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Kodak 800 SERIES Camcorder User Manual

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1. 3 32 219 GUM MENU 3 33 XVII NovaJet 800 Series Service Manual List of Illustrations cont Figure Page Chapter 3 Maintenance cont 9 20 Color GallDMIeriU sucia catia ea al at 3 33 921 Vertical OPtONS MENU 22 3 34 3 22 Deagballd tu ete ote late 3 35 3 23 SENICE MENU are eye ers E 3 36 3 24 Calibration Deadband Menu 3 36 3 25 Calibration os po dise de onds node se donc dene detecte 3 97 3 26 Color DD Mr et Ret ten et e tet dede te 3 38 Dre as Seba 3 40 3 26 DIAGNOSIICS MONU 3 41 3 29 ACCESSOLY MCUs sarras SEPET SETER pIE OEIT OPEP OT ISEE 3 41 3 31 Carriage PWA Connections 3 46 3 32 Leg Harness Connections Diagram 3 47 Chapter 4 Troubleshooting 4 1 Gartridge MISTIIG 4 19 4 2 Excessive INK Pressure cicero ata EE 4 20 4 2 Service Stator 4 21 4L Sept unmand 4 21 4 5 Unseated Flex Driver Cable
2. PAPER SENSOR TRAILING CARRIAGE RIGHT CARRIAGE a ASSEMBLY ONLY 7 CARTRIDGE 1 PWA i INKJET CARTRIDGE 2 DRIVERS gt a CARTRIDGE 3 CARTRIDGE 4 LEFT AND RIGHT CARRIAGE ASSEMBLY Figure 2 11 Carriage Assembly Circuits The Right Carriage Assembly contains 1 Carriage PWA 2 Optical Sensors 3 Paper Sensor 4 Inkjet Cartridges The Left Carriage Assembly contains 1 Carriage PWA 2 Inkjet Cartridges Theory of Operation 2 16 NovaJet 800 Series Service Manual NOTE The carriage housing has been modified from that of the Right Carriage Assembly The belt strain relief has been removed and the encoder sensor clip has been removed The Right Carriage PWA contains the logic and drive circuitry for the firing of the inkjet cartridges It also establishes an interface path for the optical sensor and paper sensor to communicate with the Main PWA The optical sensors receive their inputs from the optical encoder strip and sends this data to the Main PWA The Main PWA uses this information to determine the horizontal position of the carriage assem bly so that accurate printing can be established The paper sensor circuitry senses for the presence of loaded media It does this automatically during the start up and load sequences It also constantly monitors the media during printing to determine if the media has run out If no paper is se
3. 210010 02 6 3 5 GROUND STRAP 2 57 209160 6 3 9 BASEPLATIE RIGHT 214385 01 6 3 10 GROUND STRAP IO 209159 6 3 IL 212761 02 PARALLEL CABLE SMALL 15 215466 00 GROUND STRAP 2 IN INSIDE COVER ASSEMBLY 209606 Parts List 6 6 NovaJet 800 Series Service Manual Figure 6 3 Right Side Parts Breakdown 6 7 Parts List NovaJet 800 Series Service Manual FIGURE ITEM PART NAME PART 6 4 1 HARNESS DRYER WINDER INO WAJET 830 215188 00 INOVAJET 590 217886 01 6 4 2 MOTOR ASSY SERVO ee 215704 01 6 4 3 BLOCK RIGHT FOAM 215178 00 6 4 4 STEPPER MOTOR ASSY W GEAR AND FERRITE 214376 00 6 4 5 BRACKET LOWER ROLLER ASSY 208987 1 6 4 6 BLOCK LEFT FOAM 209177 6 4 7 LOWER ROLLER ASSY COMPLETE WITH STEPPER MOTOR AND BRACKETS OU 21745 1 00 217452 00 6 4 8 GROUND STRAP STEPPER 210837 6 4 9 FAN ASSEMBLY VACUUM 00 214401 00 FAN ASSEMBLY VACUUM 427 210140 6 4 10 EXHAUST GRILL tree 204976 6 4 FAN ASSY VACUUM 60 ONLY 214402 00 6 4 12 SUBPORT CENTER 24 216871 00 SHAFT CENTER SUPPORT 215252 00 BEARING BALL
4. 3 31 Deadband Alignments 3 34 Color Deadband 3 37 Paper AxiS Calibration eM LSU dts 3 39 Diagnostics Menu 1 1 0 3 40 Firmware Download Upgrading for the PC 3 43 Firmware Download Upgrading for the MAC 3 44 Internal Cabling and Signal Flow Diagrams 3 45 800 Series Service Manual Table of Contents cont Chapter 4 Troubleshooting 4 1 Juiferelb ere n eto eee ue hci ust 4 1 OT OWGE 345 95 26 4 1 edo c MERE 4 2 Initialization 4 2 Media Does Not 4 3 Internal ERROR Carriage Axis Failure 4 4 Internal ERROR Encoder Sensor Failure 4 5 Internal ERROR Paper Sensor Failure 4 6 Hiema ERROR nn Dia 4 6 Auto Load Paper Sensor Failure 4 6 Internal ERROR MPCB Failure 2 20222 2 4 7 Unrecognized Cartridges Error 4 7 Media Sen Ref Pts Not Initialized NJ880 only
5. Frid bah See ori Figure 4 73 Carriage Head Assembly Carriage Test Perform a Servo Cycle Test 10 cycles is sufficient to verify carriage bushings are defective Ensure Halt time does not exceed 90 Left to Right resistances are normally higher than Right to Left due to carriage heads pushing against ink delivery chain Acceleration is also higher than Slew or Deceleration values a mu Iu BON 1 Rh to Lat L IF img 1 FIT Wen n uid ien 8g 5 4 19 4 Ua 14 il a 0 LN xa IT Cid o Tp tef rea carey TA DW RIS qu HT m ha Figure 4 74 Servo Cycle PWM Menu If Halt Time is above 60 excessive drag exists on the carriage assemblies and the servo motor may be defective or the carriage bushings may be severely worn At approximately 98 a Carriage Axis Error will result Push the carriage to the left end of printing area Power the printer on carriage head should return to station and size the media without error Troubleshooting 4 71 NovaJet 800 Series Service Manual Failure Analysis 1 Isthe Encoder Strip clean Has any image skewing occurred prior to the carriage axis error If skewing resumes following a cleaning within a day or two then the encoder strip is damaged and must be replaced Normally the encoder strip cleanings should carry
6. 3 6 Flex Cable Contact Cleaning 3 7 Clean and Inspect Stepper Motor Gears 3 8 Clean and Inspect Main PWA 3 8 Clean and Inspect Carriage Assembly 3 8 Dryer Cleaning 2 3 9 Reseat Connectors on Main PWA and Carriage Boards 3 9 Replace Trailing Cables 3 12 Replace Carriage Cover Carriage Bushings 3 13 servo Motor Winding Resistance Check 3 14 Stepper Motor Winding Resistance Check 3 15 Power Feed and Take Up Motor Winding Resistance Check 3 16 Banding Hardware vs Software 3 16 Banding Differences 3 17 Banding Causes amp Quick Analysis 3 19 Horizontal Banding 3 19 Vertical Banding 3 22 Line Quality Problems Overspray 3 23 AIIGHIMENtS AGIUSUMGE IIS 3 24 Slide Shaft Profile Adjustment 2 22 22 3 24 Head Height Alignment Procedure 3 27 Color Calibration
7. 5 19 5 11 Chain Guide 5 21 5 12 Left Side of Ink Delivery System 5 22 5 13 Floating Carriage Cover Removal 5 22 5 14 Using the Belt Removal Tool 5 24 5 15 Electronics Covers Removal 5 25 5 16 Strain Relief Removal Installation 5 26 5 17 Carriage Belt Clamp 2 5 27 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 94 5 22 Paper and Encoder Sensor Installation 5 96 5 23 Floating Carriage Cover Bushing Removal 5 38 5 24 Carriage Bushing Removal 5 39 5 25 Carriage Bushing Installation 5 40 5 26 Service Station Removal 2 5 40 5 27 Stabilizer Bracket Installation Removal 5 43 5 28 Y Arm Installation Removal 5
8. Copies of these and other ENCAD Inc publications may be obtained by contacting your nearest authorized ENCAD Inc dealer or by contacting ENCAD s Technical Support and Service Department Electrostatic Discharge ESD Sensitivity All PCBs Printed Circuit Boards associated with these printers have components sensitive to ESD electrostatic discharge Care must be taken to avoid damage to any of the components by following current ESD handling procedures and practices Always use an approved ESD grounding strap when handling or working with PCBs General Description 1 3 NovaJet 800 Series Service Manual Warnings Cautions and Notes Warnings cautions and notes are used when additional information instructions or care should be observed In this manual warnings cautions and notes precede the text to which each applies The definition of each is provided below WARNINGS Warnings are used to stress that the following steps or procedures has the potential to cause serious harm or death to service personnel Extreme care should be observed when following the procedures and to exercise standard safety procedures They are Followed by a paragraph describing the concern CAUTION Cautions depict that the following steps or procedures can cause damage to the equipment if not properly followed Extreme care should be observed when following the procedures and to exercise standard safety procedures They are indicated by
9. 800 Series Service Manual List of Illustrations cont Figure Page Chapter 4 Troubleshooting cont 4 26 Unseated or Defective Trailing Cables 4 33 4 34 4 28 Defective Carriage PWAS 4 34 4 29 Carriage Head Strike 4 35 4 31 Low Data Transfer Problem 000 4 35 4 92 RESEPTIN E 4 36 4 39 4 36 4 34 Defective Carriage PWA Color Test 4 37 4 35 Defective Stepper Motor 4 37 4 36 Defective Stepper Motor 4 38 4 37 Servo System Synchronization Failure 4 39 4 39 4 39 Connectivity Problem 4 40 4 40 Dirty or Defective Encoder Strip 4 40 4 41 Main 4 41 2 42 DEPEIODIOIE ED 4 42 4 4 BentServo Motor Pulley 4 42 4 44 Dirty or Worn Carriage Bushings 0 2 72 4 43 4 45 Worn Bushings or Bushing Pads 4 43 4 46 Defective Trailing Cable Examples 4 44 4 47
10. 207503 6 4 215189 00 Parts List 6 8 NovaJet 800 Series Service Manual Figure 6 4 Inner Platen Parts Breakdown Parts List 6 9 FIGURE ITEM 6 5 6 5 6 5 6 5 6 5 6 5 6 5 6 5 6 5 6 5 6 5 6 5 1 2 3 NovaJet 800 Series Service Manual PART NAME PART COVER CARRIER ELECTRONICS 215111 02 CARRIAGE PW A 214751 04 ENCODER SENSOR W FLEX RIGHT SIDE CARRIAGE ONLY 209578 101 STRAIN RELIEF 215659 00 CARRIAGE FRAME ASSY PARTIAL LEFT SIDE 217561 00 RIGHT SIDE CARRIAGE 217559 00 CARRIAGE BUSHING SET 2 209568 SPRING COMPRESSION 216840 00 PAD BUSHING 212426 00 FERRITE FLEX 210809 SPRING PAD 208 JET 207572 PWB FLEX 215174 00 PAPER SENSOR W FLEX RIGHT SIDE CARRIAGE ONLY 207180 CARRIAGE COMPLETE ASSEMBLY LEFT SIDE CARRIAGE 217560 01 RIGHT SIDE CARRIAGE 217558 01 Parts List 6 10 NovaJet 800 Series Service Manual Figure 6 5 Carriage Assembly Parts Breakdown 6 11 Parts List NovaJet 800 Series Serv
11. 3 Toremove the Paper Sensor a Unlock the connector at J3 and remove the flex cable b Turnthe Carriage over and hold it while firmly grasping the Paper Sensor between thumb and index finger See Figure 5 21 c Pullstraight up on the Paper Sensor and remove it from the Carriage Assembly 4 Toremove the Encoder Sensor a Unlock the connector at J2 and remove the flex cable b Turnthe Carriage over and lay it with the top side facing down c Push down on the plastic clip and at the same time push down on the Encoder until the plastic pieces on each side of the Encoder clear the ridges which hold it in place Then pull it straight out Assembly Disassembly 5 35 NovaJet 800 Series Service Manual Install the Paper Sensor or the Encoder Sensor ALIGN SIDES GROOVES OF PAPER SENSOR BOARD BETWEEN GROOVES AND PUSH STRAIGHT ROUTE FLEX THROUGH SLOT INSIDE THE CARRIAGE ASSEMBLY 4 PUSH DOWN ON CLIP PUSH ENCODER IN OVER ENCODER MUST SLIDE PAST THE RIDGES AND SNAP INTO PLACE Figure 5 22 Paper and Encoder Sensor Installation NOTE The Paper Sensor and Encoder Sensor are only installed onto the right Carriage All procedures in this section refer to the right Carriage only 1 install the Paper Sensor a Turnthe Carriage so that the bottom side of it is facing up b Route the flex on the Paper Sensor through the slot in the Carriage Make sure the flex cable goes all the w
12. 4 22 4 6 Septum Connector Uta E ee US etel 4 22 4 7 Damaged Flex Driver Cable 4 23 4 8 Defective Trailing Cable 4 23 4 9 Unseated or Defective Trailing Cable 4 24 4 10 Defective Carriage PWA 4 24 4 25 4 12 Magenta Cartridge Misfires 4 25 4 13 Adjacent Jet Misfire 4 26 4 14 Service Station 4 27 4 15 Defective Cartridge Power Lines 4 27 4 16 Catastrophic Jet Failure sees 4 28 4 17 Power Ine TallUre Fa to e Ex exu ees 4 28 4 18 Address Line Failure 4 28 4 19 Multiple Address Line Failure 4 28 4 20 WIGKODANGING de oa dese dese deos dese dese deae ds onde oos oot det 4 29 4 21 Quality Print MOG6S t ene tex enn 4 29 4 22 Ink Cartridge Configurations 4 30 4 23 Defective Magenta Cartridge 4 31 4 24 AutoWipe Interference 4 32 4 25 lmproperGroundllig 252 et ta ta ta ota la t e sete e tee ts 4 32 XVIII
