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NovaJet

8-Head Family

Service Manual

NovaJet

800 Series

Summary of content (288 pages)

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NovaJet® 8-Head Family NovaJet 800 Series Service Manual
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® NOVAJET® 800 Series Color Inkjet Printer Service Manual Part Number 216520-01
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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.
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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 found to comply with the limits for a class A digital device, pursuant to part 15 of the FCC Rules.
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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. − Increase the separation between the equipment and receiver. − Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.
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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 Hinweise in der Bedienungsanleitung.
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NovaJet 800 Series Service Manual Material Safety Data Sheet ENCAD QIS (Quality Imaging Supplies) ink is nonhazardous, requiring no special disposal handling. It can be harmful if swallowed and should be kept away from children. To obtain a Material Safety Data Sheet, contact ENCAD, Inc. at: 6059 Cornerstone Court West San Diego, CA 92121-3734 (619) 452-4350 International users should contact their local dealer or distributor.
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NovaJet 800 Series Service Manual Warranty or Damage Claims United States ENCAD®, Inc., warrants its printers ("PRODUCT") to be free from defects in workmanship and materials for a period of one year from the date of purchase. In order to submit a Warranty claim, please contact the ENCAD Help Desk at (858) 452-4350. ENCAD reserves the right to make changes or improvements to Products, without incurring any obligation to similarly alter Products previously purchased.
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NovaJet 800 Series Service Manual Table of Contents Chapter 1 General Description .......................................1-1 Introduction .................................................................................. 1-1 Overview ....................................................................................... 1-3 Related Publications ..................................................................... 1-3 Electrostatic Discharge (ESD) Sensitivity ......................................
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NovaJet 800 Series Service Manual Table of Contents (cont) Chapter 3 Maintenance ...................................................3-1 Introduction .................................................................................. 3-1 Scheduled Maintenance ................................................................ 3-1 Cleaning Procedures .............................................................. 3-2 External Cleaning .............................................................
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NovaJet 800 Series Service Manual Table of Contents (cont) Chapter 4 Troubleshooting .............................................4-1 Introduction .................................................................................. 4-1 No Power ............................................................................... 4-1 No Power ............................................................................... 4-2 Initialization Failure .................................................................
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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 ........................................................ 4-43 Line Quality Problems (Overspray) ............................. 4-46 Cartridge Warranty ..................
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NovaJet 800 Series Service Manual Table of Contents (cont) Chapter 5 Assembly\Disassembly ................................5-1 Introduction .................................................................................. 5-1 Remove the Left, Top, and Right Covers ......................................... 5-2 Remove the E-Connect Network Assembly .................................... 5-6 Install the E-Connect Network Assembly ....................................... 5-7 Remove the Keypad and Display ........
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NovaJet 800 Series Service Manual Table of Contents (cont) Chapter 5 Assembly\Disassembly (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) .......................................................... 5-51 Remove the Lower Roller Assembly, Stepper Motor and Vacuum Fan (NovaJet 880) ......................................................
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NovaJet 800 Series Service Manual Table of Contents (cont) Chapter 5 Assembly\Disassembly (cont) Remove the Carriage Assembly, Carriage Belt, and the Frame Tensioner .................................................................................... 5-23 Install the Carriage Assembly, Carriage Belt, and the Frame Tensioner ......................................................................... 5-28 Remove the Carriage PWA..........................................................
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NovaJet 800 Series Service Manual Table of Contents (cont) Chapter 6 Parts List ........................................................
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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. ............................................................ 2-4 2-3. Carriage Axis Drive. .....................................................................
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NovaJet 800 Series Service Manual List of Illustrations (cont) Figure Page Chapter 3 Maintenance (cont.) 3-20. 3-21. 3-22. 3-23. 3-24. 3-25. 3-26. 3-27. 3-28. 3-29. 3-31. 3-32. Color Calib Menu. .................................................................... 3-33 Vertical Options Menu. ............................................................ 3-34 Slow Deadband. ...................................................................... 3-35 Service Menu. .............................................
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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. ........................................................ 4-34 4-29. Carriage Head Strike. ............................................................... 4-35 4-31.
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NovaJet 800 Series Service Manual List of Illustrations (cont) Figure Page Chapter 4 Troubleshooting (cont) 4-63. 4-64. 4-65. 4-66. 4-67. 4-68. 4-69. 4-70. 4-71. 4-72. 4-73. 4-74. 4-75. 4-76. 4-77. 4-78. 4-79. 4-80. 4-81. 4-82. 4-83. 4-84. 4-85. 4-86. 4-87. 4-88. 4-89. 4-90. 4-91. 4-92. 4-93. 4-94. 4-95. 4-96. 4-97. Normal Color Test (3 Pass). ..................................................... 4-61 Abnormal Test Examples. ........................................................
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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. .................................................. 4-93 4-101. Microbanding. ......................................................................... 4-93 4-102. Apparent Ink Overspray.
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NovaJet 800 Series Service Manual List of Illustrations (cont) Figure Page Chapter 5 Assembly/Disassembly (cont.) 5-18. 5-19. 5-20. 5-21. 5-22. 5-23. 5-24. 5-25. 5-26. 5-27. 5-28. 5-29. 5-30. 5-31. 5-32. 5-33. 5-35. 5-36. Carriage Coupler Installation. ................................................... 5-28 Left Carriage Installation. ......................................................... 5-29 Carriage PWA Removal/Installation. .........................................
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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 Table. ................................................................. 4-1 Chapter 5 Assembly/Disassembly 5-1. Thermal Dryer PWA Connections. ...............................................
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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 880 printer is available in a 60 inch model. It is written for service personnel who possess analog and digital circuitry experience.
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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 and Power PC computers. These printers expand upon ENCAD’s tradition of delivering fast, high-quality color or monochrome graphics for a variety of applications.
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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 automatically without a specific line-by-line instruction from the program. These characters are part of the printer’s permanent memory.
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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 to stress that the following steps or procedures has the potential to cause serious harm or death to service personnel.
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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.
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NovaJet 800 Series Service Manual Environment: Operating: 65° to 85° F (18° to 30° C) 5% to 80% RH non-condensing Storage: 40° to 95° F (4° to 35° C) 5% to 80% RH non-condensing Weight: NJ850 60” 165 lbs 42” 150 lbs Dimensions: Height 44”(1.12m) Width 48” (1.22m) 93” (2.37m) 42 inch 111” (2.82m) 60 inch Depth NJ880 235 lbs 111” (2.82m) 28” (0.71m) Contents of this Service Manual Figures are used in this manual to clarify procedures.
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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 possible causes and repairs is found in this chapter. This table is not intended to be a complete listing of troubleshooting procedures.
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NovaJet 800 Series Service Manual Technical Support ENCAD offers full technical support and service for its various products. If you are unable to find the answer to your question in either the User’s Guide, Service Manual, or other related publications, check out ENCAD’s Knowledge Base located on ENCAD’s website support: ENCAD Website: http://www.encad.com Additional information is available though our Technical Support and Service Department’s Help Desk. ENCAD, Inc. Technical Support & Service Dept.
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Theory of Operation 2 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 that eliminates micro banding by providing vibration-free printing.
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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 assemblies: 1. Paper (Media) Axis Drive 2. Carriage Axis Drive 3. Media Feed and Take-Up System and five main electrical assemblies: 1. Main PWA (Printed Wiring Assembly) 2. Carriage Assemblies (2) 3. Control Panel 4. Power Supply 5.
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NovaJet 800 Series Service Manual Figure 2-1. General Block Diagram.
