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ENCAD NovaJet 800 Series Service Manual

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NovaJet
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Summary of Contents for ENCAD NovaJet 800 Series

  • Page 1 NovaJet 8-Head Family ® NovaJet 800 Series Service Manual...
  • Page 2 ® NOVAJET® 800 Series Color Inkjet Printer Service Manual Part Number 216520-01...
  • Page 3 Encad, Inc., 6059 Cornerstone Court West, San Diego, CA 92121, U.S.A. Certain manuals developed by ENCAD are in an elec- tronic format to be distributed on CDs or over the internet. The registered user of an ENCAD product whose manual is distributed in this fashion may print one copy for their personal use only.
  • Page 4 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...
  • Page 5 Connect the equipment into an outlet on a circuit different from that to which the receiver is connected. − Consult the dealer or an experienced radio/TV technician for help. Changes or modifications not expressly approved by ENCAD, Inc. could void the user’s authority to operate the equipment.
  • Page 6 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.
  • Page 7 ENCAD QIS (Quality Imaging Supplies) ink is nonhazard- ous, requiring no special disposal handling. It can be harmful if swallowed and should be kept away from children. To obtain a Material Safety Data Sheet, contact ENCAD, Inc. at: 6059 Cornerstone Court West San Diego, CA 92121-3734...
  • Page 8 In no event shall ENCAD be liable for any loss of profit or other commercial damages, special, incidental or consequential damages, or any other damages or claims, whatsoever.

  • Page 9: Table Of Contents

    Technical Support ................. 1-8 Chapter 2 Theory of Operation ........2-1 Introduction .................. 2-1 NovaJet 800 Series Printers General Block Diagram ...... 2-2 Paper (Media) Axis Drive ............... 2-4 The Carriage Axis Drive ..............2-5 Media Feed and Take-Up System ..........2-6 Main PWA (Printed Wiring Assembly) ...........
  • Page 10 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 ............. 3-2 Slide Shaft Cleaning ............3-2 Service Station Cleaning ........... 3-3 Linear Encoder Strip Cleaning ........... 3-4 Trailing Cables Cleaning ...........
  • Page 11 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 ..............4-2 Media Does Not Move............. 4-3 Internal ERROR “Carriage Axis Failure” ........4-4 Internal ERROR “Encoder Sensor Failure”...
  • Page 12 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 ............ 4-47 Cartridge Maintenance & Testing ........ 4-48 Ink Starvation .............
  • Page 13 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 ........... 5-8 Install the Keypad and Display ............
  • Page 14 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) ............
  • Page 15 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............5-31 Install the Carriage PWA.............
  • Page 16 NovaJet 800 Series Service Manual Table of Contents (cont) Chapter 6 Parts List ............6-1...
  • Page 17 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..............2-5 2-4.
  • Page 18 NovaJet 800 Series Service Manual List of Illustrations (cont) Figure Page Chapter 3 Maintenance (cont.) 3-20. Color Calib Menu..............3-33 3-21. Vertical Options Menu............. 3-34 3-22. Slow Deadband............... 3-35 3-23. Service Menu................3-36 3-24. Calibration (Deadband) Menu........... 3-36 3-25.
  • Page 19 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.
  • Page 20 NovaJet 800 Series Service Manual List of Illustrations (cont) Figure Page Chapter 4 Troubleshooting (cont) 4-63. Normal Color Test (3 Pass)............4-61 4-64. Abnormal Test Examples............4-61 4-65. Cartridge Tubing Needle and Septum........4-62 4-66. Ink Starvation................4-63 4-67.
  • Page 21 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.
  • Page 22 NovaJet 800 Series Service Manual List of Illustrations (cont) Figure Page Chapter 5 Assembly/Disassembly (cont.) 5-18. Carriage Coupler Installation............ 5-28 5-19. Left Carriage Installation............5-29 5-20. Carriage PWA Removal/Installation.......... 5-32 5-21. Paper and Encoder Sensor Removal........5-34 5-22.
  • Page 23 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..........5-65...

  • Page 24: Chapter 1 General Description

    NovaJet 800 Series Service Manual General Description 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.
  • Page 25 ® 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. ENCAD has made significant advances in designing these printers to respond to and anticipate our customers’ needs.

  • Page 26: Overview

    Related Publications The following publication contains additional information which may be useful in servicing the NovaJet 800 Series Color Inkjet Printers: ENCAD NovaJet 800 Series Quick Start Guide, P/N 215360-XX ENCAD NovaJet 800 Series System CD-ROM, P/N 215363-XX Copies of these and other ENCAD, Inc.