13. HE axo Eee 4 95 4 106 Dirty or Defective Encoder Strip 4 95 4 107 Initialization Menu Location eeseeseesesse 4 96 4 108 Printer Hesitation Causes 4 97 4 109 E Gonnect LEDS une p t t Et t tette to e RR E s 4 99 4 110 Semi Circular Nook Test Pattern 4 99 4 TT T1 Loopback Test Cable ooi doi o 4 100 4 112 Demo Print sd verr 4 101 4 113 Firmware Download Procedures 4 102 4 114 Media Handling System 4 104 Chapter 5 Assembly Disassembly 5 1 Right Cover Assembly Removal Installation 5 9 5 2 Left Cover Removal Installation 2 5 4 5 3 E Connect Assembly Installation Remowval 5 7 5 4 Keypad Display Installation Remowval 5 8 5 5 Keypad and Display Grounding Connections 5 9 5 6 Memory Module Removal Installation 5 10 5 7 Main PWA Removal 5 13 5 8 Power Supply Removal gna nen n o ns 5 16 5 9 Cooling Fan AC Entry Module Removal 5 17 5 10 Using the Belt Removal Tool
14. Power Supply An internal UL recognized switching power module supplies power for the printers It provides a constant 24V DC output from input voltage in the 90 132 VAC and 180 246 VAC ranges A power switch turns the power on and off The 24VDC is applied to the MPCB where it is further regulated and separated into 1 8 VDC 3 3VDC and 5VDC The 24V supply is used for the stepper controller which advances the paper the servo controller which moves the Carriage and power to fire the inkjets The 5V and 3 3V supply powers the logic circuits The 1 8V powers the DSP Theory of Operation 2 18 NovaJet 800 Series Service Manual The power supply is fused using a 6 3A 250V fast blow type fuse The outputs share a common ground which is isolated from earth ground with in the supply itself Earth ground and DC ground are connected external of the power supply The power supply will shut down under overload short circuit conditions on any output over the full range of input voltage Overvoltage protection 1 20 30 above nominal for the 24V output Thermal Dryer Assembly To ensure prints are dry for unattended printing the printer features a thermal hot air convection drying system The system monitors the temperature and humidity in the environment and adjusts the heat to optimize drying time and ensure consistent image quality The fans blow air past 1200 watt heating elements quickly drying the media The dryer effectively dr
15. 217284 00 BELE OO meee etre anne ates 214370 01 214371 01 SPRING COMPRESSION IDLER 215348 00 IDLER ASSEMBLY tto tno 215386 00 FRAME TENSIONER ie 203870 1 TRAILING CABLES ASSEMBLY mime t EE 217038 00 AD c ME 217039 00 STABILIZER ASSY WITH ENCODER STRIP 216660 00 _ 216659 00 SPRING COMP PINCH ROLLER 212542 00 RING RETAINING E TYPE 200507 PINCH ROLLER ASSEMBLY 207486 SLIDE SHAPT 60 7 214381 00 SLIDE SHAFT 42 eese otto tees 214446 00 KNIFE DAMPER ASSY 202000 HEAD SPACING SENSOR ASSY 217120 01 NOVAJET 880 ONLY AUTOLOAD SENSOR ASSY 215182 00 Parts List 6 4 NovaJet 800 Series Service Manual N Figure 6 2 Platen and Above Parts Breakdown 6 5 Parts List NovaJet 800 Series Service Manual FIGURE ITEM PART NAME PART 6 3 1 COVER ASSEMBLY WITH KEYPAD AND DISPLAY RIGHT 215350 00 6 3 2 KEYPAD ASSEMBLY 209096 3 6 3 3 REFLECTIVE DISPLAY ASSY 210068 04 6 3 4 MAIN PRINTED WIRING ASSY NOVAJET SIO a 216632 00 NOVAJE T 890 218972 12 6 3 5 POWER ENTRY MODULE 215349 00 6 3 FAN COOLING POWER SUPPLY 215566 00 6 3 7 POWER SUPPLY ASSEMBLY
16. MECI IANICAL CONNECTION 1 1 MAIN BUS 25 Figure 2 1 General Block Diagram Theory of Operation 2 3 NovaJet 800 Series Service Manual Paper Media Axis Drive PINCH ROLLERS LL E EIU STEPPER MOTA AT 4 AT TL S i f ay a SSS Den Eli i i LOWER ROLLER SHAFT ASSY EA REDUCTION GEAR Figure 2 2 Paper Media Axis Drive The Paper Media Axis Drive moves the plotting media in a direction perpendicular to the length of the printer This friction drive utilizes a micro step drive technology and consists of a stepper motor reduction gears lower drive shaft assembly and pinch rollers This can be seen in Figure 2 2 The micro step technology associated with the stepper motor gives the capability of a resolution up to 9600 dpi The reduction gear meshes the stepper motor to the lower drive shaft assembly which allows the media to advance or retract The purpose of the pinch rollers is to apply pressure to the media onto the drive shaft assembly to reduce the chance of slipping 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 However these pinch rollers will not stay aligned while the media is being fed backwards Theory of Operation 2 4 N
17. NovaJet 800 Series Service Manual Figure 4 53 Service Station Cleaning If failures are occurring within 40ml ink throughput improper cleaning of electrical contacts on carriage or a connectivity problem probably exists Initially cartridges should be replaced but further investigation is required Check ink lot codes with technical support to screen for contaminated ink problems Ink Starvation Ensure cartridge is properly primed run color test 100 in 2 pass print mode Verify a solid color pattern prints ignore the poor quality of color test this test is used to check ink delivery system and cartridge pressure only Troubleshooting 4 51 NovaJet 800 Series Service Manual Inkjet Nozzle Problems Resistor burnout no firing 175 million firings average per resistor Severe clogging may be cleared using ultrasonic cleaner 30 40 sec or hot water 10 15 sec Ink Starvation Ink starvation of one or more colors can occur between 10 minutes and 3 hours of operation due to improper system setup or a defective ink delivery system air leak in the system Check pressure in the lines by initiating a Color Test in the 2 pass print mode Repeat test several times to verify pressure swaths in each color should print at 100 ink density from the 2 pass print configuration 50 ink load on each pass If the starvation stops and starts as the color test progresses i e the first swath starts to pri
18. 4 8 Image Skews or 4 8 UL DN CE 48 Ink Cartridge 4 9 Paper oKeWIDQg caeci e EE EE v uia en esie 4 10 Printer Output is Banding Horizontal 4 10 Printer Output is Banding Vertical 4 12 Printer Output is Banding Horizontally and Vertically 4 12 Keypad Locked Up or Not Functioning Properly 4 13 NOISY XODSFAlO Ll 4 13 Quality Degraded 4 14 Fan Does Not Power 4 16 Media Take UpMotor Not Operating Sensor Works 4 16 Media Feed Motor Not Operating Sensor Works 4 17 Media Feed and Take Up Motors Not Operating Both Sensors 4 17 Media Feed or Take Up Sensor s Not Operating 4 17 Print Qualy cm 4 19 Cartridge Misfires Intermittent Banding 4 19 Failure Analysis Print Misfires 4 20 COmmoniMistire Problem aa abaci a i e e n nd 4 25 Clearing Cartridge Misfires 4 26 Multiple Cartridge Failures 4 26 XI NovaJet 800 Series Servi
19. Check the print mode for the type of image being printed Is the enhanced print pass mode printing OK Note photo pass mode may microband in some of the 2 tone color ranges including blue gray orange and purple hues Enhanced modes should not microband Check to see if the media is loaded correctly and is of proper thickness no greater than 20 mil media can pass through the machine Check to see if the media guides are in place and are not defective Check the pinch rollers for alignment damage Figure 4 23 Defective Magenta Cartridge Are the color deadband and color calibrations correct Refer to Printer Calibrations Inspect the Prime pattern and verify diagonal line in the jet test is consistent throughout The diagonal line in the Prime pattern should not have sections or lighter and darker shades it should not be dissolved or broken Refer to Printer Features Jet Out Detection Clean manually bypass clogged jets or replace the cartridge if any of these abnormal conditions exist Defective or clogged cartridges account for 90 of the banding observed Change the preheat setting for the affected color To gain access select SetUp Menu Ink Option Menu Ink PreHeat Settings choose the appropriate color If this does not help then return settings to zero 0 default at completion of test Troubleshooting 4 31 NovaJet 800 Series Service Manual Figure 4 24 AutoWipe Interference 4 Ensure the Auto Wipe fea
20. Clean the carriage assembly by blowing the objects away or gently brushing them aside with a soft brush if required Be careful not to let anything to fall into the printer as you clean or it could cause a new problem Inspect the carriage assembly for any damage to the boards connections or any of the components on the assembly Maintenance 3 8 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 Do not touch or work near integrated circuits with out wearing an ESD wrist strap Ribbon connectors can be easily damaged if incorrectly handled Observe extreme caution when handling the ribbon connectors to avoid damage Many problems can be corrected simply by removing and reseating connections found in circuit assemblies This process helps to clean the contacts and can dissipate any static electrical charges that might have developed Maintenance 3 9 NovaJet 800 Series Service Manual Figure 3 4 Main PWA Connection Locations Table 3 1 Main PWA Connections Trailing Cable A Display J2 Trailing Cable B Serial Port J3 notused J12 Servo Motor J4 Vacuum Fan 2 AutoLoad Sensor J5 Parallel Port 4 not
21. The types of tests that can be performed are Servo PWM Test Servo Cycle Test Carriage Test Color Test Continuous Test Fan 1 Test Fan 2 Test and Legs Test The Fan 1 Test Fan 2 Test and Legs Test are located in the Accessory Menu as shown in Figure 3 29 A Sensor Status Menu 15 also available in the Accessory Menu Fan 1 Test Sensor Status Fan 2 Test Legs Test Figure 3 29 Accessory Menu Servo PWM Test Monitors the PWM pulse width modulation signal applied to the servo motor from the driver on the Main PWA to check the amount of force required to move the Carriage The test performs three complete cycles of the carriage assembly and lists the average PWM via a Halt Time count If Halt Time reaches 98 then a Carriage Axis Error will result When Halt Time exceeds 90 during normal operations rountine or corrective maintenance is required Maintenance 3 41 NovaJet 800 Series Service Manual Servo Cycle Test Tests the servo motor by moving the carriage back and forth across the slide shaft The number of cycles is selectable and the available options are 10 100 1 000 10 000 100 000 1 000 000 Carriage Test Prints 5 sets of 3 parallel lines to test the vibration characteristics of the carriage assembly Color Test The Color Test prints a wide swath of ink for the slot selected to test for banding and ink delivery system pressure The test is selectable in the density of ink that is to be pri
22. Vacuum Fan Novadet 850 5 51 Remove the Lower Roller Assembly Stepper Motor and Vacuum Fan Novadet 880 5 54 Lower Roller Installation Tip NovaJet 880 5 57 Y Arm Assembly Installation Tip NovaJet 880 5 57 Remove the Media Take Up and Feed Sensor Brackets and t ee ee 5 58 Install the Media Take Up and Feed Sensor Brackets and SISOS 5 59 Remove the Media Take Up and Feed Motors 5 60 Install the Media Take Up and Feed Motors 5 60 Remove the Thermal Dryer Assembly 5 61 Install the Thermal Dryer Assembly 5 62 Remove the Thermal Dryer Right Endcap Assembly 5 62 Install the Thermal Dryer Right Endcap Assembly 5 64 5 1 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 Dis