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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 drive shaft assembly, and pinch rollers. This can be seen in Figure 2-2.
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NovaJet 800 Series Service Manual The Carriage Axis Drive OPTICAL ENCODER OPTICAL SENSOR TRAILING CABLE PAPER SENSOR TRAILING CABLE CONNECTION FROM MAIN PWA CARRIAGE PWA RIGHT CARRIAGE ASSEMBLY ONLY CARTRIDGE 1 INKJET DRIVERS CARTRIDGE 2 CARTRIDGE 3 CARTRIDGE 4 LEFT AND RIGHT CARRIAGE ASSEMBLY Figure 2-3. Carriage Axis Drive. The Carriage Axis Drive moves the printer’s carriage assembly along the length of the printer.
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NovaJet 800 Series Service Manual Media Feed and Take-Up System REFLECTOR SENSORS REFLECTOR 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 roll dependent upon the signals they receive from the Main PWA.
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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: 7.
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NovaJet 800 Series Service Manual Main PWA LED Status Indicators D1 - Normally flashes when the DSP is idle. Steady during print operations. 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 - Normally OFF; Flashes during initialization, then turns off. LED staying on would indicate a problem when the FPGA is unconfigured.
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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 controls the stepper motor, LCD and keypad. The gate array is a Xilinx device. It is a static RAM-based field programmable gate array.
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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.
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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, where it can be executed faster. All printers ship with 64 MB of RAM and are upgradable to a maximum of 256 MB. Additional memory helps to free the host computer more quickly.
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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 waveform generator receives digital data from the gate array and generates a sine wave output.
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NovaJet 800 Series Service Manual Servo Motor Controller GATE ARRAY MOTOR DRIVER SERVO CONNECTOR SERVO MOTOR CARRIAGE CONNECTOR ENCODER CARRIAGE 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 signal applied to the controller. The microprocessor checks the position of the Carriage Assembly approximately 1,000 times per second (during the servo interrupt).
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NovaJet 800 Series Service Manual DETECTOR 2 DETECTOR 1 ENCODER STRIP OUTPUT OF DETECTOR 1 OUTPUT OF DETECTOR 2 COMPOSITE TRANSITION-TRIGGERED OUTPUT OF BOTH DETECTORS 4 OUTPUT PULSES PER OPTICAL LINE Figure 2-9. Quadrature Signal Generation. The direction that the Carriage Assembly is moving is calculated based upon the state of one detector’s output and the direction of the transition of the other detector’s output.
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NovaJet 800 Series Service Manual A hardware counter in the gate array increments as the Carriage Assembly 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 is read during the servo interrupt and its value compared with that from the previous interrupt. This difference is used to update the absolute position value in the software.
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NovaJet 800 Series Service Manual Carriage Assembly Circuits OPTICAL ENCODER OPTICAL SENSOR TRAILING CABLE PAPER SENSOR TRAILING CABLE CONNECTION FROM MAIN PWA CARRIAGE PWA RIGHT CARRIAGE ASSEMBLY ONLY CARTRIDGE 1 INKJET DRIVERS CARTRIDGE 2 CARTRIDGE 3 CARTRIDGE 4 LEFT AND RIGHT CARRIAGE ASSEMBLY Figure 2-11. Carriage Assembly Circuits.
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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 establishes an interface path for the optical sensor and paper sensor to communicate with the Main PWA.
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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 four buttons on the left of the display and four buttons on the right, with the display showing up to eight possible selections.
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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 circuit conditions on any output over the full range of input voltage. Overvoltage protection is 20%-30% above nominal for the 24V output.
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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 the F6 key (2nd key from the top at right side of control panel) under the Sensor Status Menu. The Dryer PWA is internal to the right side of the dryer plenum.
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NovaJet 800 Series Service Manual Beeper and Fans The beeper contains built-in driver circuitry so that it beeps under firmware 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 power supply. Air blows over the power supply and the heated air is forced out the back of the printer.
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Maintenance 3 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 maintenance since its purpose is to prolong the life of the printer.
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NovaJet 800 Series Service Manual Cleaning Procedures Always turn the printer OFF, remove the power cord and the interface cable before cleaning the printer. An electrical shock hazard may be present if these procedures are not followed. External Cleaning Do not use abrasive cleansers of any sort on the surfaces of the printer. Damage to the surface may result. The exterior surfaces of the printer may be cleaned with a soft cloth which has been dampened.
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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 cleaning the slide shaft at intervals determined by the environmental conditions. Do not use any lubrication. To clean the slide shaft: 1. Turn the printer OFF.
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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 tab locks it in place. Linear Encoder Strip Cleaning Clean the linear encoder strip weekly or as necessary to remove any buildup of debris.
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NovaJet 800 Series Service Manual 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: Disconnect the power cord and interface cable. 2. Slightly dampen a lint-free cloth with water and wipe along the length of the trailing cables on both sides. Ensure the encoder stabilizer bracket surface is thoroughly cleaned.
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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 of the jets. This can be seen as a misfiring of the cartridge. NOTE Care should be used when handling the cartridges.
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NovaJet 800 Series Service Manual 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 MAINTENANCE Flex Cable Contacts Figure 3-3. Flex Cable Contacts. Cleaning the flex cable contact area is very important due to the ease with which this area can become dirty. The flex for the yellow cartridge is deceiving because it is not readily apparent that it is dirty.
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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 debris. A cotton swab soaked isopropyl alcohol can be used to remove any ink that may have accumulated on the gears.
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NovaJet 800 Series Service Manual 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 MAINTENANCE Integrated circuits may become weakened or damaged by electrical discharge. Do not touch or work near integrated circuits without wearing an ESD wrist strap. Ribbon connectors can be easily damaged if incorrectly handled.
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NovaJet 800 Series Service Manual J 5 J 1 8 J 2 J 1 7 J 4 J 1 5 J 1 3 J 1 1 J 1 J 1 J2 6 J 8 J 7 J 1 0 U 2 4 J 9 Figure 3-4. Main PWA Connection Locations. Table 3-1. Main PWA Connections.
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NovaJet 800 Series Service Manual J 7 J 6 J 5 J 3 J 4 MAINTENANCE J 2 J 1 Figure 3-5. Carriage PWA Connection Locations. Table 3-2. Carriage PWA Connections. J1 J2 J3 J4 Trailing Cable Paper Sensor Encoder Sensor Black/Slot 1 Drivers J5 J6 J7 Cyan/Slot 2 Drivers Magenta/Slot 3 Drivers Yellow/Slot 4 Drivers Figures 3-4 and 3-5 show the locations of all the connectors on the Main PWA and carriage boards respectively.
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NovaJet 800 Series Service Manual RIBBON LOCKING MECHANISM UNLOCKED LOCKED CONNECTOR ASSEMBLY 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 operational usage.
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NovaJet 800 Series Service Manual 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 operational usage. Many factors including, but not limited to, hours/day used, cleanliness of the slide shaft and general ambient environment make it impossible to calculate the average time that the carriage bushings to last.
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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 on the meter. The acceptable range is 2-12 ohms. Typically, the reading is 3-8 ohms. 4. If the measurement is found to be unsatisfactory, replace the servo motor.
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NovaJet 800 Series Service Manual Stepper Motor Winding Resistance Check MAINTENANCE 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 the red wire. 3. The reading should indicate 7.2-8.0 ohms. 4. Continue by measuring between pins 4 and 6. Point B in Figure 3-8. 5. Reading should also indicate 7.2-8.0 ohms.