  • Page 27: Warnings, Cautions And Notes

    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.

  • Page 28: Printer Specifications

    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: Accuracy: 42 inch 60 inch +/- 0.2% line length using Norm 40.8” 58.8” ROLL feed and 4 mil 1.04m...

  • Page 29: Contents Of This Service Manual

    This manual is divided into six chapters as follows: Chapter 1 GENERAL DESCRIPTION - Contains a general description of the ENCAD NovaJet 800 Series printer. This includes printer specifications, and related materials. Also included is a description of the use of Warnings, Cautions and Notes as used in this manual and chapter contents.
  • Page 30 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.

  • Page 31: Technical Support

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

  • Page 32: Chapter 2 Theory Of Operation

    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.

  • Page 33: Novajet 800 Series Printers General Block Diagram

    NovaJet 800 Series Service Manual NovaJet 800 Series Printers General Block Diagram Figure 2-1 illustrates the major functional areas of the printers. The NovaJet 800 Series printers consist of three mechanical assem- blies: 1. Paper (Media) Axis Drive 2. Carriage Axis Drive 3.
  • Page 34 NovaJet 800 Series Service Manual Figure 2-1. General Block Diagram. Theory of Operation...

  • Page 35: Paper (Media) Axis Drive

    Misaligned pinch wheels is a main cause of skewing of the media. For that reason the NovaJet 800 Series was designed with self aligning pinch rollers. As the media is fed forward, the rollers are aligned cor- rectly.

  • Page 36: The Carriage Axis Drive

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

  • Page 37: Media Feed And Take-Up System

    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.

  • Page 38: Main Pwa (Printed Wiring Assembly)

    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: Microprocessor (CPU) Gate Array Memory Circuits Stepper Motor Controller Servo Motor Controller Interface Circuits: Serial &...

  • Page 39: Main Pwa Led Status Indicators

    NovaJet 800 Series Service Manual Main PWA LED Status Indicators D1 - Normally flashes when the DSP is idle. Steady during print opera- tions. D8 - +24V available. D9 - Normally flashes when the Power PC processor is idle. Stops flashing when processor is busy (i.e.

  • Page 40: Gate Array

    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.

  • Page 41: Memory Circuits

    NovaJet 800 Series Service Manual Memory Circuits Memory is used to retain large amounts of information. This information is stored in the device memory in the form of binary bits. Printer memory consists of Flash EEPROM, SDRAM, and EEPROM. Maximum installable memory is as follows:...

  • Page 42: Sdram

    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.
  • Page 43 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.

  • Page 44: Servo Motor Controller

    NovaJet 800 Series Service Manual Servo Motor Controller ENCODER MOTOR SERVO SERVO DRIVER CONNECTOR MOTOR GATE ARRAY CARRIAGE CARRIAGE CONNECTOR 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.
  • Page 45 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...

  • Page 46: Interface Circuits: Serial & Parallel

    NovaJet 800 Series Service Manual A hardware counter in the gate array increments as the Carriage Assem- bly moves left and decrements as the Carriage Assembly moves right. The hardware counter is only eight bits wide, so it cannot store a value large enough to represent an absolute Carriage Assembly position.
  • Page 47 NovaJet 800 Series Service Manual Carriage Assembly Circuits OPTICAL ENCODER OPTICAL SENSOR TRAILING CABLE PAPER SENSOR TRAILING CARRIAGE RIGHT CARRIAGE CABLE ASSEMBLY ONLY CONNECTION FROM CARTRIDGE 1 MAIN INKJET CARTRIDGE 2 DRIVERS CARTRIDGE 3 CARTRIDGE 4 LEFT AND RIGHT CARRIAGE ASSEMBLY Figure 2-11.
  • Page 48 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.
  • Page 49 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.
  • Page 50 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.
  • Page 51 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.
  • Page 52 NovaJet 800 Series Service Manual Beeper and Fans The beeper contains built-in driver circuitry so that it beeps under firm- ware control. The beeper alerts the user to error conditions. There exists three types of fans that can be on these printers.

  • Page 53: Chapter 3 Maintenance

    Maintenance Introduction This chapter contains general maintenance and cleaning instructions for the NovaJet 800 series printers. Scheduled Maintenance Scheduled maintenance consists of a list of checks that are planned to be performed on a regular basis or when conditions warrant it.

  • Page 54: Cleaning Procedures

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

  • Page 55: Service Station Cleaning

    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.

  • Page 56: Linear Encoder Strip Cleaning

    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.