23. or less at power up and results with a carriage axis error or if operation is intermittent with failures Servo motor power can be checked by assisting carriage head movement with one hand gently help push the carriage assembly along if successful the servo motor is defective Refer to disassembly 14 Replace encoder sensor if the encoder strip was noted as being extremely dirty and or carriage head does not move at all during printer power up Refer to disassembly 15 Replace the right carriage PWA defective encoder sensor jack or trailing cable jack Refer to disassembly Initialization Failure SYMPTOM PRINTER DOES NOT INITIALIZE AFTER THE POWER SWITCH IS TURNED ON Note there is no carriage head movement for the failure analysis below If there is carriage movement prior to the initialization failure then please refer to Carriage Axis Failure troubleshooting procedures Failure Analysis 1 Ensure the power source from wall outlet or power strip is good gt gt Figure 4 77 Boot ROM Access Function 2 While holding the top left and bottom left keypad switches turn on the power switch A double beeping should be heard from printer This will verify the initialization code BootROM is running properly printer is in a continuous run state Reseat all cable connections if this test fails then repeat step again Download BootROM and Firmware in this configuration Power off printer wait 1
24. 360 degree rotation Troubleshooting 4 37 NovaJet 800 Series Service Manual Figure 4 36 Defective Stepper Motor 17 Check carriage head height when jet plate scrapes appear on media The Banding will have jagged or slightly angled lines at the termination points or may even appear as light cuts in the media like a utility knife cut the surface of a print The normal head height range between the bottom surface of the cartridges and the platen surface is 0 062 to 0 068 Refer to Alignments Troubleshooting 4 38 NovaJet 800 Series Service Manual Figure 4 37 Servo System Synchronization Failure 18 Replace the servo motor for horizontal bands thicker than 2 mm which extend beyond the page layout from 5 mm to 20 mm The servo motor bearings may be faulty which cause excessive drag and carriage axis errors The normal servo motor life is approximately 2800 plot hours 2 8 million servo cycles Figure 4 38 RIP Error Troubleshooting 4 39 NovaJet 800 Series Service Manual Figure 4 39 Connectivity Problem 19 Horizontal bands 0 2 mm to 1 mm which extend beyond the page layout are usually caused by the RIP or workstation memory or the driver not having sufficient work space or other network data flow related problems Ensure 1GB is free on hard drive at all times 256 MB of memory is suggested Figure 4 40 Dirty or Defective Encoder Strip 20 Clean or replace encoder strip for image sk
25. 4 88 Internal oui xcti ed adeo a dene deo Fe ca 4 86 4 89 SEH Activated Test 4 87 4 90 E ConrectE EIS e NE 4 87 4 91 Driver RIP Problem 4 88 4 92 Inadaquate Network Data Transfer Rate 4 88 4 93 ESD Problems tnt AE a 4 89 4 94 Servo Cycle PWM Menu seen 4 90 4 95 Carriage Bushings nmm 4 90 4 96 Servo System Synchronization Error 4 91 4 97 Probable Defective Main PWA 4 91 XX 800 Series Service Manual List of Illustrations cont Figure Page Chapter 4 Troubleshooting cont 4 98 Probable Defective Carriage PWA 4 92 4 99 DETECTIVE PYA dob doo ioo ides 4 92 4 100 Corrupted Code PWA 4 93 4 101 2121816 1279 4 93 4 102 Apparent Ink Overspray 4 94 4 103 True Type Font PrODIGn o co os oo 4 94 4 104 Print Settings Not Printing in Black 4 94 4 105 eoo t o
26. CAUTION Followed by a paragraph describing the concern NOTE Notes are placed before a procedure to inform the service personnel of specific details to improve quality to give reminders of interrelated parts and to provide other helpful information They are indicated by Followed by a paragraph describing the concern General Description 1 4 Printer Specifications NovaJet 800 Series Service Manual The specifications and performance characteristics of the NovaJet 800 Series Color Inkjet Printers are as follows Max Printing Area 42 inch 60 inch Norm 40 8 58 8 1 04m 1 49m Extend 41 61 59 61 1 06m 1 51m Language Emulation HP RTL ENCAD RTL HP GL 2 Buffer 64 MB installed upgradeable to 256 MB Power Requirements Input Voltage 90 246 VAC 47 63 Hz Output Power 20 W idle 185 W typical 285 W maximum 1485 W maximum with dryer on Resolution 600x600 dpi or 300x300 dpi RTI Accuracy 0 2 line length using ROLL feed and 4 mil drafting matte film Interface Centronics parallel IEEE 1284 Network via 100 Interface Certifications Safety CSA CSE NRTL equivalent to UL1950 TUV GS EN 50 082 1 EN 60 950 UL1950 019 5 1993 IEC 950 AS NZS 3260 EMI FCC Class A CSA C108 8 EN 55 022 Class A CE Mark CISPR 22 Class A AS NZS 3548 General Description 1 5 NovaJet 800 Series Service Manual Environment Weight NJ850 7880 Operating 60
27. Using a cotton swab dampened with distilled water wipe the seals and the rubber wiper in the service station until no more ink residue or dust can be removed With a dry swab wipe all moisture from the seals and wipers Close the lid and reconnect the power cord and interface cable Maintenance 3 3 NovaJet 800 Series Service Manual 7 Ifthe service station is filling with ink or very dirty it can be removed and rinsed under warm water To remove pull the tab on the right side of the service station and lift out Wash dry thoroughly and replace by placing the left side in first then pushing down on the right side until the tab locks it in place Linear Encoder Strip Cleaning Clean the linear encoder strip weekly or as necessary to remove any buildup of debris Distilled water or isopropyl alcohol may be used You may notice that it tends to fog the encoder strip however no detrimental effect has been observed in the field To clean the Encoder Strip 1 Disconnect the power cord and interface cable 2 Slightly dampen a cotton swab with distilled water and wipe along the length of the encoder strip on both sides Do not use denatured alcohol MEK acetone or keytone substances on the encoder strip as this is known to have caused damage to the encoder strip Reconnect the power cord and interface cable Figure 3 1 Encoder Strip Cleaning Maintenance 3 4 NovaJet 800 Series Service Manual Trailing Cables Clea
28. Using a flathead screwdriver insert tip into 4 cover tab slots and gently twist to release cover from slide plate Disengage the retracting stop or latch between the left cover and rear cover Pull up and remove the left cover Remove 6 ink delivery system carriage cover securing screws 3 screws are located on each side of carriage assembly Remove trailing cable bracket Remove 2 screws at rear of printer which secure the ink delivery system and chain shelf Remove the chain shelf Remove 7 remaining screws which secure the ink delivery system Lift the Carriage cover and move to left side of printer lift the metal bracket and simultaneously slide the ink delivery chain out of rear cover Assembly Disassembly 5 54 15 16 17 18 19 20 21 22 NovaJet 800 Series Service Manual Remove the ink delivery system 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 Disconnect all Main PWA connections Disconnect the power supply servo motor stepper motor takeup feed system Autoload sensor both vacuum fans power supply cooling fan both trailing cables and two grounds Remove 2 screws securing the right side electronics assembly and remove assembly by pulling straight out Disconnect the print gap sensor from takeup harness wiring Remove the right side plate by
29. modes in the 1x4 and 2x4 configurations Note 6 pass speed 10 is the true photo mode in 1x4 operations Figure 4 21 Quality Print Modes Troubleshooting 4 29 NovaJet 800 Series Service Manual Banding Differences Consistent horizontal banding is usually hardware related Normally horizontal microbanding is caused by improper color deadband or color calibrations dirty cartridges or service station Inconsistent banding is usually software related However electrostatic discharge ESD from media i e Backlit Duratrans films can also cause inconsistent horizon tal banding While minimal microbanding in an image typically occurs due to cartridge jet failures and clogs dirty service station or an im proper calibration of the printer gross microbanding can be caused by a dirty encoder strip causing image skew or real hardware failures such as a defective stepper motor Vertical banding is always hardware related Ink Cartridge Configurations Y M C amp Ra Aight 1 1 TUBE Uitte Mi Cy I RA d Octachromg GO MaCe Y M CK Cartridge Set snd Configurations Figure 4 22 Ink Cartridge Configurations Ensure that the cartridges are properly installed particularly for 1x8 print modes Refer to the following Horizontal and Vertical Banding paragraphs for more information Troubleshooting 4 30 NovaJet 800 Series Service Manual Horizontal Banding 1
30. o n 4 102 Media Handling System Failure 4 104 xii 800 Series Service Manual Table of Contents cont Chapter 5 Assembly Disassembly 5 1 E ETT 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 5 9 Remove Memory 5 10 IistallMermory Modules 5 11 Remove the Main Printed Wiring Assembly PWA 5 11 Install the Main Printed Wiring Assembly PWA 5 14 Remove Power Supply Cooling Fan and Entry Module 5 15 Install the Power Supply Cooling Fan and AC Entry Module 5 17 Remove Servo Motor 5 18 Servo e eds 5 20 Remove the Ink Delivery System 5 21 Install the Ink Delivery System E 5 23 Remove the Carriage Assembly Carriage Belt and the Frame TENSIONE CT 5 23 Install the Carriage Assembly Carriage Belt and the Fr
31. 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 Principal features are summarized below Locally or Remotely Configured via Host Computer Powered Media Handling System Dynamic Thermal Drying System V8 12 Ink Line Delivery System Quick Ink Changeover Anti Skew Pinch Rollers PowerPC 50 MHz Microprocessor 8 User Configurable Settings 208 Jet Ink Cartridges Ink Priming System 500ml Ink Reservoirs Smart Cartridges Media Tracking Function 10 100BaseT Network Interface Rigid Media Handling System NJ880 only General Description 1 2 Overview NovaJet 800 Series Service Manual Printers draw according to instructions issued from a host computer Every printer is engineered to understand a specific set of instructions and to execute each instruction in a precise manner In addition most printers are designed to execute predetermined characters automatically without a specific line by line instruction from the program These characters are part of the printer s permanent memory 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
32. 45 S oc Jolie ERFIOIGR 0 994 906i edis 5 46 5 30 Stepper Motor Removal Installation 5 51 5 31 Inside Platen Right Side 2 5 53 5 32 Media Take Up and Feed Sensor Removal 5 59 5 33 Media Take Up and Feed Motor Removal 5 61 5 35 Dryer Right Endcap Removal Installation 5 63 5 36 Right Endcap Connector Locations 5 65 Chapter 6 Parts List 6 1 Left Side Parts Breakdown 6 3 6 2 Platen and Above Parts Breakdown 6 5 6 3 Right Side Parts 6 7 6 4 Inner Platen Parts Breakdown 6 9 6 5 Carriage Assembly Parts Breakdown 6 11 6 6 Floating Carriage Cover Parts Breakdown 6 13 6 7 Service Station Parts Breakdown 6 15 6 8 Power Feed and Take Up Parts Breakdown 6 17 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 Troubles