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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 enough to disconnect the motor wires from the leg harness. 4. Using a standard ohmmeter or multimeter, measure between the + and - connections on the motor.
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NovaJet 800 Series Service Manual Banding Differences MAINTENANCE 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 (ESD) from media (i.e. Backlit/Duratrans films) can also cause inconsistent horizontal banding.
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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 power. Because it is not directly tied to a mechanical movement, the bands become inconsistent in both frequency and duration.
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NovaJet 800 Series Service Manual Banding Causes & Quick Analysis Horizontal Banding Problems MAINTENANCE 1. Check the print mode for the type of image being printed. Refer to Printer Calibrations - 'Checking Print Mode'.
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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 vertical bars) is present then the trailing cable is either unseated or defective. 6. Clean the encoder strip (top and bottom) and inside of carriage belt with distilled water.
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NovaJet 800 Series Service Manual 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 troubleshooting checks have been made. MAINTENANCE 13. For single color or multiple color print failures replace the carriage PWA. If normal test patterns (i.e.
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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 'Scheduled Maintenance' for cleaning or 'Disassembly' for encoder strip replacement. 19. Improper grounding or earthing.
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NovaJet 800 Series Service Manual 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 Super Draft mode is 600 x 300, not 600 x 600 like the other modes.
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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 adjustment requirements include the slide shaft profile and cartridge head height adjustments. They do not require any electrical alignments.
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NovaJet 800 Series Service Manual Calibration Jo Block (1.434”) Plastic Gauge Card (0.011”) - Not used - 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 Setting MAINTENANCE 1. Connect the dial gauge micrometer to the Shaft mounting block as shown in Figure 3-11. ZERO GAUGE TIGHTEN SET SCREW (NOT SHOWN) SHAFT MOUNTING BLOCK Figure 3-11.
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NovaJet 800 Series Service Manual MEASURE FIRST MEASURE LAST MEASURE SECOND 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 turnbuckle with an open ended wrench if required, for the average value (the value found in step 3.) See Figure 3-13.
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NovaJet 800 Series Service Manual THESE ARE THE TURNBUCKLE SCREWS. POSITION GAUGE IN BETWEEN THE SCREWS AND AS CLOSE TO CENTER AS POSSIBLE. MAINTENANCE THIS IS THE INNER SCREW. POSITION GAUGE DIRECTLY IN FRONT OF IT. Figure 3-13. Slide Shaft Profile Adjustment. For example: If the Left = 0, Right = +0.004”, then the center should be adjusted to + 0.002”. This will ensure a smooth plane of travel for the carriage assembly. There are no adjustments on either end of the shaft in all models.
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NovaJet 800 Series Service Manual CARTRIDGE JET PLATE PLATEN HEAD HEIGHT 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 Head Height Alignment Plate. Assemble the tools as shown in Figure 3-15.
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NovaJet 800 Series Service Manual 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. 0 ZERO GAUGE ENSURE PRESSURE IS PLACED ON THE REAR OF THE CARTRIDGE MAINTENANCE Figure 3-16. Zeroing the Micrometer Gauge. 4. Remove the Cyan ink cartridge.
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NovaJet 800 Series Service Manual Damage may occur to the micrometer gauge if the Carriage is moved without lifting up on the measuring tip. This action could also take the micrometer out of alignment and foul the results of the alignment. 6. While lifting up the measuring tip of the micrometer, slide the Carriage to the left side of the stabilizer. Position it as close to the screw as possible and drop the measuring tip onto the platen. Do this a couple of times to ensure an accurate reading. 7.
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NovaJet 800 Series Service Manual 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. Adjust for 67 +/-3 reading the RED number only. 13. Continue performing steps 10 through 12 until all six of the stabilizer screws have been adjusted. MAINTENANCE 14.
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NovaJet 800 Series Service Manual Y M C COLOR VERTICAL HEAD-TO-HEAD CALIBRATION C M Y -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 COLOR HORIZONTAL HEAD-TO-HEAD CALIBRATION 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 currently entered. This is just an overview of all heads and how they are aligned. Do not attempt to align the heads using this view.
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NovaJet 800 Series Service Manual * Prime Display Settings Access Menu Print Settings Color Calib Menu Service Menu Calibration Menu Exit MAINTENANCE 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. Calib Test Horiz. Calib Test Exit Figure 3-20. Color Calib Menu. 3. Select “Vert.
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NovaJet 800 Series Service Manual 4 Vertical * Cancel Next Option Prev Option 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 “Ok” to accept the selection and return to the Color Calib Menu. 6. Continue until all seven vertical calibrations on the Color Calib Menu have been accomplished. 7.
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NovaJet 800 Series Service Manual 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 lines to the center set of lines would be appearant. Allowable values for the Slow Deadband calibration is -2, -1, 0, 1 and 2.
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NovaJet 800 Series Service Manual Calibration Menu * About Diagnostics Menu 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 test. Deadband Test Slow Db Test * Slow Deadband Single Line Test All Lines Test Exit Figure 3-24. Calibration (Deadband) Menu. 5.
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NovaJet 800 Series Service Manual 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 a bidirectional mode. To perform the Color Deadband Alignments: 1. Select “Utility Menu” from the Main Menu. This brings up the Utility Menu as shown in Figure 3-19. 2.
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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 * Color Db Test Right 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 print out a pattern of 5 calibration lines for each of the 12 settings. It will print this pattern for K, 1, C, 2, M, 3, Y, 4 .
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NovaJet 800 Series Service Manual 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 performing steps 4 through 6 until the all color deadband adjustments are correct on the left carriage. 8.
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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 similiar to the menu depicted in Figure 3-21. 7.
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NovaJet 800 Series Service Manual Servo PWM Test * Carriage Test Servo Cycle Test Color Test Menu Accessory Menu Continuous Test Exit 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 Cycle Test, Carriage Test, Color Test, Continuous Test, Fan #1 Test, Fan #2 Test and Legs Test. The Fan #1 Test, Fan #2 Test and Legs Test are located in the Accessory Menu as shown in Figure 3-29.
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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 the carriage assembly. Color Test - The Color Test prints a wide swath of ink for the slot selected to test for banding and ink delivery system pressure.
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NovaJet 800 Series Service Manual 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 near the center of the printer. The 42 inch printer does not have this second suction fan, therefore, the Fan #2 Test is disabled.
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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. Approximately 20 - 40 seconds later a single beep should be heard indicating the update was successful. After a one second delay, the printer will automatically reboot. The printer should come up normally. Verify the new firmware revision by sequencing through Utility Menu/Service Menu/ About Menu.
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NovaJet 800 Series Service Manual 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. MAINTENANCE 5. After hearing the single beep, remove power from printer for 15-20 seconds. Apply power to the printer. The printer should initialize properly.
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1 2 3 4 J1 1 2 3 4 +5V GND +5V PSIN GND EXA +5V EXB BLACK/1 CYAN/2 MAGENTA/3 YELLOW/4 CARRIAGE A ONLY CARTRIDGE DRIVERS PAPER SENSE PWA OPTICAL ENCODER SENSOR J1 J7 J6 J5 J4 1 2 3 4 J3 1 2 3 4 J2 CARRIAGE A OR B PWA 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 J1 ** NOT CONNECTED ON CARRIAGE B +24V +24V +24V +24V GND GND Y1 GND CARR_DATA (A/B) GND EXB ** GND EXA ** +5V TXOUT (A/B)0TXOUT(A/B)0+ GND TXOUT(A/B)1TXOUT(A/B)1+ GND TXOUT(A/B)2TXOUT(A/B)2+ GND TXCLK
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MAIN PRINTED WIRING ASSEMBLY J6 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 N.C. N.C. DRYER FAN 1 DRYER FAN 2 DRYER FAN CONTROL DRYER GND DRYER GND DRYER GND DRYER GND N.C.