  • Page 57: Trailing Cables Cleaning

    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.

  • Page 58: Cartridge Dimples Cleaning

    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.

  • Page 59: Flex Cable Contact Cleaning

    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 Flex Cable Contacts Figure 3-3.

  • Page 60: Clean And Inspect Stepper Motor Gears

    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.

  • Page 61: Dryer Cleaning

    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 Integrated circuits may become weakened or damaged by electri- cal discharge.
  • Page 62 NovaJet 800 Series Service Manual J 1 8 J 1 7 J 1 5 J 1 3 J 1 1 J 1 2 U 2 4 J 1 0 Figure 3-4. Main PWA Connection Locations. Table 3-1. Main PWA Connections.
  • Page 63 NovaJet 800 Series Service Manual Figure 3-5. Carriage PWA Connection Locations. Table 3-2. Carriage PWA Connections. Trailing Cable Cyan/Slot 2 Drivers Paper Sensor Magenta/Slot 3 Drivers Encoder Sensor Yellow/Slot 4 Drivers Black/Slot 1 Drivers Figures 3-4 and 3-5 show the locations of all the connectors on the Main PWA and carriage boards respectively.

  • Page 64: Replace Trailing Cables

    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.

  • Page 65: Replace Carriage Cover/Carriage Bushings

    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 opera- tional usage. Many factors including, but not limited to, hours/day...

  • Page 66: Servo Motor Winding Resistance Check

    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.

  • Page 67: Stepper Motor Winding Resistance Check

    NovaJet 800 Series Service Manual Stepper Motor Winding Resistance Check 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.

  • Page 68: Power Feed And Take-Up Motor Winding Resistance Check

    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.

  • Page 69: Banding Differences

    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.
  • Page 70 1) Remove any RIP or network systems and connect the printer directly to the computer via the printers parallel port. 2) Print a test file approved by ENCAD that uses only the ENCAD print file utility version 3.0 (EFPU 3.0) and the ENCAD printer. Send a test file via LPT1 with ECP mode enabled with DMA channel assignment.

  • Page 71: Banding Causes & Quick Analysis

    NovaJet 800 Series Service Manual Banding Causes & Quick Analysis Horizontal Banding Problems 1. Check the print mode for the type of image being printed. Refer to Printer Calibrations - 'Checking Print Mode'. Is the high pass mode (5 pass for 2x4 configuration, 10 pass for 1x4, 1x6, and 1x8 cartridge...
  • Page 72 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.
  • Page 73 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.

  • Page 74: Vertical Banding Problems

    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.

  • Page 75: Line Quality Problems (Overspray)

    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.

  • Page 76: Alignments/Adjustments

    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.
  • Page 77 NovaJet 800 Series Service Manual Calibration Jo Block (1.434”) - Not used Plastic Gauge Card (0.011”) - Not used There are two basic measurements that are to be made using this kit (ensure power is off prior to performing these proceures): 1.
  • Page 78 NovaJet 800 Series Service Manual MEASURE MEASURE MEASURE LAST SECOND FIRST 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.

  • Page 79: Head Height Alignment Procedure

    NovaJet 800 Series Service Manual THESE ARE THE TURNBUCKLE SCREWS. POSITION GAUGE IN BETWEEN THE SCREWS AND AS CLOSE TO CENTER AS POSSIBLE. THIS IS THE INNER SCREW. POSITION GAUGE DIRECTLY IN FRONT OF IT. Figure 3-13. Slide Shaft Profile Adjustment.
  • Page 80 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.
  • Page 81 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.
  • Page 82 NovaJet 800 Series Service Manual Damage may occur to the micrometer gauge if the Carriage is moved without lifting up on the mea- suring tip. This action could also take the microme- ter out of alignment and foul the results of the align- ment.

  • Page 83: Color Calibration

    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.
  • Page 84 NovaJet 800 Series Service Manual COLOR VERTICAL HEAD-TO-HEAD CALIBRATION 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.
  • Page 85 NovaJet 800 Series Service Manual Prime Display Settings Access Menu Print Settings Color Calib Menu Service Menu Calibration Menu Exit Figure 3-19. Utility Menu. 2. From the Utility Menu, select “Color Calib Menu”. This brings up the color calibration menu and it looks like Figure 3-20.

  • Page 86: Deadband Alignments

    NovaJet 800 Series Service Manual 4 Vertical Cancel Next Option < selected > Prev Option 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.
  • Page 87 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.
  • Page 88 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.