33. 800 Series Service Manual 13 Remove the Stepper Motor Extension Spring from the Stepper Motor and the post on the Left Lower Drive Shaft Bracket See Figure 5 30 ATTACH SPRING TO POST ON BRACKET Figure 5 30 Stepper Motor Removal Installation 14 Remove the hardware securing the Stepper Motor to the Left Lower Drive Shaft Bracket and remove the Stepper Motor Install the Lower Roller Assembly Stepper Motor and Vacuum Fan NovaJet 850 1 Loosely attach the Stepper Motor to the Lower Roller bracket using otepper Motor hardware as shown in Figure 5 30 2 Attach the Stepper Motor tension spring to the Stepper Motor and the Lower Roller Bracket Tighten the Stepper Motor hardware to 8 in lb of torque It may be necessary to loosen do not remove the screws that secure the Y Arm Assembly to the Platen so that the Lower Drive Roller Assembly clears the ends of the screws Assembly Disassembly 5 51 NovaJet 800 Series Service Manual that protrude inside of the Platen while installing the Lower Drive Roller Assembly It may be necessary to loosen do not remove the screws that secure the left Leg Assembly to the Platen so that the Lower Drive Roller Assembly clears the ends of the screws that protrude inside of the Platen when removing the Lower Drive Roller Assembly NOTE Ensure that the Lower Drive Supports and Fan Assem blies are oriented in the correct position before inserting into the Platen Slide the righ
34. Dirty Encoder Strip 4 45 4 48 Defective Teflon Strip 4 45 4 49 RIP Error Page Layout Violation 4 46 4 50 ESD a ee ee een ER RR 4 47 4 48 4 52 Cartridge Cleaning 4 50 4 53 Service Station Cleaning aa 4 51 4 54 Magenta Ink Pressure Failure 4 52 M e E 4 53 4 56 Cartridge Tubing Needle and Septum 4 54 4 57 208 WOU GaN a 4 55 4 58 Operation 4 55 4 59 Reservoirs and Ink Delivery 4 56 4 60 Excessive Ink Pressure eese 4 57 4 61 Excessive Ink PreHeat Settings 4 58 4 62 Dirty Service Station 4 60 XIX 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 56 4 63 4 67 Cartridge Identification
35. Head Strike Ensure the vacuum fan or fans are providing adequate suction for media If the exhaust grill s are installed incorrectly then carriage head scraping will occur on the media causing streaking or inconsistent banding This could also be due to thick media greater than 20 ml or possibly canvas or vinyl exposed to high humidity which then becomes still Turn printer off Slowly move carriage head back and forth manually to ensure no obstructions are causing the print defects observed i e tape on the rear cover tie straps under the electronics cover or low carriage head height Verify connectivity through E Connect SEH or the built in print server Contact technical support for network configuration procedures Improper connectivity can cause low data transfer problems and may provide false starts of the printer carriage carriage moves out but does not execute print operations Figure 4 31 Low Data Transfer Problem Troubleshooting 4 35 NovaJet 800 Series Service Manual 12 Printa 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 5096 of the test print before deciding the next course of action The Test Print Utility Menu Service Menu Test Print may be used but this test is a compressed vector based file and may exhibit certain dithering propertie
36. Keypad Secure using four standoffs and washers Tighten by hand 3 Attach the Keypad grounding flex cable to the cover standoff as shown in Figure 5 5 Ribbon must be closer to the plastic side of the cover with the contact side towards the ground strap Assembly Disassembly 5 9 NovaJet 800 Series Service Manual 4 Placethe ESD Shield onto the Display standoffs using four kepnuts with 1 4 socket or wrench Torque to 2 5 in Ibs 5 Attach ground connections to the Cover Standoffs as shown in Figure 5 5 Apply a small drop of loctite into the Cover holes attach Standoffs and torque to 6 in lbs 6 Install the Top and Right Covers following procedures outlined earlier in this chapter Remove Memory Module Integrated circuits may become weakened or damaged by electrical discharge Do not touch or work near integrated circuits without wearing an ESD wrist strap 1 Remove the Top and Right Covers following procedures outlined earlier in this chapter Figure 5 6 Memory Module Removal Installation 2 Facing the right side of the Memory Module push the side clips gently to the outside away from the memory module Lift up and pull the module out See Figure 5 6 Assembly Disassembly 5 10 NovaJet 800 Series Service Manual Install Memory Module 1 Slowly push the Memory Module into place Make sure the module is fully seated Push the side clips towards the Memory Module until they hold the module securely
37. Left Support Bracket to the left away from the Carriage Assembly and Floating Carriage Cover Carefully move the Floating Carriage Cover Right Support Bracket Assembly to the right Remove the Electronics Covers and release the left end of the Trailing Cables from the Carriage PWAs Release the Strain Reliefs with the Trailing Cables and ferrite attached from the Carriages Disconnect the Trailing Cable Assembly connectors at the J1 and J2 locations on the Main PWA Use the thumb and forefinger to pull forward on the connector lock and remove the Trailing Cables from their connectors See Figure 3 6 Assembly Disassembly 5 41 NovaJet 800 Series Service Manual 7 Trailing Cable Assembly is secured to the Stabilizer Bracket by two pieces of double sided tape Remove the Trailing Cable Assembly from the Stabilizer Bracket 8 Mark the position of the double sided tape on the Stabilizer Bracket before removing It is important that the new tape is placed in the exact position as the older pieces were Remove any remnants of tape still on the Stabilizer Bracket Install the Trailing Cable Assembly 1 Apply two new pieces of double sided tape to the Stabilizer Bracket Ensure that the tape is in the same location as the original tape was The right side of the Trailing Cable the side connected to the Main PWA must extend beyond the Stabilizer Bracket by 5 4 7 8 5 1 8 or 128mm 125mm 131mm 2 Slip the fer
38. Module 1 Remove the four screws located below the Right Baseplate securing the Power Supply Bracket to the Right Baseplate Remove the Power Supply Bracket See Figure 5 9 2 Usinga Phillips screwdriver and a 1 4 wrench or socket remove the Fan from the Right Baseplate 3 Using a 1 4 wrench or socket disconnect the AC Entry Module ground from the ground stud on the Right Baseplate 4 Remove the AC Entry Module by pressing on the securing tabs until the module is released Assembly Disassembly 5 16 NovaJet 800 Series Service Manual Figure 5 9 Cooling Fan AC Entry Module Removal Install the Power Supply Cooling Fan and AC Entry Module To install the Cooling Fan and AC Entry Module 1 Insert the AC Entry Module into the AC Entry Module hole on the Right Baseplate Press in until it snaps securely into place Attach the AC Entry Module ground connection to the grounding stud on the Right Baseplate Hold the Cooling Fan into place while inserting the four bolts into the assembly Attach the four 1 4 nuts to the bolts to secure Fan assembly Torque to 4 in lbs Reinstall the Power Supply Bracket using four screws Assembly Disassembly 5 17 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 Pus
39. NovaJet 800 Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Media Does Not Move trailing cable defective perform Stepper Motor Winding Resistance check e rough motion while spinning stepper motor e paper sensor not responding e media control switches are operating correctly firmware corrupted bad MPWA ESD discharge electrostatic discharge replace trailing cable replace stepper motor 1f out of tolerance bad bearings replace stepper motor replace paper sensor driver corrupted reload printer driver reload firmware in continuous run state replace MPWA ensure that all ESD components are properly installed then replace MPWA Troubleshootina 4 3 NovaJet 800 Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Internal ERROR Carriage Axis Failure e dirty or lubricated slide shaft perform Servo Motor Winding Resistance check check servo motor for smooth movement obstruction in path of carriage may or may not be visible dirty encoder strip dirt under the carriage bushings damaged encoder strip bad encoder sensor worn outrigger bushings perform Slide Shaft Cleaning procedure replace servo motor bad bearings replace servo motor remove obstruction perform Encoder Strip Cleaning procedure remove carriage bushings and clean replace en
40. OFF Flashes during initialization then turns off LED staying on would indicate a problem when the FPGA 1 unconfigured Ensures the gate array chips have been properly programmed one on Main PWA and on each Carriage PWA D8 24V available D13 5V available Troubleshooting 4 79 NovaJet 800 Series Service Manual 7 Replace failed subassemblies Inconsistent Operations Reinitialize unit Select Init Settings to re initialize printer 1 beep should sound Functional Problems Figure 4 82 Functional Problem Verify proper grounds from power source exist plug both the computer and printer into the same electrical outlet for direct printing systems or non networked environments Noise in Image Figure 4 83 Connectivity Problem Typically a bad parallel printer cable will cause noise to show up on the printed image typically characterized by random lines extending horizon tally from the printed output Replace defective cable with an IEEE 1284 compliant parallel printer cable Troubleshooting 4 80 NovaJet 800 Series Service Manual ESD Problems Ink Figure 4 84 ESD Problem 1 Intermittent Banding jet failures 2 OverSpray 3 Severe color loss in either 1x4 right or the 1x4 left print mode Verify media is not causing the problem Change to a different media type Dryer Failure Sensor Error From the top level menu of the printer check the sensor status Utility Men
41. Remove the three screws securing the Left Support Bracket to the Floating Cover Slide the Left Support Bracket to the left away from the Carriage Assembly and Floating Carriage Cover NOTE Only one Support Bracket needs to be removed from the Floating Carriage Cover for this procedure In these pro cedures the left one is being removed but the right one can just as easily be taken off instead Assembly Disassembly 5 37 NovaJet 800 Series Service Manual 3 Usinga small tool remove the bushing from the Left Support Bracket The bushing must be removed from the right side of the bracket 4 Rotate the bushing 180 to pass the bushing through the Left Support Bracket without it getting caught on the tab of the bushing See Figure 5 23 Slide the bushing through the support bracket and out the other side Figure 5 23 Floating Carriage Cover Bushing Removal 5 Rotate the bushing 180 again so that it will clear the Pinch Rollers and the Slide Shaft Supports Slide the bushing off the left side of the Slide Shaft NOTE If the bushing falls through the hole on the side removal of that particular cover will need to be performed to retrieve the bushing 6 Slide a new bushing onto the Slide Shaft and position it near the Left Support Bracket 7 Rotate the bushing 180 to pass the bushing through the Left Support Bracket without it getting caught on the tab of the bushing See Figure 5 23 Slide the bushing through the suppo