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NovaJet 800 Series Service Manual Troubleshooting 4 Introduction Chapter 4, Troubleshooting consists of a table that is intended to aide the technician in troubleshooting the NovaJet 800 series printers. This table addresses symptoms with their possible causes and solutions. Basic troubleshooting skills will be required to perform the symptom identification, troubleshooting, fault isolation, and repair of the printer when using this table.
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NovaJet 800 Series Service Manual Table 4-1. Troubleshooting Table (cont).
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NovaJet 800 Series Service Manual Table 4-1. Troubleshooting Table (cont).
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NovaJet 800 Series Service Manual Table 4-1. Troubleshooting Table (cont).
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NovaJet 800 Series Service Manual Table 4-1. Troubleshooting Table (cont).
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NovaJet 800 Series Service Manual Table 4-1. Troubleshooting Table (cont).
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NovaJet 800 Series Service Manual Table 4-1. Troubleshooting Table (cont). Symptoms Possible cause Solution Internal ERROR “MPCB Failure” • bad MPWA replace MPWA • faulty connection of cartridge ID chip to flex cable check cartridges • wrong cartridges installed check cartridges • incorrect MB version verify MB version (MB 87-27-0) and replace MPWA if -27-0 is not displayed.
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NovaJet 800 Series Service Manual Table 4-1. Troubleshooting Table (cont). Symptoms Possible cause Solution Media Sen Ref. Pts Not Initialized (NJ880 only) • reference points were accidentally cleared reset all eleven reference p9oints by performing the Media Ref Pts.
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NovaJet 800 Series Service Manual Table 4-1. Troubleshooting Table (cont). Symptoms Possible cause Solution • bad MPWA replace MPWA • cartridge low on ink refill or replace cartridge • defective septum needle replace cartridge tubing needle/ septum assy.
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NovaJet 800 Series Service Manual Table 4-1. Troubleshooting Table (cont).
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NovaJet 800 Series Service Manual Table 4-1. Troubleshooting Table (cont). Symptoms Possible cause Printer Output is Banding (Horz.
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NovaJet 800 Series Service Manual Table 4-1. Troubleshooting Table (cont).
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NovaJet 800 Series Service Manual Table 4-1. Troubleshooting Table (cont).
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NovaJet 800 Series Service Manual Table 4-1. Troubleshooting Table (cont).
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NovaJet 800 Series Service Manual Table 4-1. Troubleshooting Table (cont).
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NovaJet 800 Series Service Manual Table 4-1. Troubleshooting Table (cont).
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NovaJet 800 Series Service Manual Table 4-1. Troubleshooting Table (cont).
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NovaJet 800 Series Service Manual Table 4-1. Troubleshooting Table (cont).
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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 problem.
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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) dirty? Clean with isopropyl alcohol. Does the Prime pattern print correctly? Refer to Routine Maintenance. 3.
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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 cartridge septum connector and tubing needle, reservoir tubing needle, and female valve as necessary. Figure 4-4. Septum and Valves. 6.
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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 indicate excessive current is passing through the flexible printed circuit; a black line indicates severe burning of the line. 9.
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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 Left carriage stalls (1, 2, 3, or 4) or Right carriage stalls (Y, M, C, K). Refer to Disassembly. Figure 4-8. Defective Trailing Cable.
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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. 14. Replace the carriage PWA for single or multiple color firing related problems.
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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. Please exercise caution when handling circuit assemblies and always attach an electrostatic discharge (ESD) wrist strap. Refer to Disassembly.
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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 resistor life. For severe clogs use ultrasonic cleaner (30-40 sec) or hot water (10-15 sec) to break down kogation (clogging of jet plate holes) at nozzle. Figure 4-13.
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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 cartridges can affect other cartridges via the flex driver cable connectivity.
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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, and sometimes 3 pass print modes) with dense images and depending on the color fill it may occur in the photo mode, but should never occur in the enhanced modes.
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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.
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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 (ESD) from media (i.e. Backlit/Duratrans films) can also cause inconsistent horizontal banding.
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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 the media is loaded correctly and is of proper thickness (no greater than 20 mil media can pass through the machine).
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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 normally defaulted off. Figure 4-25. Improper Grounding. 5. For direct printing environments, ensure all switchboxes and cables are IEEE 1284 compliant.
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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 of print. If more than one color (represented by the vertical bars) is present then the trailing cable is either unseated or defective. 7.
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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.
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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 (greater than 20 ml) or possibly canvas or vinyl exposed to high humidity which then becomes still. 10. Turn printer off.
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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.
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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 system due to defects or gear cleanliness. Figure 4-35. Defective Stepper Motor. 16.
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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 normal head height range between the bottom surface of the cartridges and the platen surface is 0.062" to 0.068". Refer to Alignments.
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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 motor life is approximately 2800 plot hours (2.8 million servo cycles). Figure 4-38. RIP Error.
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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 times; 256 MB of memory is suggested. Figure 4-40. Dirty or Defective Encoder Strip. 20. Clean or replace encoder strip for image skewing (image walking or skipping).
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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 internal file failures (i.e.
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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 demonstration print from the Support or Customer’s Demo Image CD. Additional problems such as diagonal banding could be due to a defective Servo Motor pulley.
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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 carriage bushings for wear and ensure the bushings are free of dirt and ink residue buildup.
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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 replacement. Replace trailing cable assembly for vertical jumps in color (i.e.
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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 skewing (image walking or skipping). Typically characterized as horizontal banding, often a walking image can also create vertical bands to appear in the print.
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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. Are any compression utilities being used? Avoid embedding text onto a layer that is compressed or resized within the application.
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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 print fine lines with no jagged edges. 9. Print a demo print from the sample images CD. If no overspray or similar problems show, then check the software driver or original file.
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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 compatibility with ENCAD inks. If diminished print quality is observed, please follow these simple steps: 1. Scroll through the printer display to obtain total ink throughput.
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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 Pattern jet out detection and the previous three steps have already been performed, contact ENCAD Technical Support or your service representative.
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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 to hot water (10-15 sec) to break down clogging at nozzle.
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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 with technical support to screen for contaminated ink problems. Ink Starvation - Ensure cartridge is properly primed, run color test @100% in 2 pass print mode.
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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 operation due to improper system setup or a defective ink delivery system (air leak in the system). Check pressure in the lines by initiating a Color Test in the 2 pass print mode.
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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 head pressure in the upper chamber of the cartridge. The cartridge must have between 15 and 40 ml of ink inside the cartridge for adequate printing pressure.
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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. Prime cartridge using 3 consecutive 1 second bursts and then wait 5 seconds, repeat 4-6 times over a 1 minute period.
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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 and check the 4 AA batteries in the unit. Replace the 4 AA batteries in the EasyPrime unit.
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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 carriage cover. Refer to Disassembly. 11. Replace the blue or gray female valve near reservoir. 12. Replace the ink reservoir. Figure 4-59. Reservoirs and Ink Delivery System.
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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 dirty environment can also cause large ink droplets to form.
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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 ambient or surrounding temperature could be causing the cartridge to get too hot. This could cause the ink to boil inside the jetplate and create air bubbles.
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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 the day, you may have to modify the settings to compensate for your own individual circumstances.
