. Slide the Carriage PWA to the right to remove the tab on the left end of the Carriage PWA from the slot in the Carriage. CAUTION Failure to use an approved antistatic bag[...]

AssemblyDisassembly 5-34 NovaJet 800 Series Service Manual Remove the Paper Sensor or the Encoder Sensor 1. Remove the T op, Left and Right Covers following procedures outlined earlier in this chapter . 2. Remove the Ink Delivery System and the Carriage Assembly following procedures outlined earlier in this chapter to remove the Carriage Assembly [...]

NovaJet 800 Series Service Manual AssemblyDisassembly 5-35 NOTE The Paper Sensor and Encoder Sensor are only installed onto the right Carriage. All procedures in this section refer to the right Carriage only . 3. T o remove the Paper Sensor: a. Unlock the connector at J3 and remove the flex cable. b. Turn the Carriage over and hold it while firmly[...]

AssemblyDisassembly 5-36 NovaJet 800 Series Service Manual Install the Paper Sensor or the Encoder Sensor ROUTE FLEX THROUGH SLO T INSIDE THE CARRIAGE ASSEMBLY 1 2 GROOVES 1 PUSH DOWN ON CLIP . PUSH ENCODER IN OVER CLIP . ENCODER MUST SLIDE P A ST THE RIDGES AND SNAP INTO PLACE ALIGN SIDES OF P APER SENSOR BOARD BETWEEN GROOVES AND PUSH STRAIGHT D[...]

NovaJet 800 Series Service Manual AssemblyDisassembly 5-37 e. Turn the Carriage over and insert the Paper Sensor flex cable into the connector at J3. f . Push both sides of the connector lock shut at the same time. 2. T o inst all the Encoder Sensor: a. Turn the Carriage so that the bottom side of it is facing up. b. Push down on the plastic clip [...]

AssemblyDisassembly 5-38 NovaJet 800 Series Service Manual 3. Using a small tool, remove the bushing from the Left Support Bracket. The bushing must be removed from the right side of the bracket. 4. Rotate the bushing 180° to pass the bushing through the Left Support Bracket without it getting caught on the tab of the bushing. See Figure 5-23. Sl[...]

NovaJet 800 Series Service Manual AssemblyDisassembly 5-39 9. Perform the same procedure to replace the Right Support Bracket bushing. Replacing the Carriage Bushings 1. Remove the T op, Left and Right Covers following procedures outlined earlier in this chapter . 2. Remove the Ink Delivery System and the Carriage Assembly following procedures out[...]

AssemblyDisassembly 5-40 NovaJet 800 Series Service Manual T ABS Figure 5-25. Carriage Bushing Installation. 6. Orient the new bushing as shown in Figure 5-25 so that the metal tab on top of the bushing goes into the Carriage Assembly first. 7. Push the bushings in until they snap into place. 8. Install the Carriage Assembly and Ink Delivery Syste[...]

NovaJet 800 Series Service Manual AssemblyDisassembly 5-41 5. Lift out the left side of the Service S tation from the Platen and remove the Service S tation. Moving the Service S tation farther to the right might be required to release the left side of the Service S tation. Install the Service Station 1. T o inst all the Service S tation, position[...]

AssemblyDisassembly 5-42 NovaJet 800 Series Service Manual 7. The T railing Cable Assembly is secured to the S t abilizer Bracket by two pieces of double sided tape. Remove the Trailing Cable Assembly from the S tabilizer Bracket. 8. Mark the position of the double sided tape on the S tabilizer Bracket before removing. It is important that the new[...]

NovaJet 800 Series Service Manual AssemblyDisassembly 5-43 6. Reposition the Floating Carriage Cover/Right Support Bracket Assembly and the Left Support Bracket around the Carriage Assembly . Secure the Lef t Support Bracket to the Floating Carriage Assembly . T orque to 15 in-lbs. 7. Install the T op and Right Covers following procedures outlined[...]

AssemblyDisassembly 5-44 NovaJet 800 Series Service Manual 4. Remove the S tabilizer Bracket from the Y -Arm Assembly by removing the four alignment Allen screws and washers located on the back of the Y -Arm Assembly . CAUTION The Encoder Strip is not a field removable item. The en- tire Stabilizer Bracket Assembly with the Encoder Strip is to be [...]