42. age to the stainless steel slide shaft may result if cleaned with wa ter and not completely dried off Maintenance 3 2 NovaJet 800 Series Service Manual Printer problems can be caused by an accumulation of dirt or other contamination on the slide shaft This contamination may lead to drag on the carriage Extreme drag results in a carriage axis failure fault and will stop the carriage motion These problems may be eliminated by maintaining and cleaning the slide shaft at intervals determined by the environmental conditions Do not use any lubrication To clean the slide shaft Turn the printer OFF Disconnect the power cord and interface cable Raise the printer lid Moisten a clean cloth or paper wipe with isopropyl alcohol Wipe the length of the slide shaft with the moistened cloth or wipe Manually move the carriage assembly from side to side Wipe the shaft again to remove any deposits left from the carriage Close the cover and reconnect the power cord and interface cable turn the printer ON and perform the PRIME procedure Be sure that the carriage moves freely on the slide shaft Service Station Cleaning Ink and dust may build up on the service station resulting in contamination which may smear the prints The service station is cleaned as follows 1 2 Turn the printer OFF Disconnect the power cord and interface cable Raise the printer lid Carefully move the carriage toward the center of the printer
43. alcohol only Ensure carriage belt is installed properly with the idler wheel installed right side up Also the block on the carriage belt should be aligned to the right carriage assembly studs or a vertical line may show in the prints Refer to Carriage Assembly removal procedure Is the Frame tensioner attached properly broken Ensure the ink delivery system electronics cover is attached to the carriage assembly properly and is not rubbing against the rear support bracket rear white cover Power unit off and slide back and forth to test this Does the carriage assembly move back and forth freely without hitting any obstacles including the pinch roller assemblies Run the Servo Cycle Test set for 100 cycles under the Diagnostics Menu if the tests were successful then check the firmware version If the carriage assembly moves only 1 3 2 to 8 cm from the home position at power up then the servo motor is most likely defective Also see step 10 below Power off the printer move the carriage assembly to extreme left hand side of unit Power on the printer If the carriage returns to the service station on the first pass then the trailing cables large flat white cable are probably good But if a carriage axis error occurs the faster return pass then first suspect worn carriage cover bushings then check internal right and left carriage bushings Replace bushings 4 total as required verify shims are in good condition
44. available D9 Normally flashes when the Power PC processor is idle Stops flashing when processor is busy 1 e during paper sensing operations or printing D10 Normally OFF Flashes during initialization then turns off LED staying on would indicate a problem when the FPGA 1 unconfigured Ensures the gate array chips have been properly programmed one on Main PWA and on each Carriage PWA D13 5V available Microprocessor CPU The microprocessor 45MHz PowerPC 860 from Motorola is the central processor unit which supervises system functions executes the printer firmware manipulates data and controls input output data busses It has four built in serial ports a two channel DMA Direct Memory Access controller a timer module clock generator and an on board chip select generator The serial ports are not used and are disabled in all shipping firmware One DMA channel is used to receive data through the parallel port via the gate array One timer generates a servo interrupt every millisecond another is used to coordinate firmware multi tasking The chip select generator is programmed to generate chip selects at the appropriate addresses with the appropriate data size byte word and with the appropriate number of wait states Theory of Operation 2 8 NovaJet 800 Series Service Manual Gate Array KEYPAD LCD SERVO CONTROLLER 2 oF STEPPER CONTROLLER STATIC RAM Figure 2 6 Gate Array T
45. 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 Remove the pinch roller From the bottom of the Y Arm Assembly remove the four screws that secure the Slide Shaft and its two supports from the Y Arm Assembly Remove the two screws that secure the AutoLoad Sensor to the Y Arm Remove the AutoLoad Sensor wires from the four wire clamps on the back part of the Y Arm Bracket Assembly Disassembly 5 46 NovaJet 800 Series Service Manual Install the Y Arm Assembly Pinch Rollers Slide Shaft and AutoLoad Sensor 10 12 Install the AutoLoad Sensor Assembly into the back part of the Y Arm Bracket Torque to 6 in lbs Route the AutoLoad Sensor wires through the four wire clamps on the back part of the Y Arm Bracket Install the Slide Shaft and its supports to the Y Arm Assembly Torque to 8 in Ibs Insert the back compression spring onto the shaft of the pinch roller and push the back of the shaft through the back of the Y Arm Assembly Install the C clamp around the shaft of the pinch roller While compressing the forward pinch roller spring with a screwdriver or other flat object position the pinch roller onto the Y Arm Assembly until the forward spring is located under the hole in the Slide Shaft Release the spring and verify that the spring enters the hole in the Slide Shaft and that no kinks are pres
46. cartridge drive voltage for this PWA is 10 8 vdc Troubleshooting 4 93 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 E m BH E SH NU E UNS a P HER pM etme e A mE om im md m n m S E EB LE mum a Figure 4 104 Print Settings Not Printing in Black 19 Ifthe print settings are printed in any color other than black normal then the right carriage PWA is defective Troubleshooting 4 94 NovaJet 800 Series Service Manual i 1 E EIE a AES EZ oly E Hm m m A my Figure 4 105 Text Field Problem 20 Diagonal banding within text or lines adjacent to text indicates a text field problem Figure 4 106 Dirty or Defective Encoder Strip 21 If color deadband appears correct on both edges of the printer but is off at the center then the encoder strip is either dirty or defective Reinitializing the Printer To reinitialize the printer select User Menu User Setup Menu In
47. clears the Left Cover while still depressing the retracting stop assembly then slide the cover to the left to disengage it from the Right Cover To remove the Right Cover Assembly Figure 5 1 Right Cover Assembly Removal Installation 4 With a 2 Phillips screwdriver remove the three screws securing the Right Cover Assembly to the Right Baseplate and the two screws securing it to the Right Sideplate See Figure 5 1 5 Reach under the Support Bracket and depress and hold the retracting stop assembly that secures the Right Cover Assembly to the Support Bracket 6 Carefully lift up on the Right Cover Assembly until it clears the printer enough to gain access to the Keypad and Display connections going to the Main Printed Wiring Assembly PWA 7 Disconnect the Keypad flex cable connection at the J9 location on the Main PWA See Figure 3 4 for jack locations on the Main PWA Assembly Disassembly 5 3 NovaJet 800 Series Service Manual 8 Disconnect the Display data ribbon cable connector at the J10 location on the Main PWA To remove the Left Cover Assembly 1 Disconnect and remove all ink reservoirs Figure 5 2 Left Cover Removal Installation 2 Remove the two screws securing the Left Cover to the Left Frame See the upper portion of Figure 5 2 3 Reach under the Support Bracket and depress and hold the retracting stop assembly that secures the Left Cover to the Support Bracket 4 Insert the tip of a flath
48. deadband adjustment on the cartridge located in slot 4 This menu is similiar to the menu depicted in Figure 3 21 NOTE The only acceptable values for the color deadband adjustments are 12 20 28 36 44 52 60 68 76 84 92 and 100 Any other value entered will appear to be accepted because it will be displayed in the current settings section the next time this test is run In actual ity the system will default to the closest allowable setting as listed above Maintenance 3 98 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 Continue performing steps 4 through 6 until the all color deadband adjustments are correct on the left carriage To make adjustments to the right carriage deadband alignments follow similiar procedures as those above but replace left with right Paper Axis Calibration The paper axis calibration procedure ensures that the processing that drives the stepper motor 1 correct to minimize line length accuracy errors To perform the paper axis procedure 1 Select Utility Menu from the Main Menu This brings up the Utility Menu as shown in Figure 3 19 From the Utility Menu select Calibration Menu This brings up the Calibrat
49. environment make it impossible to calculate the average time that the trailing cables will last If the trailing cables are cleaned weekly the life of the cables should effectively double If not replaced the wear on the trailing cable flexible printed circuits can result in erratic carriage motion and or carriage axis failures vertical white bands jumps in printed output vertical color band jumps and unrecognized cartridge error messages Cables should always be replaced in sets never replace one cable only To replace the trailing cables follow the procedures for Trailing Cable Replacement found in Chapter 5 Maintenance 3 12 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 used cleanliness of the slide shaft and general ambient environment make it impossible to calculate the average time that the carriage bushings to last If not replaced the wear on the bushings can result in erratic carriage motion and or carriage axis failures It can even cause the cartridge head height to become uneven To replace the carriage bushings follow the procedures for Car riage Cover Bushing and Carriage Bushing Replacement found in Chapter 5 Mainten
50. has been established inside the cartridge see SetUp procedures Note When priming the cartridge it is important to ensure the suction end of the EasyPrime or NovaPrime assembly is flush against the cartridge jet plate Prime cartridge using 3 consecutive 1 second bursts and then wait 5 seconds repeat 4 6 times over a 1 minute period A sucking noise should be heard from the EasyPrime or NovaPrime when procedure is performed correctly Ensure the reservoirs are properly attached to the female valves otherwise this may cause ink starvation in the ink delivery system after only 10 minutes of print operations Figure 4 56 Cartridge Tubing Needle and Septum Ensure the cartridge needle septum connector assembly is tightly secure The assembly is composed of three parts which must be tightly twisted together do not overtighten Also ensure the printer is level on floor A height difference from one side of the printer to the other can also cause ink starvation Ensure the septum cartridge tubing needle is properly connected between the cartridge and carriage assembly Replace reservoir tubing needle and or cartridge tubing needle if pressure is lost after the procedure has been performed a leak is present in the line Troubleshooting 4 54 NovaJet 800 Series Service Manual Figure 4 57 208 Jet Cartridge 5 Heplace the cartridge with a new cartridge print head Re prime the ink delivery line Figure 4 58 EasyPrime Op