  • Page 89: Color Deadband Alignment

    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. These adjustments help to compensate for any deviations that may have become apparent due to the carriage speed and/or the type of media loaded.
  • Page 90 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.

  • Page 91: Paper Axis Calibration

    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.

  • Page 92: Diagnostics Menu

    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.
  • Page 93 NovaJet 800 Series Service Manual Servo PWM Test Carriage Test Servo Cycle Test Color Test Menu Accessory Menu Continuous Test Exit Figure 3-28. Diagnostics Menu. All tests under the Diagnostics Menu should be performed by competent technicians only. The types of tests that can be performed are: Servo PWM Test, Servo Cycle Test, Carriage Test, Color Test, Continuous Test, Fan #1 Test, Fan #2 Test and Legs Test.
  • Page 94 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: 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.

  • Page 95: Firmware Download/Upgrading For The Pc

    Downloading new firmware is a simple procedure. You will need the firmware, nnnnxxx.rom, and the Encad File Print Utility (EFPU) to download the code. (‘nnnn’ identifies the product and ‘xxx’ is the version number of the firmware.) The EFPU can be found on the CD that shipped with...

  • Page 96: Firmware Download/Upgrading For The Mac

    2. Connect an Image Writer II cable between the printer and MAC. 3. Turn the printer ON. 4. Obtain the latest firmware revision from the ENCAD web site, unpack the file and launch the EFPU. File names may be different from that listed below.

  • Page 97: Internal Cabling And Signal Flow Diagrams

    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.
  • Page 98 NovaJet 800 Series Service Manual Figure 3-31. Carriage PWA Connections Diagram. Maintenance 3-46...
  • Page 99 NovaJet 800 Series Service Manual Figure 3-32. Leg Harness Connections Diagram. Maintenance 3-47...

  • Page 100: Chapter 4 Troubleshooting

    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.

  • Page 101: Initialization Failure

    NovaJet 800 Series Service Manual Table 4-1. Troubleshooting Table (cont). Symptoms Possible cause Solution No Power • printer not ON depress power switch • faulty power replace power cord cord • AC input not replace AC entry present at power...

  • Page 102: Media Does Not Move

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

  • Page 103: Internal Error "Carriage Axis Failure

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

  • Page 104: Internal Error "Encoder Sensor Failure

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

  • Page 105: Internal Error "Paper Sensor Failure

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

  • Page 106: Internal Error "Mpcb Failure

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

  • Page 107: Media Sen Ref. Pts Not Initialized (Nj880 Only)

    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 reset all eleven refer- were accidentally ence p9oints by per- cleared forming the Media Ref Pts. Alignment...

  • Page 108: Ink Cartridge Misfiring

    NovaJet 800 Series Service Manual Table 4-1. Troubleshooting Table (cont). Symptoms Possible cause Solution • bad MPWA replace MPWA Ink Cartridge Misfiring • cartridge low on refill or replace cartridge • defective septum replace cartridge needle tubing needle/ septum assy.

  • Page 109: Paper Skewing

    NovaJet 800 Series Service Manual Table 4-1. Troubleshooting Table (cont). Symptoms Possible cause Solution Ink Cartridge • service station 1) perform Service Misfiring (cont) dirty or not Station Cleaning properly sealing procedures cartridge jet area 2) replace seal on service station •...
  • Page 110 NovaJet 800 Series Service Manual Table 4-1. Troubleshooting Table (cont). Symptoms Possible cause Solution Printer Output is 2) inspect and/or Banding (Horz.) replace stepper (cont) motor gears and/or lower roller assembly 3) replace MPWA • insufficient replace or refill ink in cartridges...

  • Page 111: Printer Output Is Banding (Vertical)

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

  • Page 112: Keypad Locked-Up Or Not Functioning Properly

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

  • Page 113: Line Quality Degraded

    NovaJet 800 Series Service Manual Table 4-1. Troubleshooting Table (cont). Symptoms Possible cause Solution • carriage replace carriage bushings worn bushings (4) • debris or clean fan assembly obstruction in fan • drive belt replace frame slipping on idler tensioner, spring, or idler •...
  • Page 114 NovaJet 800 Series Service Manual Table 4-1. Troubleshooting Table (cont). Symptoms Possible cause Solution • color calibration perform Color needed Calibration • deadband perform Deadband calibration needed Calibration (in bidirectional printing mode) • debris or clean slide shaft lubrication on slide shaft •...