NovaJet 800 Series Service Manual AssemblyDisassembly 5-45 4. Disconnect the AutoLoad Sensor connector at the J13 location on the Main PW A. Grasp the AutoLoad Sensor connector with the thumb and forefinger and pull straight out. 5. Remove the seven screws that secures the Y -Arm Assembly to the Platen. See Figure 5-28. Figure 5-28. Y -Arm Install[...]

AssemblyDisassembly 5-46 NovaJet 800 Series Service Manual Figure 5-29. Pinch Roller . 7. S pin the back of the pinch roller to either side and remove the back spring. 8. Carefully tilt the back of the pinch roller upwards. This brings the front of the pinch roller down, away from the Slide Shaft. Carefully remove the spring that is going into the[...]

AssemblyDisassembly 5-47 NovaJet 800 Series Service Manual Inst all the Y -Arm Assembly , Pinch Rollers, Slide Shaf t, and AutoLoad Sensor 1. Install the AutoLoad Sensor Assembly into the back part of the Y - Arm Bracket. T orque to 6 in-lbs. 2. Route the AutoLoad Sensor wires through the four wire clamps on the back part of the Y -Arm Bracket. 3.[...]

AssemblyDisassembly 5-48 NovaJet 800 Series Service Manual Remove the Gap Sensor (NovaJet 880 only) T o remove the print gap sensor: 1. Remove the top cover by pulling on the retracting stop at the left end, remove by pulling cover to the left slightly to dislodge tab at the right end. 2. Locate and remove the 2 inside right cover screws. 3. Locat[...]

NovaJet 800 Series Service Manual AssemblyDisassembly 5-49 3. Remove the Service S tation following procedures outlined earlier in this chapter . CAUTION Be careful when removing any foam blocks so that it does not tear . It is very important to have an intact foam block to produce sufficient vacuum inside the Platen. This is re- quired to properl[...]

AssemblyDisassembly 5-50 NovaJet 800 Series Service Manual 1 1. Remove the black flat-head screws from the top of the Platen that holds the left and right Drive Shaft Supports in place. CAUTION It may be necessary to loosen (do not remove) the screws that secure the Y -Arm Assembly to the Platen so that the Lower Drive Roller Assembly clears the e[...]

NovaJet 800 Series Service Manual AssemblyDisassembly 5-51 13 . Remove the S tepper Motor Extension S pring from the S tepper Motor and the post on the Left Lower Drive Shaft Bracket. See Figure 5-30. A TTACH SPRING T O POST ON BRACKET Figure 5-30. Stepper Motor Removal/Installation. 14 . Remove the hardware securing the S tepper Motor to the Left[...]

AssemblyDisassembly 5-52 NovaJet 800 Series Service Manual that protrude inside of the Platen while installing the Lower Drive Roller Assembly . CAUTION It may be necessary to loosen (do not remove) the screws that secure the left Leg Assembly to the Platen so that the Lower Drive Roller Assembly clears the ends of the screws that protrude inside [...]

NovaJet 800 Series Service Manual AssemblyDisassembly 5-53 10 . Reinsert the right Foam Block. Make sure that the S tepper Motor and Fan(s) cables are exiting out of the back corner of the Foam Block. See Figure 5-31. The Foam Block is positioned between the S tepper Motor and the Servo Motor . Make sure it is not tilted at an angle. SERVICE ST AT[...]

AssemblyDisassembly 5-54 NovaJet 800 Series Service Manual Remove the Lower Roller Assembly , Stepper Motor and V acuum Fan (NovaJet 880) 1. T o remove the stepper motor/lower roller , first remove power from the printer . 2. Unplug the dryer power cord and disconnect the dryer logic cable. 3. Remove dryer by pulling locking pins and lifting strai[...]

NovaJet 800 Series Service Manual AssemblyDisassembly 5-55 Remove the ink delivery system. 15 . Ensure the ink delivery system carriage cover brackets are clear of the rear cover . Remove rear cover by lifting up and pulling away from the Y -Arm. Note: do not lose the 2 retracting stop springs. 16 . Disconnect all Main PW A connections. Disconnect[...]

AssemblyDisassembly 5-56 NovaJet 800 Series Service Manual Disconnect the 2 carriage electronic covers by pressing in on the inner tabs with a small tool. Disengage the trailing cables from the carriage ZIF connectors. At rear of printer disengage each strain relief from each carriage assembly using a small flat-head screwdriver – gently pry the[...]