51. instructions and data constants which the micro processor can access and interpret with no loss of information when power is off The system firmware is stored in Flash EEPROM The Flash EEPROM allows the firmware to be upgraded by downloading the files containing the new firmware It can be erased and reprogrammed more than 10 000 times The term Flash means that bytes cannot be individually erased A block or the whole device is erased at the same time and the block or whole device is then reprogrammed The normal method of downloading new firmware 15 to send the unit the files containing the code using either the GO EXE utility or printing the file to the unit This requires using an appropriate host utility and can be done through the parallel port See Firmware Downloading in Chapter 3 for the procedures Theory of Operation 2 10 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 15 also copied from the Flash EEPROM to RAM where it can be executed faster printers ship with 64 MB of RAM and are upgradable to a maxi mum of 256 MB Additional memory helps to free the host computer more quickly Printer memory may be upgraded by installing PC100 or faster 168 pin DIMMs or Dual In line Memory Mo
52. into the Spool Folder Maintenance 3 44 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 5 After hearing the single beep remove power from printer for 15 20 seconds Apply power to the printer The printer should initialize properly Verify firmware revision by sequencing through Utility Menu Service Menu About menu Verify firmware has been incorporated If the firmware download is not successful you may hear more than 1 beep or complete silence Check port connections and return to step 4 Internal Cabling and Signal Flow Diagrams Figures 3 30 through 3 32 are schematics of the major components and the cabling associated between them The diagrams depicts component boards or assemblies jack connections cables and signal flow It is to be used by the technician as an additional aid in troubleshooting and improve understanding of the printers theory of operation Figure 3 30 shows all cable connections to the Main PWA and the power supply Figure 3 31 shows all cable connections to the carriage PWAs and Figure 3 32 shows all connections of the leg harness assembly Maintenance 3 45 NovaJet 800 Series Service Manual AT8IA3SSV NMN 72 NO C 3103NNO
53. of lines would be appearant SLOW DEADBAND calibration is a precision test that checks the firing time of the jets as related to the forward and reverse direction Allowable values for the Slow Deadband calibration 1s 2 1 0 1 and 2 The Single Line Test and Line Test are variations of the deadband test except they print longer lines so that long time integration of the deadband calibration can be observed The Single Line Test prints only one line at a time while the AII Line Test prints all lines at the same time These tests were designed primarily to be used in manufactoring only The deadband test on a NovaJet 850 will print a display similiar to Figure 3 22 but will print the pattern for each of the eight cartridges This is just a visual check of the color deadband alignment No adjustments can be made for this test at this control panel page To make adjustments if needed see the Color Deadband Alignment section Allowable values for the Color Deadband Alignments on this printer is from to 120 but the actual value used by the printer will only accept certain numbers The real value used by the printer will be the closest of 12 20 28 36 44 52 60 68 76 84 92 or 100 To perform the Slow Deadband Alignment 1 Select Utility Menu from the Main Menu This brings up the Utility Menu as shown in Figure 3 19 2 Selectthe Service Menu from the Utility Menu This brings up the Service Menu as shown in
54. providing feedback to the gate array on the Main PWA and thus monitoring carriage position over 1000 times per second and is responsible for exact ink drop placement onto the media The sensor uses binary counts to track carriage position along the encoder strip 4 basic counts are used 00 01 10 11 There are 150 lines per inch along the encoder strip so 4 x 150 2 600 dpi resolution is achieved However home position is the left edge of media and should a miscount occur then the image will walk or skew from its intended print position on each pass of the carriage head Improper cleaning agents on the encoder strip can cause encoder strip pitting to occur and thus lead to miscounts Encoder strips should be maintained in accordance with the Routine Maintenance If the encoder strip is not maintained then the ink residue and air debris will transfer to the encoder strip causing it to fail Symptoms include failure of the carriage assembly to move at power up with Carriage Axis Error displayed on the control panel display AutoLoad Paper Sensor Error The Autoload Paper sensor error only functions to pull media into the printer Triggered by the front edge of the media with a 6 second delay the sensor activates the stepper motor to drive the lower roller Typically the autoload paper sensor does not fail it becomes nonoperational due to ink covering Y Arm surface or covering the LED XMTR or sensor RCVR Initially clean the Y
55. the Carriage Belt into the Belt Clamp Check the position of the Carriage Belt to make sure it matches Figure 5 17 Make sure the left end of the Trailing Cables extends out beyond the left end of the Trailing Cable Support Assembly Position and hold into place the Carriage Coupler onto the right Carriage See Figure 5 18 Figure 5 18 Carriage Coupler Installation Slide the right Carriage onto the left end of the Slide Shaft making sure that the Encoder Strip fits into the slot in the Slider and the Assembly Disassembly 5 28 NovaJet 800 Series Service Manual Encoder on the Carriage PWA Ensure that the Carriage Coupler goes over the top of Slide Shaft Stretch out the Belt towards the Servo Motor to ensure that there are no twists in it Leave enough of the Belt loop overhanging the left side to ensure that the left Carriage will not bind in the Belt when installing the left Carriage 7 While holding the Carriage Compression Spring in place on the right Carriage position the left Carriage above and to the left of the right Carriage as shown in Figure 5 19 Slowly move the left Carriage down and to the right until the Carriage Compression Spring and Carriage Coupler are attached to the left Carriage At this point the left Carriage should easily slide onto the Slide Shaft Figure 5 19 Left Carriage Installation 8 Movethe Carriage Assembly back and forth over the Slide Shaft to ensure that
56. the printer is reassembled Remove the right side plate from the middle platen section by removing the 4 securing screws Disconnect both vacuum fans by removing the 6 securing screws Remove the exhaust grills by removing the 8 securing screws and lifting grills free Disconnect lower roller assembly by removing the 6 securing screws Remove the platen plug by forcing a screwdriver past lower roller and pounding out forcefully Remove the center lower roller Support bracket and bearing Note The thick arm of the bracket faces towards the front of the printer on reinstallation Remove the stepper motor lower roller assembly out the right side of platen Caution do not pull lower roller too hard as this may cause damage to the vacuum fans The vacuum fans may have to be lifted over the pemnuts when removing Assembly Disassembly 5 56 NovaJet 800 Series Service Manual NOTE The right side fixed nylon helical wedge and pin assembly flange should not have to be removed unless the screw length prohibits lower roller removal Three 1 8 and 5 32 allen head screws are used to secure these assemblies To remove the stepper motor from lower roller remove the 2 securing screws 2 nuts and spring Note the orientation of the motor with respect to the lower roller For new motor installations verify support bracket to motor gap is 005 to 015 on the non screwed side using a feeler gauge Lower Roller Installation Tip NovaJet 880 To instal
57. through the hole where the Exhaust assembly was remove the 3 screws on the bottom of the Platen that secure the Vacuum Fan s Do not allow the screws to come out at an angle Remove the Platen Plug from under the Platen Remove the black flat head screws from the top of the Platen that holds the Center Support in place Remove the Center Support through the Platen Plug hole Assembly Disassembly 5 49 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 It may be necessary to loosen do not remove the screws that secure the Y Arm Assembly to the Platen so that the Lower Drive Roller Assembly clears the ends of the screws that protrude inside of the Platen when removing the Lower Drive Roller Assembly It may be necessary to loosen do not remove the screws that secure the left Leg Assembly to the Platen so that the Lower Drive Roller Assembly clears the ends of the screws that protrude inside of the Platen when removing the Lower Drive Roller Assembly The Fan Assemblies will be removed at the same time that the Lower Drive Roller Assembly is removed Exercise extreme care that the fan assemblies do not drop out of the Platen when removing the Lower Drive Roller Assembly 12 Carefully slide the Lower Drive Roller Assembly and the Fan Assemblies out of the left side of the Platen Assembly Disassembly 5 50 NovaJet
58. to activate both or Roll Mode to activate feed motor only under Supply Type from Paper Option Menu clean decal and or clear obstruction Troubleshootina 4 17 NovaJet 800 Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms reflective decal replace reflective missing decal sensor not replace or reshape aligned correctly sensor bracket sensor bracket bent or misaligned Troubleshootina 4 18 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 Any clogged jet or misfiring jet should be cleared through cleaning of the cartridge jet plate See Routine Maintenance or through Manual Jet Bypass up to 20 jets may be manually bypassed in each color to maintain satisfactory print performance Note 1 Satisfactory print performance is defined for each give mode 2x4 mode 3 pass print mode 1x8 mode 4 pass print mode 1 4 4 pass print mode 1x4L 4 pass print mode Note 2 Warranty is applied to cartridges that have 10 or more defective jets 100 filled blocks only Figure 4 1 Cartridge Misfire Troubleshooting 4 19 NovaJet 800 Series Service Manual Failure Analysis Pr
59. wait for this time period to elapse before evaluating test results If the Troubleshooting 4 82 NovaJet 800 Series Service Manual firmware 15 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 The Dryer Mode and Plenum items will also modify their display if a dryer component or main board sensor error is detected If the dryer circuit board detects an over temperature condition or if it is disconnected from the printer Dryer Mode will indicate DISABLED and Plenum T will indicate Hdw Fault The dryer firmware will shut down the dryer by switching to OFF mode turning the heater power off and turning the fans on automatically The dryer circuit board will react in a similar fashion by switching to its own shutdown mode which turns the heater power off and turns the fans on automatically This duplicate reaction by hardware is provided in the case where the firmware has lost control The dryer will remain in this shutdown state until power is recycled If the firmware detects a Plenum T sensor error Dryer Mode will display DISABLED and Plenum T will display Error This error can occur if the plenum temperature falls below 10 degrees C or if the firmwar