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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 station, autowipe feature activation, servo motor failure or firmware related problems. Please verify by checking all ‘Microbanding’ and ‘Horizontal banding’ causes first.
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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: Figure 4-64. Abnormal Test Examples. A – Total ink starvation; recheck using the EasyPrime.
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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. The assembly is composed of three parts which must be tightly twisted together prior to installation and use. 4.
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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 electrical integrated chip contacts on the rear of the cartridge have been penetrated. Replace the cartridge to verify problem. Unrecognized Cartridge Failure Analysis Steps: 1.
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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 position or is not mating correctly within the carriage assembly. After correcting, reattach cartridge, message should clear automatically after selecting OK. 4.
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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 respective carriage PWA is defective. 7. Replace both Trailing Cables. 8. Replace the Main PWA. 9. Refer to ‘Cartridge Warranty’.
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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 supply. The paper sensor should sense the platen on the return trip but may fail to do so - no error code given.
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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 detection second, then media right edge detection last.
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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 the encoder sensor assembly. The encoder sensor will need replacement should the error display.
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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 trailing cable is proven defective first.
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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 for this problem is to loosen the two securing screws and change the pitch or angle of the sensor to the media surface.
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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 delivery chain. Acceleration is also higher than Slew or Deceleration values. Figure 4-74. Servo Cycle/PWM Menu.
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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 7 day/24 hour operation for a minimum of 2 weeks without error. Refer to disassembly to replace the encoder stabilizer bracket and the trailing cables. Figure 4-75.
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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 damage - ensure tension is tight on belt and not loose. Clean inside of carriage belt with isopropyl alcohol (greater than 70% alcohol only!).
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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. Verify servo motor resistance values with an ohmmeter or multimeter. The resistance should be 2-8 ohms (1.5 to 30 ohms is acceptable).
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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 disassembly. 14. Replace encoder sensor if the encoder strip was noted as being extremely dirty and/or carriage head does not move at all during printer power up. Refer to disassembly.
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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 sensing operations). D10 – Normally OFF; Flashes during initialization, then turns off. LED staying on would indicate a problem when the FPGA is unconfigured.
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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 access). Replace the memory module to verify memory is not the cause of failure. Refer to disassembly. 4.
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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 paper sensor should sense the platen on the return trip but may fail to do so - no error code given.
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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 trailing cable connections if necessary. 3. Check feed/take-up modes and operation. Run a legs test under Diagnostics. 4. Reseat all printer cable connections. 5.
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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 electrical outlet for direct printing systems or non-networked environments. Noise in Image Figure 4-83. Connectivity Problem.
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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 printer, check the sensor status.
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NovaJet 800 Series Service Manual Figure 4-85. Main PWA Humidity Sensor. The Dryer Mode: (cccccccc) indicates the current dryer setting. Operational 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 humidity) indicates the ambient relative humidity as a percentage. If the dryer mode is set to “AUTO” and the firmware times-out trying to read the MBoard T. or the MBoard H.
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NovaJet 800 Series Service Manual firmware is unable to read the plenum temperature, main-board temperature, or main-board humidity, the corresponding equals sign (=) will change to a tilde (~). This error condition signifies an internal bus communication failure only. It does not indicate sensor connection or performance errors. The Dryer Mode: and Plenum T. items will also modify their display if a dryer component or main-board sensor error is detected.
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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. Perform electrical pin-out to verify continuity of cables (refer to service manual).
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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.
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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. Reinitialize the printer. From the Main Menu select Setup Menu, then select User Setup Menu, and choose Init Settings.
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NovaJet 800 Series Service Manual Blue test button SEH 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 run a continuous test with loopback cable attached (not provided with printer). Refer to the ‘Parallel Port Test’. The Semi-Circular Nook test pattern will print.
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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, select Service Menu, select About.
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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 (DIMM) at the Main circuit board. Power off printer.
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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 to 8 cm) from the home position at power up, resulting in a ‘Carriage Axis Error’ (occurs @ value 98), then the servo motor is most likely defective. Also, see step 10 below.
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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 trailing cable assembly. Figure 4-97. Probable Defective Main PWA.
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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 gate array I/C or driver I/C most likely). Ensure the 1x4 right and 1x4 left cartridge sets are utilized for isolating the defective carriage PWA.
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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 following problems if issue cannot be solved by any other means: Horizontal banding (1cm spacing) Microbanding (.5 to 2mm banding) 16.
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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 print settings are printed in any color other than black (normal) then the right carriage PWA is defective.
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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 either dirty or defective. Reinitializing the Printer To reinitialize the printer select User Menu - User Setup Menu - Init Settings.
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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 Starvation’ normally occurs when the printer has to wait for additional data from the host computer to complete another print pass.
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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-networked printing). For NT systems suggest using a unique PCI card to ensure a 1 MB per second data transfer rate. Figure 4-108. Printer Hesitation Causes.
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NovaJet 800 Series Service Manual Suggest increasing memory to 256 MB for low pass print mode operations. 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 mode, an additional parallel port (PCI card) must be installed or a configuration with a network and print server is suggested.
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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 LONGER THAN 2 SECONDS AS THIS WILL CHANGE THE SERVER CONFIGURATION.
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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 patterns, the “parallel port test equals passed” should be printed. If successful then the parallel port is operating correctly.
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NovaJet 800 Series Service Manual Figure 4-112. Demo Print. 2. Refresh printer firmware. Refer to the ‘Firmware Download’ procedure. 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 Menu, About - firmware version and boot code versions will be displayed. 2.
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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 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.
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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 steps as listed for the NJ850. Expanded Instructions for Firmware Download/Upgrade 1. Ensure customer wishes to upgrade to select firmware version.
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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 the System CD. 6. Using the EFPU, send the XXXX.ROM file to the printer. Open the EFPU and press the Add button in the Folders section of the dialog box.
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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 TakeUp. Roll 1 activates only the top roller to feed media while Roll 2 activates only the bottom roller to feed media. Figure 4-114. Media Handling System.
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Assembly\Disassembly 5 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 each procedure before beginning the removal and replacement of any assemblies or mechanisms.
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NovaJet 800 Series Service Manual A Hardware Kit is available for the printers. See Chapter 6 of this manual for the part number. WARNING Always turn the printer OFF, remove the power cord and the interface cable before beginning any disassembly procedures. An electrical shock hazard may be present if these precautions are not followed.
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NovaJet 800 Series Service Manual 3. Lift up on the left side of the Top 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. To remove the Right Cover Assembly: Figure 5-1. Right Cover Assembly Removal/Installation. 4. With a #2 Phillips screwdriver, remove the three screws securing the Right Cover Assembly to the Right Baseplate and the two screws securing it to the Right Sideplate.
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NovaJet 800 Series Service Manual 8. Disconnect the Display data ribbon cable connector at the J10 location on the Main PWA. To 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 the upper portion of Figure 5-2. 3. Reach under the Support Bracket and depress and hold the retracting stop assembly that secures the Left Cover to the Support Bracket. 4.
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NovaJet 800 Series Service Manual Install the Left, Top, and Right Covers To 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. CAUTION Applying too much torque to the lower screws can cause the mounts for the standoffs on the cover to break, requiring a replacement of the cover. 2.
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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, requiring 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 to 8 in-lbs.) To install the Top Cover: 1. Insert the pin located on the right side of the Top Cover into the corresponding hole on the Right Cover Assembly. 2.
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NovaJet 800 Series Service Manual 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. Install the E-Connect Network Assembly 1. Connect the power cable to the connection located near the center of the circuit board. 2. Hold the E-Connect Assembly in place and secure using 4 screws. Torque to 15 in-lbs 3.