NovaJet 800 Series Service Manual AssemblyDisassembly 5-57 NOTE The right side fixed nylon helical wedge and pin assembly/flange should not have to be removed unless the screw length prohibits lower roller removal. Three 1/8” and 5/32” allen head screws are used to secure these assemblies). T o remove the stepper motor from lower roller remove[...]

AssemblyDisassembly 5-58 NovaJet 800 Series Service Manual Remove the Media T ake-Up and Feed Sensor Bracket s and Sensors NOTE The sensors for the media T ake-Up and Feed Assembly are identical, but the brackets that they mount to have dis- tinct differences. The top bracket has an additional ex- tended arm attached to help in directing the media[...]

NovaJet 800 Series Service Manual AssemblyDisassembly 5-59 assembly . WIRE TIE WRAPS Figure 5-32. Media T ake-Up and Feed Sensor Removal. Inst all the Media T ake-Up and Feed Sensor Brackets and Sensors 1. Install the two screws securing the bracket to the leg assembly . 2. Insert the sensor into the hole on the sensor bracket, secure by screwing [...]

AssemblyDisassembly 5-60 NovaJet 800 Series Service Manual Remove the Media T ake-Up and Feed Motors 1. Remove all media and media rollers from the printer . 2. Remove the four screws holding the Cradle Idler to the leg assembly . See Figure 5-33. 3. Carefully slide the Cradle Idler assembly out of the leg assembly until the wires going to the mot[...]

NovaJet 800 Series Service Manual AssemblyDisassembly 5-61 CRADLE IDLER MO TOR MOUNT MO TOR MO TOR GEAR C CLAMP Figure 5-33. Media T ake-Up and Feed Motor Removal. Remove the Thermal Dryer Assembly W ARNING Once the dryer is plugged in, there is continuous power being applied to the dryer , even when the printer is turned off. DISCONNECT POWER COR[...]

NovaJet 800 Series Service Manual AssemblyDisassembly 5-62 Inst all the Thermal Dryer Assembly 1. Carefully place the Thermal Dryer Assembly onto the support brackets. See Figure 5-34. Secure and torque to 15 in-lbs. 2. Attach the data cable to the right side of the Thermal Dryer Assembly . 3. Attach the Thermal Dryer Assembly power cord the to ba[...]

AssemblyDisassembly 5-63 NovaJet 800 Series Service Manual W ARNING This assembly emits heat by radiation. 1. Disconnect the Thermal Dryer Assembly power cord from the back of the printer . 2. Disconnect the data cable from the right side of the Thermal Dryer Assembly . 3. Locate and remove the four screws securing the Thermal Dryer Right Endcap A[...]

NovaJet 800 Series Service Manual AssemblyDisassembly 5-64 NOTE Some units may have very small servicing loops in the wir- ing of the Dryer Assembly . When removing the Right Endcap, the possibility exists that a connection may have been pulled loose elsewhere within the body of the dryer if extreme force is used to pull the endcap away from the m[...]

AssemblyDisassembly 5-65 NovaJet 800 Series Service Manual J1 J2 J3 J6 J7 J9 Figure 5-36. Right Endcap Connector Locations. T able 5-1. Thermal Dryer PW A Connections. J1 Fan 1 J6 Element, Right Conn J2 Fan 2 J7 Thermistor J3 Element, Left Conn J8 Fuse, on back of PW A J 4 Power J 9 Thermistor J 5 Power P1 Data cable 2. Reconnect the power cord gr[...]

6 6-1 Part s List This chapter lists the items and their associated numbers for the parts and assemblies of the NovaJet 800 Series printers that are field replace- able. 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[...]

Parts List 6-2 NovaJet 800 Series Service Manual 6- 1 7 FITTING , FEMALE, BLUE ...................... 214244-00 FITTING , FEMALE, GRA Y .................. 214245-00 6- 1 8 C-RING 7/16 .............................................. 207789 HARDW ARE KIT .................................... 208810 EASYPRIME ............................................[...]

Parts List 6 - 3 NovaJet 800 Series Service Manual Figure 6-1. Left Side Parts Breakdown. 1 4 8 5 6 7 2 3[...]

Parts List 6-4 NovaJet 800 Series Service Manual FIGURE ITEM P AR T NAME P AR T # 6- 2 1 SPRING , COMPESSION .......................... 209052 6- 2 2 RETRACTING STOP , ASSEMBL Y ......... 208838-01 6- 2 3 COVER ASSY , TOP , 60” .......................... 215571-00 COVER ASSY , TOP , 42” ....................... 215572-00 6- 2 4 CHAIN SUPPOR T AS[...]