60. 0 seconds reapply power to printer Check operations Troubleshooting 4 75 NovaJet 800 Series Service Manual Pas 111 uen IER Figure 4 78 PWA LED Operation Ensure Main PWA LEDs light emitting diodes are properly functioning D1 Normally flashes DSP is not active Steady during print operations D9 Normally flashes Power PC processor is idle Stops flashing when processor is active i e during paper sensing operations D10 Normally OFF Flashes during initialization then turns off LED staying on would indicate a problem when the FPGA 1 unconfigured Ensures the gate array chips have been properly programmed one on Main PWA and on each Carriage PWA D8 24V available 5V available a ee ee ieee LE HD DALH pet FE LI ar l1 uL i a i 1 t m zi Figure 4 79 Memory Module Troubleshooting 4 76 NovaJet 800 Series Service Manual Hemove power from the printer Ensure the memory module DIMM dual in line memory module at the Main PWA is seated properly There must be installed memory for the printer to initialize The top and right cover assemblies must be removed to access the Main PWA remove 5 screws to gain access Replace the memory module to verify memory is not the cause of failure Refer to disassembly Refresh the printer firmware during the cyc
61. 165 Ibs 235 Ibs 65 to 85 F 42 150 Ibs 18 to 30 C 5 to 80 RH Dimensions non condensing Height 44 1 12m 48 1 22m Storage Width 93 2 37m 40 to 95 F 42 inch 4 to 35 C 5 to 80 RH 111 2 82m 111 2 82m non condensing 60 inch Depth 28 0 7 1m Contents of this Service Manual Figures are used in this manual to clarify procedures They are for illustrative purposes only and may not necessarily be drawn to scale Material in this manual may be repeated in various chapters so that each chapter can stand alone This allows information to be located without having to refer back and forth between chapters Figures and tables are easily located and cross referenced and are listed in the front of the manual under List of Illustrations and List of Tables This manual is divided into six chapters as 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 Chapter 2 THEORY OF OPERATION Functional descriptions of the overall printer and major assemblies are contained in this chapter General Description 1 6 NovaJet 800 Series Service Manual Chapter 3 MAINTENANCE This chapter covers the scheduled maintenance cleaning procedures and alignme
62. 2 10 cE 2 15 2 11 Carriage Assembly Circuits 2 16 Ceca Tod 2 18 Chapter 3 Maintenance 3 1 Encoder Strip Cleaning 3 4 3 2 Cartriddge DiImpbledegdiOl 3 6 3 3 Flex Cable 3 7 3 4 Main PWA Connection Locations 3 10 3 5 Carriage PWA Connection Locations 3 11 3 6 Ribbon Connector Locking Mechanism 3 12 3 14 350 3 15 3 9 Power Feed Take Up Motor 3 16 3 10 Examples of Horizontal Banding 3 17 3 11 Dial Gauge Micrometer Assembly 3 25 3 12 Measurement Positions for Slide Shaft 3 26 3 13 Slide Shaft Profile Adjustment 3 27 3 14 Carriage Head Height Tolerance 3 28 3 15 Setting Up Tools from Height Gauge Kit 3 28 3 16 Zeroing the Micrometer Gauge 3 29 3 17 Test Cartridge Installed dct ees 3 29 3 18 Vert and Horiz Color Calibration
63. 2 9 Quadrature Signal Generation The direction that the Carriage Assembly is moving 15 calculated based upon the state of one detector s output and the direction of the transition of the other detector s output Theory of Operation 2 14 NovaJet 800 Series Service Manual A hardware counter in the gate array increments as the Carriage Assem bly moves left and decrements as the Carriage Assembly moves right The hardware counter is only eight bits wide so it cannot store a value large enough to represent an absolute Carriage Assembly position Instead it is read during the servo interrupt and its value compared with that from the previous interrupt This difference 15 used to update the absolute position value in the software Interface Circuits Serial amp Parallel MICRO PARALLEL PROCESSOR dmm ARRAY lt a CONNECTOR Figure 2 10 Interface Circuits Data from the host computer is received through the Centronics parallel port The gate array provides the control signals for DMA transfers from the parallel port to SDRAM The serial port is not used Possible solutions for the Macintosh computer user include using the print server device with an established network or installing a parallel port add on card in the computer to interface with the printer Theory of Operation 2 15 NovaJet 800 Series Service Manual Carriage Assembly Circuits OPTICAL ENCODER e ff OPTICAL SENSOR TRAILING CABLE
64. 800 Series Service Manual Dim T uuo NM ri d LEE ii i i Figure 4 112 Demo Print 2 Refresh printer firmware Refer to the Firmware Download proce dure Firmware Downloading Procedures NJ850 Printer 1 Power on the printer Verify current firmware version on printer to see if a firmware upgrade is necessary Select Utility Menu Service Menu About firmware version and boot code versions will be displayed Power off printer and directly connect an IEEE 1284 compliant parallel printer cable to the PC workstation and the printer 3 Download firmware files into the same file directory They can be found on the Encad web site www encad com 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 6 Using the EFPU send the XXXX ROM file to the printer Open the EFPU and press the Add button in the Folders section Troubleshooting 4 101 NovaJet 800 Series Service Manual of the dialog box Give the new folder a name and press OK 7 Now press the Add button in the Files section of the dialog box Find the firmware file that you downloaded from Encad s website and press the Open button This will add the firmware file t
65. Arm surface below the sensor with a cotton swab or lint free towel dampened with distilled water or isopropyl alcohol then remove the sensor and clean Troubleshooting 4 69 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 alint free cloth One quick solution for this problem is to loosen the two securing screws and change the pitch or angle of the sensor to the media surface The second solution involves cleaning of the Y Arm surface or optic infrared sensors Carriage Axis Error A carriage axis error is the most common error observed on the printer and 1 typically caused by an obstruction or an electronic hindrance of the carriage assembly during travel Causes of failure include the slide shaft encoder strip trailing cable outrigger carriage cover bushings left or right carriage bushings cutter servo motor service station carriage belt frame tensioner and spring Typically the outrigger bushings are clogged with debris causing the error condition Remove and clean Carriage Axis Failure The carriage stops suddenly during initialization or during normal printing Carriage Axis Failure is displayed on control panel display Troubleshooting 4 70 NovaJet 800 Series Service Manual
66. Axis Drive 2 4 The Carnage AMIS DU Dice SUD Del 2 5 Media Feed and Take Up System 2 6 Main PWA Printed Wiring Assembly 2 7 PWA LED Status 2 8 MIGFOPIOCESSON ORU NN m 2 8 2 9 Digital Signal Processor DSP 2 9 Memory raes a 2 10 Flash PROM 2 10 SDRAM che 2 11 2 11 Stepper Motor Controller 2 11 Servo Motor Controle 2 13 Interface Circuits Serial amp Parallel 2 15 NovaJet 800 Series Service Manual Table of Contents cont Chapter 3 Maintenance 1 3 1 e 3 1 Scheduled Maintenance 3 1 Cleaning 3 2 External 3 2 Slide Shaft Cleaning 3 2 Service Station Cleaning 3 3 Linear Encoder Strip Cleaning 3 4 Trailing Cables Cleaning 2 3 5 Platen Vacuum Hole Cleaning 3 5 Cartridge Dimples Cleaning
67. Brackets and SE SO 5 59 Remove the Media Take Up and Feed Motors 5 60 Install the Media Take Up and Feed Motors 5 60 Remove the Thermal Dryer Assembly 5 61 Install the Thermal Dryer Assembly 5 62 Remove the Thermal Dryer Right Endcap Assembly 5 62 Install the Thermal Dryer Right Endcap Assembly 5 64 XV NovaJet 800 Series Service Manual Table of Contents cont 6 1 800 Series Service Manual List of Illustrations Figure Page Chapter 1 General Description 1 1 NovaJet 800 Series Inkjet Printer 1 1 Chapter 2 Theory of Operation 2 1 General Block Diagram 2 9 2 2 Paper Media Axis Drive 2 4 2 3 Garriage AXIS DfIVB e eee dte e vns 2 5 2 4 Power Feed and Take Up System 2 6 2 5 Main PWA Printed Wiring Assembly 2 7 2 6 Gale Altay re EPUM 2 9 2 7 Stepper Motor Controller 2 11 2 8 Servo Motor Controller 2 13 2 9 Quadrature Signal Generation 2 14
68. Chip 2 4 64 4 59 FEX DIVE Cable hehehe betur 4 65 4 09 4 66 4 70 4 68 4 71 Encoder Sensor 2 2 4 68 4 72 AutoLoad Paper Sensor 2 4 70 4 73 Carriage Head Assembly 4 71 4 74 Servo Cycle PWM Menu 4 71 4 75 Dirty or Defective Encoder Strip 4 72 4 76 Main PWA Trailing Cable Connection 4 74 4 77 Boot ROM Access Function 4 75 4 78 Main PWA LED 4 76 4 79 Memory Module ron ena rou on eua EErEE 4 76 4 80 Paper Sensor etie ates deco esed catenis 4 78 4 81 Main PWA LED Operation 4 79 4 82 F ricuorial secco one iri e i i iri ui 4 80 4 83 Connectivity 4 4 80 4 84 ESD Problem exea 4 81 4 85 PWA Humidity Sensor 4 82 4 00 4 85 4 87 Dryer Connectivity 2 4 85
69. DRIVE WIRING ASSY WFIORROUD 215088 00 6 8 8 MOUNT BRACKET DRYER NJ850 214917 02 6 8 9 MOUNT BRACKET DRYER L NJ850 214918 02 6 8 MOTOR DIRTY 207767 6 8 GEAR MOTOR DRIVE 207666 6 8 IZ CRADLE DRIVE 207671 6 8 13 STRIKEPLATE ESD BRUSH ASSY 211170 6 8 14 CRADLE DRIVE ASSY W MOTOR 7 AND GEAR 8 207655 1 68 14 CRADLE IDLER ossessi 207667 68 15 DRYER ASSEMBLY 60 NJ850 216951 01 DRYER ASSEMBLY 42 NJ850 216952 01 DRYER ASSEMBLY NJ880 218997 00 68 16 ENDCAP RIGHT ASSY W PWA NOVAJET 850 22 0 44002 215377 04 NOVAJET 880 ee 218338 00 DRYER BRACKETS ASSY NJ880 218802 00 Parts List 6 16 NovaJet 800 Series Service Manual Figure 6 8 Power Feed and Take Up Parts Breakdown Parts List 6 17 Index A alignments slide shaft 3 24 axis drive carrier 2 5 paper media 2 4 B banding 3 16 C cabling 3 45 calibration color 3 81 deadband 3 34 X axis 3 39 carrier 5 23 cartridges 3 6 3 31 cautions 1 4 control panel 2 18 D download firmware 3 43 E encoder strip 5 43 ESD 1 3 F fan cooling 5 15 firmware downloading 2 10 3 43 3 44 NovaJet 800 Series Service Manual G general block diagram 2 2 ink del
70. ENCAD NovaJet 8 Head Family Nova Jet 900 Series Service Manual ENCAD NOVAJET 800 Series Color Inkjet Printer Service Manual Part Number 216520 01 NovaJet 800 Series Service Manual Copyright Eastman Kodak Company 2002 KODAK ENCADS VinylJet VinylJet CADJET Extreme Color Printing M and Graphic Outdoor Matched System GO are trademarks of Eastman Kodak Company Other trademarks and registered trademarks are the property of their respective owners No part of this manual may be copied or distributed transmitted transcribed stored in a retrieval system or translated in any human or computing language in any form or by any means electronic mechanical magnetic or otherwise or disclosed to a third party without the express written permission of Encad Inc 6059 Cornerstone Court West San Diego CA 92121 U S A 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 Printing history 1st Edition HevA December 2000 2nd Edition Hev B June 2002 NovaJet 800 Series Service Manual FCC Statement U S A The United States Federal Communications Commision has specified that the following notice be brought to the attention of the users of the NOVAJET 800 series printers FEDERAL COMMUNICATIONS COMM
71. Figure 3 23 Maintenance 3 35 NovaJet 800 Series Service Manual Calibration Menu About Diagnostics Menu Cartridge Info Test Print Exit Figure 3 23 Service Menu 3 Select the Calibration Menu from the Service Menu 4 The Calibration Menu shown in Figure 3 24 is where the deadband tests are performed Select Slow Db Test to run the slow deadband test Deadband Test Slow Db Test Slow Deadband Single Line Test All Lines Test Figure 3 24 Calibration Deadband Menu 5 When the plot is complete select Slow Deadband at the Calibration Menu This brings up the options menu for the slow deadband adjustment This menu is similiar to the menu depicted in Figure 3 21 6 Observe the plot and using either Prev Option or Next Option rotate through the selections until the value you want is selected Press Ok to accept the selection and return to the Calibration Menu Maintenance 3 36 NovaJet 800 Series Service Manual 7 Continue performing steps 4 through 6 until the slow deadband adjustment is correct Color Deadband Alignment The color deadband alignments are necessary to ensure that the output images are being produced with the highest quality standards available while using the ENCAD printer in a bidirectional mode 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 Precis