  • Page 115: Fan Does Not Power Up

    NovaJet 800 Series Service Manual Table 4-1. Troubleshooting Table (cont). Symptoms Possible cause Solution Fan Does Not Power Up • MPWA has 1) reseat connection 24 VDC at J3 at MPWA to fan pins 1-2 2) replace fan • power not being...

  • Page 116: Media Feed Motor Not Operating, Sensor Works

    NovaJet 800 Series Service Manual Table 4-1. Troubleshooting Table (cont). Symptoms Possible cause Solution Media Feed Motor Not Operating, Sensor Works • bad connection reconnect Feed to the motor motor • bad Feed motor replace Feed motor • faulty wiring leg...
  • Page 117 NovaJet 800 Series Service Manual Table 4-1. Troubleshooting Table (cont). Symptoms Possible cause Solution • reflective decal replace reflective missing decal • sensor not replace or reshape aligned correctly sensor bracket (sensor bracket bent or misaligned) Troubleshooting 4-18...

  • Page 118: Print Quality Issues

    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.

  • Page 119: Failure Analysis - Print Misfires

    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.
  • Page 120 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.
  • Page 121 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.
  • Page 122 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).
  • Page 123 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.

  • Page 124: Common Misfire Problems

    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.

  • Page 125: Clearing Cartridge Misfires

    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.
  • Page 126 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.

  • Page 127: Microbanding

    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,...
  • Page 128 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.

  • Page 129: Banding Differences

    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.

  • Page 130: Horizontal Banding

    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.
  • Page 131 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.
  • Page 132 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.
  • Page 133 NovaJet 800 Series Service Manual Figure 4-27. ESD Problems. Figure 4-28. Defective Carriage PWAs. 8. Change media to see if electrostatic discharge from media is causing the banding to occur. Add 3rd party static eliminator protection if required. Troubleshooting 4-34...
  • Page 134 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.
  • Page 135 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.
  • Page 136 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.
  • Page 137 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).
  • Page 138 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’.
  • Page 139 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.
  • Page 140 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.
  • Page 141 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.

  • Page 142: Vertical Banding

    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.
  • Page 143 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.
  • Page 144 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.

  • Page 145: Line Quality Problems (Overspray)

    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.

  • Page 146: Cartridge Warranty

    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.

  • Page 147: Cartridge Maintenance & Testing

    Cartridge Maintenance & Testing ENCAD cartridges are engineered for optimum reliability and compatibil- ity 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. If the cartridge displays greater than 100% or 500 ml of ink throughput, the cartridge has reached its warranted life.
  • Page 148 Prime Pattern jet out detection and the previous three steps have already been performed, contact ENCAD Technical Support or your service representative. General Print Misfire Analysis - Is ink in supply to cartridge jets?
  • Page 149 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.

  • Page 150: Ink Starvation

    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.
  • Page 151 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).
  • Page 152 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.
  • Page 153 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.
  • Page 154 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.
  • Page 155 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.

  • Page 156: Ink Dropout

    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.
  • Page 157 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.
  • Page 158 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...

  • Page 159: Color Test Problems

    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.
  • Page 160 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.
  • Page 161 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.

  • Page 162: Unrecognized Cartridge" Error Message

    2. Check MSB version. Select Utility Menu - Service Menu - About. MB: 87-27-0. Where 87 or 88 indicates the 800 series printer model; 27 indicates the printer is an ENCAD model; 0 indicates printing is authorized. Any other number sequence indicates the Main PWA is programmed incorrectly.
  • Page 163 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.

  • Page 164: Paper Sensor Error

    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.
  • Page 165 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.
  • Page 166 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.

  • Page 167: Encoder Sensor Error

    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.

  • Page 168: Autoload Paper Sensor Error

    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.

  • Page 169: Carriage Axis Error

    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.
  • Page 170 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.
  • Page 171 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.
  • Page 172 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.
  • Page 173 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.

  • Page 174: Initialization Failure

    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.
  • Page 175 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.
  • Page 176 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).
  • Page 177 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.

  • Page 178: Media Sensor Reference Points Not Initialized

    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;...
  • Page 179 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.

  • Page 180: Dryer Failure/Sensor Error

    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.
  • Page 181 NovaJet 800 Series Service Manual Figure 4-85. Main PWA Humidity Sensor. The Dryer Mode: (cccccccc) indicates the current dryer setting. Opera- tional modes are “OFF”, “ON”, “AUTO”, or “DISABLED”. Plenum T. and MBoard T. (main-board T.) indicate temperature and are displayed in degrees C.
  • Page 182 NovaJet 800 Series Service Manual firmware is unable to read the plenum temperature, main-board tempera- ture, or main-board humidity, the corresponding equals sign (=) will change to a tilde (~). This error condition signifies an internal bus commu- nication failure only. It does not indicate sensor connection or perfor- mance errors.
  • Page 183 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.
  • Page 184 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.