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NovaJet 800 Series Service Manual Remove the Keypad and Display 1. Remove the Top and Right Covers following procedures outlined earlier in this chapter. 2. Turn 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 the ESD Shield. 3. With a 1/4” socket or wrench, remove the four standoffs and washers that secure the LCD Display Assembly to the Keypad. Remove the Display Assembly. Figure 5-4.
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NovaJet 800 Series Service Manual 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 cables into the Right Cover Assembly through the hole provided for the Keypad. 2. Place the Keypad into position and hold.
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NovaJet 800 Series Service Manual 4. Place the ESD Shield onto the Display standoffs using four kepnuts with a 1/4” socket or wrench. Torque to 2.5 in-lbs. 5. Attach ground connections to the Cover Standoffs as shown in Figure 5-5. Apply a small drop of loctite into the Cover holes, attach Standoffs and torque to 6 in-lbs. 6. Install the Top and Right Covers following procedures outlined earlier in this chapter.
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NovaJet 800 Series Service Manual 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 Top and Right Covers following procedures outlined earlier in this chapter. Remove the Main Printed Wiring Assembly (PWA) CAUTION Integrated circuits may become weakened or damaged by electrical discharge.
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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 the Trailing Cable from the connector. 9. Disconnect the Trailing Cable A connection at the J1 location.
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NovaJet 800 Series Service Manual Figure 5-7. Main PWA Removal.
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NovaJet 800 Series Service Manual CAUTION Failure to use an approved antistatic bag for storage or shipment may cause damage to the Main PWA and affect the Warranty. 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 facility for repair. Install the Main Printed Wiring Assembly (PWA) CAUTION Integrated circuits may become weakened or damaged by electrical discharge.
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NovaJet 800 Series Service Manual 8. Connect the Vacuum Fan 1 connector to J15 on the Main PWA. 9. Connect the AutoLoad Sensor connector to J13 on the Main PWA. 10. Connect and lock the Trailing Cable A connector to J1 on the Main PWA. 11. Connect and lock the Trailing Cable B connector to J2 on the Main PWA. 12. Connect the Leg Harness connector to J6 on the Main PWA. 13. Connect the Servo Motor connector to J12 on the Main PWA. 14. Connect the Stepper Motor connector to J7 on the Main PWA. 15.
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NovaJet 800 Series Service Manual Figure 5-8. Power Supply Removal. To 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” wrench or socket, remove the Fan from the Right Baseplate. 3. Using a 1/4” wrench or socket, disconnect the AC Entry Module ground from the ground stud on the Right Baseplate. 4.
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NovaJet 800 Series Service Manual Figure 5-9. Cooling Fan/AC Entry Module Removal. Install the Power Supply, Cooling Fan, and AC Entry Module To 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. Attach the AC Entry Module ground connection to the grounding stud on the Right Baseplate. 3. Hold the Cooling Fan into place while inserting the four bolts into the assembly.
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NovaJet 800 Series Service Manual 5. Insert and hold the Power Supply into place while securing it with four screws. Torque 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. 7. Install the Main PWA, Top and Right Covers following procedures outlined earlier in this chapter. Remove Servo Motor 1.
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NovaJet 800 Series Service Manual Figure 5-10. Using the Belt Removal Tool. 6. Turn the movable side so that the tool begins to expand and the Frame Tensioner Spring compresses. Continue to turn on the Belt Removal Tool until the belt can be lifted off of the Servo Motor pulley. 7. Move the Carriage Belt to the left so it is out of the way of the Servo Motor pulley. 8. Move the Carriage Assembly to the left end of the Slide Shaft. 9. Lift up gently and hold the right end of the Trailing Cables. 10.
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NovaJet 800 Series Service Manual 11. 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 the connector facing the FRONT side of the Platen. Guide the pulley up through the opening in the Platen. 2.
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NovaJet 800 Series Service Manual 10. Route the E-Connect power cable through the grommet on the EConnect Plate. Reinstall the E-Connect Plate under the Platen. Torque to 15 in-lbs. 11. Connect the Servo Motor connector to J12 on the Main PWA. 12. Install the E-Connect Network Assembly and the Top, Left and Right Covers following procedures outlined earlier in this chapter. Remove the Ink Delivery System 1. Remove the Top, Left and Right Covers following procedures outlined earlier in this chapter. 2.
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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 Removal.
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NovaJet 800 Series Service Manual 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 slide the Ink Delivery System into the printer. 2. Secure the Floating Carriage Cover to the Left and Right Support Brackets. Torque to 6 in-lbs. 3.
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NovaJet 800 Series Service Manual Figure 5-14. Using the Belt Removal Tool. 4. Turn the movable side so that the tool begins to expand and the Frame Tensioner Spring compresses. Continue to turn on the Belt Removal Tool until the belt can be lifted off of the Servo Motor pulley. 5. Turn the Belt Removal Tool in the opposite direction to remove the pressure exerted onto the Frame Tensioner. Remove the Belt Removal Tool. Remove the Frame Tensioner Assembly. 6.
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NovaJet 800 Series Service Manual Figure 5-15. Electronics Covers Removal. 8. Remove the Trailing Cables and Strain Reliefs from both Carriages by releasing the latch on the left lower side of the Strain Relief and lifting it off of the Carriages. See Figure 5-16.
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NovaJet 800 Series Service Manual LATCH Figure 5-16. Strain Relief Removal/Installation. 9. Slide the Carriage Assembly to the left edge of the Slide Shaft 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 Carriage. The left Carriage moves with the right Carriage, which is driven by the Belt. 10.
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NovaJet 800 Series Service Manual BUMP CARRIAGE BELT RIGHT POST OF BELT CLAMP LEFT POST OF BELT CLAMP Figure 5-17. Carriage Belt Clamp. 13. To 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 clears the top of the left post. 14. Push the Carriage Belt away from the right post of the Belt Clamp and gently lift up to finish removing the Carriage Belt from the Belt Clamp.
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NovaJet 800 Series Service Manual Install the Carriage Assembly, Carriage Belt, and the Frame Tensioner 1. To install the Belt onto the right Carriage, the “bumps” on the belt (where the ends of the belt are joined together to make the belt continuous) must be positioned between the left and right posts of the Belt Clamp. See Figure 5-17. 2. Slide the Carriage Belt between the right post and the middle post and guide it down into the Belt Clamp.
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NovaJet 800 Series Service Manual Encoder on the Carriage PWA. Ensure that the Carriage Coupler goes over the top of Slide Shaft. Stretch 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 the Belt when installing the left Carriage. 7.
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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. 11. Position the Electronics Cover over the right Carriage and gently press down on the ends of the Electronics Cover until the latches snap into the right Carriage. Perform the same procedure to attach the other Electronics Cover onto the left Carriage. 12.
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NovaJet 800 Series Service Manual 22. Turn the Belt Removal Tool 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 Tool. 24. Gently move the Carriage Assembly from end to end and make sure that the Carriage Belt is not binding 25. Install the Ink Delivery System following procedures outlined earlier in this chapter. 26.
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NovaJet 800 Series Service Manual LATCH TAB SLOT Figure 5-20. Carriage PWA Removal/Installation.
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NovaJet 800 Series Service Manual 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 for storage or shipment may cause damage to the Carriage PCB and affect the Warranty. 7.
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NovaJet 800 Series Service Manual Remove the Paper Sensor or the Encoder Sensor 1. Remove the Top, 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 from the Slide Shaft.