Parts List 6 - 5 NovaJet 800 Series Service Manual Figure 6-2. Platen and Above Parts Breakdown.[...]

Parts List 6-6 NovaJet 800 Series Service Manual FIGURE ITEM P AR T NAME P AR T # 6- 3 1 COVER ASSEMBL Y , WITH KEYP AD AND DISPLA Y , RIGHT ....................... 215350-00 6- 3 2 KEYP AD ASSEMBL Y ............................. 209096-3 6- 3 3 REFLECTIVE DISPLA Y ASSY .............. 210068-04 6- 3 4 MAIN PRINTED WIRING ASSY NOV AJET 850 .........[...]

Parts List 6 - 7 NovaJet 800 Series Service Manual Figure 6-3. Right Side Parts Breakdown.[...]

Parts List 6-8 NovaJet 800 Series Service Manual FIGURE ITEM P AR T NAME P AR T # 6- 4 1 HARNESS, DR YER/WINDER NOV AJET 850 ....................................... 215188-00 NOV AJET 880 ....................................... 217886-01 6- 4 2 MOTOR ASSY , SER VO ........................... 215704-01 6- 4 3 BLOCK, RIGHT FOAM ......................[...]

Parts List 6 - 9 NovaJet 800 Series Service Manual Figure 6-4. Inner Platen Parts Breakdown. 2 5 9 6 7 8 3 4 10 12 13 10 11 1[...]

Parts List 6-10 NovaJet 800 Series Service Manual FIGURE ITEM P AR T NAME P AR T # 6- 5 1 COVER, CARRIER ELECTRONICS ..... 2151 11-02 6- 5 2 CARRIAGE PW A ..................................... 214751-04 6- 5 3 ENCODER SENSOR W/FLEX RIGHT SIDE CARRIAGE ONL Y ........ 209 5 78-101 6- 5 4 STRAIN RELIEF ...................................... 215659-00 [...]

Parts List 6-11 NovaJet 800 Series Service Manual Figure 6-5. Carriage Assembly Parts Breakdown.[...]

Parts List 6-12 NovaJet 800 Series Service Manual FIGURE ITEM P AR T NAME P AR T # 6- 6 1 ACTUA TOR, V AL VE ............................... 214886-01 6- 6 2 CLIP , V AL VE ............................................ 214521-00 6- 6 3 V AL VE ASSEMBL Y , BLUE ..................... 215703-01 GR A Y ...................................................[...]

Parts List 6-13 NovaJet 800 Series Service Manual Figure 6-6. Floating Carriage Cover Parts Breakdown.[...]

Parts List 6-14 NovaJet 800 Series Service Manual FIGURE ITEM P AR T NAME P AR T # SER VICE ST A TION ASSY ...................... 214393-03[...]

Parts List 6-15 NovaJet 800 Series Service Manual Figure 6-7. Service Station Parts Breakdown.[...]

Parts List 6-16 NovaJet 800 Series Service Manual FIGURE ITEM P AR T NAME P AR T # 6- 8 1 SHAFT ASSY , W/FIXED R T SIDE, GUIDE, ADJ (2) AND CLAMP (3) 60” ................................................. 207657-1 42” ................................................. 207657-2 6- 8 2 GUIDE, P APER ADJUST ABLE .............. 207644 6- 8 3 CLAMP , [...]

Parts List 6-17 NovaJet 800 Series Service Manual Figure 6-8. Power Feed and T ake-Up Parts Breakdown.[...]

Index-1 NovaJet 800 Series Service Manual Index A alignments slide shaft . . 3-24 axis drive carrier . . 2-5 paper (media) . . 2-4 B banding . . 3-16 C cabling . . 3-45 calibration color . . 3-31 deadband . . 3-34 X-axis . . 3-39 carrier . . 5-23 cartridges . . 3-6 , 3-31 cautions . . 1-4 control panel . . 2-18 D download firmware . . 3-43 E encode[...]

Index-2 NovaJet 800 Series Service Manual removal/installation . . 5-18 resistance check . . 3-14 stepper (media) controller . . 2-11 removal/installation . . 5-48, 5-54 resistance check . . 3-15 MPCB . . 5-6, 5-7, 5-1 1 N notes . . 1-4 O optical encoder strip . . 2-5 , 2-13 P pinch rollers . . 5-44 power supply . . 2-19 , 5-15 R related publicatio[...]