  • Page 185: Intermittent Problems/Continuity

    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.
  • Page 186 NovaJet 800 Series Service Manual Blue test button IP ADDRESS 192.168.2.10 Figure 4-89. SEH Activated Test Pattern. Figure 4-90. E-Connect LEDs. 4. For data or communications problems to the printer check parallel port interface by running a E-Connect Test (quickly depress Test Button at rear of printer at E-Connect Box) or run a continuous test with loopback cable attached (not provided with printer).
  • Page 187 Utility Menu, select Service Menu, select About. The display will indicate the firmware version as follows: MB: xx-27-0 where: xx is the model type 27 indicates the printer is an ENCAD model 0 indicates that printing is authorized. Refer to the ‘Checking Firmware’ procedure. Troubleshooting 4-88...
  • Page 188 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 party ESD protection (static eliminator strip).
  • Page 189 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.
  • Page 190 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.
  • Page 191 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).
  • Page 192 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...
  • Page 193 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.

  • Page 194: Reinitializing The Printer

    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.

  • Page 195: Printer Hesitation/Networking Problems

    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.
  • Page 196 NovaJet 800 Series Service Manual worked environments) - E-Connect is improperly configured for high data transfer rate; redundant protocols turned on (900 kbyte optimum data rate normally required) - Network has high traffic (limit workstations on server) - Computer parallel port mode not set to ECP with DMA (for non-net- worked printing).
  • Page 197 Another tip is to RIP to disk or print to file and then send the file via the EFPU3.0 (ENCAD File Print Utility version 3.0) to see if this elimi- nates the hesitation. For hesitation associated with only vector files, such as plot or hp2 files, the problem could be insufficient memory.
  • Page 198 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.

  • Page 199: Parallel Port Test

    A/B parallel connection switch from one printer to another. Figure 4-111. Loopback Test Cable. Please contact ENCAD technical support for the loopback test cable (The loopback test cable is a short test cable which has a centronics port on one end and a mini-din connector on the other).

  • Page 200: Firmware Downloading Procedures

    4. Power on the printer. 5. 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 or downloaded from Encad’s website, www.encad.com.
  • Page 201 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.

  • Page 202: Nj880 Printer

    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.
  • Page 203 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.

  • Page 204: Media Handling System Failure

    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.

  • Page 205: Chapter 5 Assembly\Disassembly

    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.

  • Page 206: Remove The Left, Top, And Right Covers

    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 pro- cedures.
  • Page 207 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.
  • Page 208 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.
  • Page 209 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.

  • Page 210: Remove The E-Connect Network Assembly

    NovaJet 800 Series Service Manual CAUTION Applying too much torque to the lower screws can cause the mounts for the standoffs on the cover to break, requir- ing a replacement of the cover. 4. Secure the Right Cover with two screws located on the left side (torque to 15 in-lbs) and three located under the baseplate (torque to 8 in-lbs.)

  • Page 211: Install The E-Connect Network Assembly

    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.

  • Page 212: Remove The Keypad And Display

    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.

  • Page 213: Install The Keypad And Display

    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.
  • Page 214 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.

  • Page 215: Install Memory Module

    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.
  • Page 216 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.
  • Page 217 NovaJet 800 Series Service Manual Figure 5-7. Main PWA Removal. Assembly\Disassembly 5-13...
  • Page 218 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)

  • Page 219: Remove Power Supply, Cooling Fan, And Ac Entry Module

    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.
  • Page 220 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.

  • Page 221: Install The Power Supply, Cooling Fan, And Ac Entry Module

    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.

  • Page 222: Remove Servo Motor

    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.
  • Page 223 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.

  • Page 224: Install Servo Motor

    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.

  • Page 225: Remove The Ink Delivery System

    NovaJet 800 Series Service Manual 10. Route the E-Connect power cable through the grommet on the E- Connect 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.
  • Page 226 NovaJet 800 Series Service Manual 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.

  • Page 227: Install The Ink Delivery System

    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.
  • Page 228 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.
  • Page 229 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.
  • Page 230 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.
  • Page 231 Carriage PWA and affect the Warranty. 15. Place the Carriage(s) in an ESD (antistatic) bag in preparation for shipment to ENCAD for replacement or repair, or if it is to be stored for repair at your facility. Assembly\Disassembly...