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NovaJet 800 Series Service Manual 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. To 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 grasping the Paper Sensor between thumb and index finger. See Figure 5-21. c. Pull straight up on the Paper Sensor and remove it from the Carriage Assembly. 4.
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NovaJet 800 Series Service Manual Install the Paper Sensor or the Encoder Sensor GROOVES ALIGN SIDES OF PAPER 2 SENSOR BOARD BETWEEN GROOVES AND PUSH STRAIGHT DOWN 1 ROUTE FLEX THROUGH SLOT INSIDE THE CARRIAGE ASSEMBLY 1 PUSH DOWN ON CLIP. PUSH ENCODER IN OVER CLIP. ENCODER MUST SLIDE PAST THE RIDGES AND SNAP INTO PLACE Figure 5-22. Paper and Encoder Sensor Installation. NOTE The Paper Sensor and Encoder Sensor are only installed onto the right Carriage.
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NovaJet 800 Series Service Manual 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. To install the Encoder Sensor: a. Turn the Carriage so that the bottom side of it is facing up. b. Push down on the plastic clip and slide the back of the Encoder Sensor over it. c. Push the Encoder Sensor in past the ridges until the Encoder Sensor snaps into place. d.
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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. Slide the bushing through the support bracket and out the other side. Figure 5-23. Floating Carriage Cover Bushing Removal. 5.
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NovaJet 800 Series Service Manual 9. Perform the same procedure to replace the Right Support Bracket bushing. Replacing the Carriage Bushings 1. Remove the Top, 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 from the Slide Shaft. Figure 5-24. Carriage Bushing Removal. 3.
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NovaJet 800 Series Service Manual TABS 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 System following procedures outlined earlier in this chapter. 9. Install the Top, Left and Right Covers following procedures outlined earlier in this chapter.
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NovaJet 800 Series Service Manual 5. Lift out the left side of the Service Station from the Platen and remove the Service Station. Moving the Service Station farther to the right might be required to release the left side of the Service Station. Install the Service Station 1. To install the Service Station, position the Service Station inside the Right Cover and place the left side of the Service Station into the Platen. 2.
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NovaJet 800 Series Service Manual 7. The Trailing Cable Assembly is secured to the Stabilizer Bracket by two pieces of double sided tape. Remove the Trailing Cable Assembly from the Stabilizer Bracket. 8. Mark the position of the double sided tape on the Stabilizer Bracket before removing. It is important that the new tape is placed in the exact position as the older pieces were. Remove any remnants of tape still on the Stabilizer Bracket. Install the Trailing Cable Assembly 1.
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NovaJet 800 Series Service Manual 6. Reposition the Floating Carriage Cover/Right Support Bracket Assembly and the Left Support Bracket around the Carriage Assembly. Secure the Left Support Bracket to the Floating Carriage Assembly. Torque to 15 in-lbs. 7. Install the Top and Right Covers following procedures outlined earlier in this chapter. Remove the Stabilizer Bracket and Encoder Strip 1. Remove the Top, Left and Right Covers following procedures outlined earlier in this chapter. 2.
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NovaJet 800 Series Service Manual 4. Remove the Stabilizer 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 entire Stabilizer Bracket Assembly with the Encoder Strip is to be replaced if the Encoder Strip is damaged. Install the Stabilizer Bracket and Encoder Strip 1.
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NovaJet 800 Series Service Manual 4. Disconnect the AutoLoad Sensor connector at the J13 location on the Main PWA. 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 Installation/Removal. 6. The pinch rollers are held on by a small C clamp located on the back of the Y-Arm Assembly. See Figure 5-29.
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NovaJet 800 Series Service Manual Figure 5-29. Pinch Roller. 7. Spin 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 Slide Shaft from the top of the pinch roller. 9. Remove the pinch roller. 10.
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NovaJet 800 Series Service Manual Install the Y-Arm Assembly, Pinch Rollers, Slide Shaft, and AutoLoad Sensor 1. Install the AutoLoad Sensor Assembly into the back part of the YArm Bracket. Torque 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. Install the Slide Shaft and its supports to the Y-Arm Assembly. Torque to 8 in-lbs. 4.
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NovaJet 800 Series Service Manual Remove the Gap Sensor (NovaJet 880 only) To 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. Locate and remove the 3 bottom right cover screws. 4. Disengage the retracting latch between right cover and rear cover, pull up and ease right cover over on one side. 5.
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NovaJet 800 Series Service Manual 3. Remove the Service Station 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 required to properly hold the media down onto the Platen. 4.
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NovaJet 800 Series Service Manual 11. 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 ends of the screws that protrude inside of the Platen when removing the Lower Drive Roller Assembly.
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NovaJet 800 Series Service Manual 13. Remove the Stepper Motor Extension Spring from the Stepper Motor and the post on the Left Lower Drive Shaft Bracket. See Figure 5-30. ATTACH SPRING TO POST ON BRACKET Figure 5-30. Stepper Motor Removal/Installation. 14. Remove the hardware securing the Stepper Motor to the Left Lower Drive Shaft Bracket and remove the Stepper Motor. Install the Lower Roller Assembly, Stepper Motor and Vacuum Fan (NovaJet 850) 1.
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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 of the Platen when removing the Lower Drive Roller Assembly.
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NovaJet 800 Series Service Manual 10. Reinsert the right Foam Block. Make sure that the Stepper 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 Stepper Motor and the Servo Motor. Make sure it is not tilted at an angle. SERVICE STATION STEPPER MOTOR FOAM BLOCK P/O LEG HARNESS Figure 5-31. Inside Platen, Right Side. 11. Reinsert the Service Station. 12. Reinstall the Right Sideplate.
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NovaJet 800 Series Service Manual Remove the Lower Roller Assembly, Stepper Motor and Vacuum Fan (NovaJet 880) 1. To 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 straight up. 4. Remove the flattening roller thumb screws and remove the flattening rollers. 5. Disconnect the SEH print server from the parallel port if connected. 6.
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NovaJet 800 Series Service Manual 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 PWA connections. Disconnect the power supply, servo motor, stepper motor, takeup/feed system, Autoload sensor, both vacuum fans, power supply cooling fan, both trailing cables, and two grounds.
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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 securing foot to one side to release the strain relief. Caution: do not force strain relief or damage to carriage assembly may result. 23.
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NovaJet 800 Series Service Manual 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). To remove the stepper motor from lower roller remove the 2 securing screws, 2 nuts, and spring. Note the orientation of the motor with respect to the lower roller. For new motor installations verify support bracket to motor gap is .005” to .
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NovaJet 800 Series Service Manual Remove the Media Take-Up and Feed Sensor Brackets and Sensors NOTE The sensors for the media Take-Up and Feed Assembly are identical, but the brackets that they mount to have distinct differences. The top bracket has an additional extended arm attached to help in directing the media from blocking the sensor’s beam path. Ensure that the bracket is being replaced with the correct bracket. 1. Remove all media and media rollers from the printer. 2.
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NovaJet 800 Series Service Manual WIRE TIE WRAPS assembly. Figure 5-32. Media Take-Up and Feed Sensor Removal. Install the Media Take-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 on the plastic nut onto the front of the sensor. 3. Route the sensor wires to the back of the bracket and secure the wires using two wire tie wraps. 4.
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NovaJet 800 Series Service Manual Remove the Media Take-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 motor can be removed. 4. Remove the wires from the motor. 5. From the back of the Cradle Idler, disconnect the tension spring from the post located on the Cradle Idler. 6.