  • Page 232: Install The Carriage Assembly, Carriage Belt, And The Frame Tensioner

    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.
  • Page 233 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.
  • Page 234 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.

  • Page 235: Remove The Carriage Pwa

    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.
  • Page 236 NovaJet 800 Series Service Manual LATCH SLOT Figure 5-20. Carriage PWA Removal/Installation. Assembly\Disassembly 5-32...

  • Page 237: Install The Carriage Pwa

    Warranty. 7. Place the Carriage 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 Carriage PWA 1.

  • Page 238: Remove The Paper Sensor Or The Encoder Sensor

    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.
  • Page 239 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.

  • Page 240: Install The Paper Sensor Or The Encoder Sensor

    NovaJet 800 Series Service Manual Install the Paper Sensor or the Encoder Sensor GROOVES ALIGN SIDES OF PAPER SENSOR BOARD BETWEEN GROOVES AND PUSH STRAIGHT DOWN ROUTE FLEX THROUGH SLOT INSIDE THE CARRIAGE ASSEMBLY PUSH DOWN ON CLIP . PUSH ENCODER IN OVER CLIP .

  • Page 241: Replacing The Floating Carriage Cover Bushings

    NovaJet 800 Series Service Manual e. Turn the Carriage over and insert the Paper Sensor flex cable into the connector at J3. Push both sides of the connector lock shut at the same time. 2. To install the Encoder Sensor: a.
  • Page 242 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.

  • Page 243: Replacing The Carriage Bushings

    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.

  • Page 244: Remove The Service Station

    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.

  • Page 245: Install The Service Station

    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.

  • Page 246: Install The Trailing Cable Assembly

    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.

  • Page 247: Remove The Stabilizer Bracket And Encoder Strip

    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.

  • Page 248: Install The Stabilizer Bracket And Encoder Strip

    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 en- tire Stabilizer Bracket Assembly with the Encoder Strip is to be replaced if the Encoder Strip is damaged.
  • Page 249 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.
  • Page 250 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.

  • Page 251: Install The Y-Arm Assembly, Pinch Rollers, Slide Shaft, And Autoload Sensor

    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 Y- Arm 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.

  • Page 252: Remove The Gap Sensor (Novajet 880 Only)

    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.
  • Page 253 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.
  • Page 254 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...
  • Page 255 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.
  • Page 256 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...
  • Page 257 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.
  • Page 258 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.
  • Page 259 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.
  • Page 260 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 –...
  • Page 261 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).
  • Page 262 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 dis- tinct differences. The top bracket has an additional ex- tended arm attached to help in directing the media from blocking the sensor’s beam path.
  • Page 263 NovaJet 800 Series Service Manual WIRE 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.
  • Page 264 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.
  • Page 265 NovaJet 800 Series Service Manual MOTOR MOTOR MOUNT MOTOR GEAR 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.
  • Page 266 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.
  • Page 267 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.
  • Page 268 NovaJet 800 Series Service Manual NOTE Some units may have very small servicing loops in the wir- ing of the Dryer Assembly. When removing the Right Endcap, the possibility exists that a connection may have been pulled loose elsewhere within the body of the dryer if extreme force is used to pull the endcap away from the main body.
  • Page 269 NovaJet 800 Series Service Manual Figure 5-36. Right Endcap Connector Locations. Table 5-1. Thermal Dryer PWA Connections. J1 Fan 1 J6 Element, Right Conn J2 Fan 2 J7 Thermistor J3 Element, Left Conn J8 Fuse, on back of PWA J4 Power...
  • Page 270 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 replace- able. The list is in order of part name as identified in the assembly/ disassembly chapter.
  • Page 271 NovaJet 800 Series Service Manual FIGURE ITEM PART NAME PART # FITTING, FEMALE, BLUE ...... 214244-00 FITTING, FEMALE, GRAY ....214245-00 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 ....216131-00...
  • Page 272 NovaJet 800 Series Service Manual Figure 6-1. Left Side Parts Breakdown. Parts List...
  • Page 273 NovaJet 800 Series Service Manual FIGURE ITEM PART NAME PART # SPRING, COMPESSION ......209052 RETRACTING STOP, ASSEMBLY ..208838-01 COVER ASSY, TOP, 60” ......215571-00 COVER ASSY, TOP, 42” .......215572-00 CHAIN SUPPORT ASSEMBLY 60” ............217283-00 42” ............217284-00 BELT, 60” ..........214370-01 BELT, 42” ..........214371-01 SPRING, COMPRESSION (IDLER) ..215348-00...
  • Page 274 NovaJet 800 Series Service Manual Figure 6-2. Platen and Above Parts Breakdown. Parts List...
  • Page 275 NovaJet 800 Series Service Manual FIGURE ITEM PART NAME PART # COVER ASSEMBLY, WITH KEYPAD AND DISPLAY, RIGHT .......215350-00 KEYPAD ASSEMBLY ......209096-3 REFLECTIVE DISPLAY ASSY ....210068-04 MAIN PRINTED WIRING ASSY NOVAJET 850 ........216632-00 NOVAJET 880 ........218972-12 POWER ENTRY MODULE ....215349-00 FAN COOLING, POWER SUPPLY ..215566-00...
  • Page 276 NovaJet 800 Series Service Manual Figure 6-3. Right Side Parts Breakdown. Parts List...
  • Page 277 NovaJet 800 Series Service Manual FIGURE ITEM PART NAME PART # HARNESS, DRYER/WINDER NOVAJET 850 ........215188-00 NOVAJET 880 ........217886-01 MOTOR ASSY, SERVO ......215704-01 BLOCK, RIGHT FOAM ......215178-00 STEPPER MOTOR ASSY, W/ GEAR AND FERRITE ......214376-00 BRACKET, LOWER ROLLER ASSY ..208987-1 BLOCK, LEFT FOAM ......209177...
  • Page 278 NovaJet 800 Series Service Manual Figure 6-4. Inner Platen Parts Breakdown. Parts List...
  • Page 279 NovaJet 800 Series Service Manual FIGURE ITEM PART NAME PART # COVER, CARRIER ELECTRONICS ..215111-02 CARRIAGE PWA ........214751-04 ENCODER SENSOR W/FLEX RIGHT SIDE CARRIAGE ONLY ..209578-101 STRAIN RELIEF ........215659-00 CARRIAGE FRAME ASSY, PARTIAL LEFT SIDE CARRIAGE .......217561-00 RIGHT SIDE CARRIAGE ....217559-00 CARRIAGE BUSHING SET (2) ....209568...
  • Page 280 NovaJet 800 Series Service Manual Figure 6-5. Carriage Assembly Parts Breakdown. Parts List 6-11...
  • Page 281 NovaJet 800 Series Service Manual FIGURE ITEM PART NAME PART # ACTUATOR, VALVE .......214886-01 CLIP, VALVE ..........214521-00 VALVE ASSEMBLY, BLUE .....215703-01 GRAY .............215702-01 CARRIAGE COVER ASSY .....215663-03 P/O INK DELIVERY SYSTEM 60” ..217294-00 P/O INK DELIVERY SYSTEM 42” ..217295-00 SUPPORT, LEFT, CARRIAGE COVER ..........214922-01...
  • Page 282 NovaJet 800 Series Service Manual Figure 6-6. Floating Carriage Cover Parts Breakdown. Parts List 6-13...
  • Page 283 NovaJet 800 Series Service Manual FIGURE ITEM PART NAME PART # SERVICE STATION ASSY ......214393-03 Parts List 6-14...
  • Page 284 NovaJet 800 Series Service Manual Figure 6-7. Service Station Parts Breakdown. Parts List 6-15...
  • Page 285 NovaJet 800 Series Service Manual FIGURE ITEM PART NAME PART # SHAFT ASSY, W/FIXED RT SIDE, GUIDE, ADJ (2) AND CLAMP (3) 60” ..........207657-1 42” ..........207657-2 GUIDE, PAPER ADJUSTABLE ....207644 CLAMP, GUIDE PAPER ......207659 SENSOR, ASSY ........207727 SENSOR, BRACKET, TOP, ASSY ..207656-1 SENSOR, BRACKET, BTM, ASSY ..207752-1...
  • Page 286 NovaJet 800 Series Service Manual Figure 6-8. Power Feed and Take-Up Parts Breakdown. Parts List 6-17...
  • Page 287 NovaJet 800 Series Service Manual Index general block diagram . . 2-2 alignments slide shaft . . 3-24 axis drive carrier . . 2-5 ink delivery system . . 5-21 paper (media) . . 2-4 jack banding . . 3-16 connections carrier .
  • Page 288 NovaJet 800 Series Service Manual removal/installation . . 5-18 legs . . 3-43 resistance check . . 3-14 loopback . . 3-42 stepper (media) parallel port . . 3-42 controller . . 2-11 serial port . . 3-42 removal/installation . . 5-48, 5-54 servo cycle .

Table of Contents