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NovaJet 800 Series Service Manual MOTOR GEAR MOTOR MOTOR MOUNT C CLAMP CRADLE IDLER Figure 5-33. Media Take-Up and Feed Motor Removal. Remove the Thermal Dryer Assembly WARNING Once the dryer is plugged in, there is continuous power being applied to the dryer, even when the printer is turned off. DISCONNECT POWER CORD BEFORE SERVICING! 1. Lift the entire drying fan assembly off of the printer.
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NovaJet 800 Series Service Manual Install 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 back of the printer. Remove the Thermal Dryer Right Endcap Assembly NOTE The Thermal Dryer Right Endcap Assembly contains the Printed Wiring Assembly for the Dryer.
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NovaJet 800 Series Service Manual WARNING 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 Assembly. See Figure 5-35. Figure 5-35. Dryer Right Endcap Removal/Installation. 4.
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NovaJet 800 Series Service Manual NOTE Some units may have very small servicing loops in the wiring 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 main body. During assembly, ensure that all internal connections are good, including connections located at the left side of the dryer. 5.
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NovaJet 800 Series Service Manual J9 J6 J7 J3 J1 J2 Figure 5-36. Right Endcap Connector Locations. Table 5-1. Thermal Dryer PWA Connections. J1 J2 J3 J4 J5 Fan 1 Fan 2 Element, Left Conn Power Power J6 J7 J8 J9 P1 Element, Right Conn Thermistor Fuse, on back of PWA Thermistor Data cable 2. Reconnect the power cord ground to the main body of the Thermal Dryer. 3. Attach and secure the Right Endcap Assembly. Torque to 15 in-lbs. 4.
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6 Parts List This chapter lists the items and their associated numbers for the parts and assemblies of the NovaJet 800 Series printers that are field replaceable. The list is in order of part name as identified in the assembly/ disassembly chapter. This list is to be used in conjunction with the assembly/disassembly procedures to aquire the necessary parts and properly install them into the printer. The parts and assemblies may be ordered through your local authorized dealer or ENCAD, Inc.
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NovaJet 800 Series Service Manual FIGURE ITEM 6-1 7 PART NAME PART # FITTING, FEMALE, BLUE ...................... 214244-00 FITTING, FEMALE, GRAY ..................214245-00 6-1 8 C-RING 7/16 ..............................................207789 HARDWARE KIT ....................................208810 EASYPRIME ............................................216072-01 SDRAM, DIMM, 8M X 64MB, PC133 ....215919-00 ASSY, HEIGHT GAGE KIT .....................209996-1 ADAPTER, HEAD HEIGHT ...................
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NovaJet 800 Series Service Manual 1 4 5 8 2 7 6 3 Figure 6-1. Left Side Parts Breakdown.
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NovaJet 800 Series Service Manual FIGURE ITEM PART NAME PART # 6-2 1 SPRING, COMPESSION ..........................209052 6-2 2 RETRACTING STOP, ASSEMBLY .........208838-01 6-2 3 COVER ASSY, TOP, 60” ..........................215571-00 COVER ASSY, TOP, 42” .......................215572-00 6-2 6-2 4 5 CHAIN SUPPORT ASSEMBLY 60” ......................................................217283-00 42” ......................................................217284-00 BELT, 60” .....................
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NovaJet 800 Series Service Manual Figure 6-2. Platen and Above Parts Breakdown.
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NovaJet 800 Series Service Manual FIGURE ITEM 6-3 1 PART NAME PART # COVER ASSEMBLY, WITH KEYPAD AND DISPLAY, RIGHT .......................215350-00 6-3 2 KEYPAD ASSEMBLY .............................209096-3 6-3 3 REFLECTIVE DISPLAY ASSY ..............210068-04 6-3 4 MAIN PRINTED WIRING ASSY NOVAJET 850 .......................................216632-00 NOVAJET 880 .......................................218972-12 6-3 5 POWER ENTRY MODULE ....................
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NovaJet 800 Series Service Manual Figure 6-3. Right Side Parts Breakdown.
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NovaJet 800 Series Service Manual FIGURE ITEM 6-4 1 PART NAME PART # HARNESS, DRYER/WINDER NOVAJET 850 .......................................215188-00 NOVAJET 880 .......................................217886-01 6-4 2 MOTOR ASSY, SERVO ...........................215704-01 6-4 3 BLOCK, RIGHT FOAM ...........................215178-00 6-4 4 STEPPER MOTOR ASSY, W/ GEAR AND FERRITE ..........................214376-00 6-4 5 BRACKET, LOWER ROLLER ASSY ....208987-1 6-4 6 BLOCK, LEFT FOAM ......
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NovaJet 800 Series Service Manual 1 2 3 4 6 5 8 7 10 9 12 10 11 13 Figure 6-4. Inner Platen Parts Breakdown.
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NovaJet 800 Series Service Manual FIGURE ITEM PART NAME PART # 6-5 1 COVER, CARRIER ELECTRONICS .....215111-02 6-5 2 CARRIAGE PWA .....................................214751-04 6-5 3 ENCODER SENSOR W/FLEX RIGHT SIDE CARRIAGE ONLY ........209578-101 6-5 4 STRAIN RELIEF ......................................215659-00 6-5 5 CARRIAGE FRAME ASSY, PARTIAL LEFT SIDE CARRIAGE .......................217561-00 RIGHT SIDE CARRIAGE ....................217559-00 6-5 6 CARRIAGE BUSHING SET (2) ......
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NovaJet 800 Series Service Manual Figure 6-5. Carriage Assembly Parts Breakdown.
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NovaJet 800 Series Service Manual FIGURE ITEM PART NAME PART # 6-6 1 ACTUATOR, VALVE ...............................214886-01 6-6 2 CLIP, VALVE ............................................214521-00 6-6 3 VALVE ASSEMBLY, BLUE .....................215703-01 GRAY .....................................................215702-01 6-6 4 CARRIAGE COVER ASSY .....................215663-03 P/O INK DELIVERY SYSTEM 60” ....217294-00 P/O INK DELIVERY SYSTEM 42” ....
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NovaJet 800 Series Service Manual Figure 6-6. Floating Carriage Cover Parts Breakdown.
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NovaJet 800 Series Service Manual FIGURE ITEM PART NAME PART # SERVICE STATION ASSY ......................
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NovaJet 800 Series Service Manual Figure 6-7. Service Station Parts Breakdown.
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NovaJet 800 Series Service Manual FIGURE ITEM 6-8 1 PART NAME PART # SHAFT ASSY, W/FIXED RT SIDE, GUIDE, ADJ (2) AND CLAMP (3) 60” .................................................207657-1 42” .................................................207657-2 6-8 2 GUIDE, PAPER ADJUSTABLE ..............207644 6-8 3 CLAMP, GUIDE PAPER .........................207659 6-8 4 SENSOR, ASSY ........................................207727 6-8 5 SENSOR, BRACKET, TOP, ASSY ..........
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NovaJet 800 Series Service Manual Figure 6-8. Power Feed and Take-Up Parts Breakdown.
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NovaJet 800 Series Service Manual Index A G alignments slide shaft . . 3-24 axis drive carrier . . 2-5 paper (media) . . 2-4 general block diagram . . 2-2 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 encoder strip . . 5-43 ESD . . 1-3 F fan, cooling . . 5-15 firmware downloading . . 2-10, 3-43, 3-44 I ink delivery system . .
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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, 5-11 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 publications . . 1-3 S scheduled maintenance . . 3-1 service station . . 3-3, 5-40 signal flow . . 3-45 specifications . . 1-5 T technical support ENCAD website . .