72. ISION RADIO AND TELEVISION INTERFERENCE FOR CLASS B DEVICE This equipment has been tested and found to comply with the limits for a class A digital device pursuant to part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference in a residential installation This equipment generates uses and can radiate radio frequency energy and if not in stalled and used in accordance with the instructions may cause harmful interference to radio communications NovaJet 800 Series Service Manual User Instructions If the equipment does cause harmful interference to radio or television reception which can be determined by turning the equipment off and on the user is encouraged to try to correct the interference by one of the following measures Reorient or relocate the receiving antenna ncrease the separation between the equipment and receiver Connect the equipment into an outlet on a circuit different from that to which the receiver is connected Consult the dealer or an experienced radio TV technician for help Changes or modifications not expressly approved by ENCAD Inc could void the user s authority to operate the equipment NovaJet 800 Series Service Manual VDE Statement Hiermit wird bescheinigt da die NOVAJET 800 Serie von Drucker in bereinstimmung mit den Bestimmungen der BMPT AmstblVfg 234 1991 funkentst rt ist Der vorschriftsm BDige Be
73. O ION xx aN E gv MTOXL No ClAMWIINOXL H mo H geom JIavO SN IIVelL VMd d JO V JOVIUVO L MOV Ig GINVAD VINJOVIN Sel3Ala eJOSN3S tlHGOONA 7 8 Figure 3 31 Carriage PWA Connections Diagram 3 46 Maintenance NovaJet 800 Series Service Manual treo E ene aaa 02 LI 7OYINOD H Z NYJ AJANG L JIAN NT TE 33A a AlgiN3SSvans 6 SLU SNIS H CNS HANG Ave HANG a IO3IGA 33AG Nid dvi i AT8IN3SSV amp NIV YOSNAS 1 eL UNS eJOSN3S AlddNs 6 6L Alddns LE AVC Figure 3 32 Leg Harness Connections Diagram CN WO SOM 554 291 554 NALV 1d 3 47 Maintenance NovaJet 800 Series Service Manual Troubleshooting 4 Introduction Chapter 4 Troubleshooting consists of a table that is intended to aide the technician in troubleshooting the NovaJet 800 series printers This table addresses symptoms with their possible causes and solutions Basic troubleshooting skills will be required to perform the symptom identification troubleshooting fault isolation and repair of the printer w
74. RESERVOIR BLUE 215930 00 TUBE ASSY RESERVOIR GRAY 215933 00 6 1 5 RESERVOIR ASSY 215918 PAG I E 215987 00 6 1 6 RESERVOIR ASSEMBLY WITH CAP AND TUBE ASSEMBLY BLUE 215971 00 216000 00 GRAY 215972 00 PACI OE 3 SERRA 216001 00 NovaJet 800 Series Service Manual FIGURE ITEM PART NAME PART 6 1 7 FEMALE BLUE 2 4244 00 FITTING FEMALE GRAY 214245 00 6 1 8 XCSRING DO 207789 HARDWARE KIT 208810 BAS Y PRIME 216072 01 SDRAM DIMM 8M X 64MB PC133 215919 00 ASSY HEIGHT GAGE KIT 209996 1 ADAPTER HEAD HEIGHT 216131 00 BELT REMOVAL TOOL 216629 00 SERVER IOO0BASET 218239 00 Parts List 6 2 NovaJet 800 Series Service Manual Figure 6 1 Left Side Parts Breakdown Parts List 6 3 FIGURE ITEM 6 2 6 2 6 2 6 2 6 2 6 2 6 2 6 2 6 2 6 2 6 2 6 2 6 2 6 2 6 2 YN 10 12 13 14 15 16 17 NovaJet 800 Series Service Manual PART NAME PART SPRING 209052 RETRACTING STOP ASSEMBLY 208838 01 COVER ASSY TOP 60 uctor omae 215571 00 COVER ASSY TOP 42 215572 00 CHAIN SUPPORT ASSEMBLY 217283 00 H
75. Replace shims if necessary Troubleshooting 4 73 10 11 12 13 NovaJet 800 Series Service Manual Figure 4 76 Main PWA Trailing Cable Connection 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 Verify servo motor resistance values with an ohmmeter or multimeter The resistance should be 2 8 ohms 1 5 to 30 ohms is acceptable Replace servo motor if values are out of tolerance Measure brush resistance across servo motor windings to verify a short does not exist replace servo motor if new trailing cable does not fix carriage axis error There is no way to verify faulty bearings other than grinding when the shaft is turned The typical motor will last approximately 2800 plot hours 2 8 million servo cycles The brushes or bearings may fail Replace motor at 4000 plot hours in accordance with prescribed routine maintenance Check slide shaft profile carriage head height adjustment perform both alignments Refer to alignments A severely bent slide shaft upwards or low carriage head height can cause carriage axis failures or head strike Replace trailing cables assembly Refer to disassembly Replace servo motor if carriage head advances only a few inches Troubleshooting 4 74 NovaJet 800 Series Service Manual
76. System REFLECTOR REFLECTOR p 0 m JN Figure 2 4 Power Feed and Take Up System The media feed and take up system comprises of two optical sensors two dc motors and a dryer assembly See Figure 2 4 Motors are used to advance the media feed roll and the media take up roll dependent upon the signals they receive from the Main PWA The Main PWA generates the control signals for the motors from the informa tion it receives from the media feed and take up sensors The Main PWA also controls the dryer assembly Theory of Operation 2 6 NovaJet 800 Series Service Manual Main PWA Printed Wiring Assembly CNTRE PANEL EIJdERSEI H lt lt PRICCE S03 Y ARA HUMIDETY dE Pye er EP AMD STEPPL 4 MOTO WERORY DARALTE Figure 2 5 Main PWA Printed Wiring Assembly The Main PWA Printed Wiring Assembly consists of seven functional areas 1 Microprocessor CPU 2 Gate Array 3 Memory Circuits 4 Stepper Motor Controller X Servo Motor Controller 6 Interface Circuits Serial amp Parallel hs Temperature and Humidity Control Theory of Operation 2 7 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
77. able to the printer s parallel port contact ENCAD Technical Support to obtain Activate the Continuous Test by selecting the Utility Menu Service Menu Diagnostics Menu Continuous Test The printer will activate several test patterns the parallel port test equals passed should be printed If successful then the parallel port is operating correctly Caution Connecting a parallel printer cable to a printer that is turned on can cause damage to the printer U9 U17 U22 buffer I C s on the Main PWA are subject to failure when power arcs across the parallel pins Always turn printer off before connecting a parallel printer cable or switching an 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 Connect cable to parallel port only Disregard the Serial Port test as this is only for manufacturer testing Power printer off and disconnect loopback cable wait 10 seconds apply power Also refer to the Intermittent Problems Continuity procedure Other port testing procedures 1 Perform a follow up test print using a known good file Obtain test file from the Servicing Support CD service item only File must be sent through the EFPU 3 0 Encad File Print Utility Troubleshooting 4 100 NovaJet
78. abs with a small tool Disengage the trailing cables from the carriage ZIF connectors At rear of printer disengage each strain relief from each carriage assembly using a small flat head screwdriver gently pry the securing foot to one side to release the strain relief Caution do not force strain relief or damage to carriage assembly may result Remove both carriage assemblies belt frame tensioner idler and spring by sliding assemblies gently off the left side of the slide shaft Note the carriage assemblies are connected together with a latch and tension spring ensure the orientation is correct for installation the right carriage assembly contains the sensor assemblies Remove the Y Arm assembly by removing the 8 securing screws Caution do not damage trailing cable or sensor wiring during removal the 2 middle platen section pin assembly compression springs by removing the securing screw Remove 3 screws from right leg and twist 90 degrees to gain access to screw holes Hemove 4 screws securing the right fixed platen end Right stand leg will have to be twisted to gain access to screw holes Move platen end away from stepper motor location and pull wiring free Do not disconnect leg harness wiring Caution do not loosen or remove any main beam screws or improper printer alignment will result Remove the middle platen section by pulling straight up Caution do not tamper with the media thickness hand wheel until
79. ach an electrostatic discharge ESD wrist strap Refer to Disassembly Common Misfire Problems Cartridge electrical contacts may have oil or ink on surface clean with isopropyl alcohol See illustration below for an example of a defective magenta cartridge Figure 4 12 Magenta Cartridge Misfires Carriage assembly flex driver cable may have ink or debris on contacts clean with alcohol Troubleshooting 4 25 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 nsert cartridge and initiate a Color Test 100 in the 2 pass mode Note running the color test in the single pass mode severely reduces printhead resistor life For severe clogs use ultrasonic cleaner 30 40 sec or hot water 10 15 sec to break down kogation clogging of jet plate holes at nozzle bis gp Figure 4 13 Adjacent Jet Misfire Cyan Note Adjacent misfires in the prime pattern will cause microbanding These types of misfires must be manually compensated or cleared through cleaning procedures Multiple Cartridge Failures Assuming cartridges flex driver cables are clean and connectivity 15 good recommend to customer to replace service station should be replaced every 6 months Check ink lot codes of possible contamina tion Contact technical support Troubleshooting 4 26 NovaJet 800 Series Servic
80. agonal 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 amp 1 1414 1 L4 44 Figure 4 45 Worn Bushings or Bushing Pads 1 Forvertical banding check carriage bushings for wear and ensure the bushings are free of dirt and ink residue buildup Perform the carriage vibration test under Diagnostics Menu the lines should print fine with no jagged edges Clean the bushings with a dry lint free towel if necessary Replace all carriage bushings and both outrigger bushings Refer to Disassembly procedures Troubleshooting 4 43 NovaJet 800 Series Service Manual 2 Rotate image in software 90 degrees and or print a test RTL file to verify banding Obtain the Sample Images CD and refer to Demonstration Print for proper procedures Figure 4 46 Defective Trailing Cable Examples 3 Heplace the trailing cable assembly prior to any circuit assembly replacement Replace trailing cable assembly for vertical jumps in color i e one color does not print through one part of the print the image appears to have a vertical pattern or for vertical white spaces down a print Replace the trailing cable assembly if Troubleshooting 4 44 NovaJet 800 Series Service Manual multiple sets of vertical bars appear along the right edge of the print usually containing CMYK colors The
81. ailing Cable Troubleshooting 4 23 NovaJet 800 Series Service Manual 1 k LA Figure 4 9 Unseated or Defective Trailing Cable 13 Replace both trailing cables for vertical white gaps or spaces in the Prime pattern jumps in color or for irregular patterns with horizontal lines Also refer to Microbanding Refer to Disassembly for trailing cable replacement procedures 14 Replace the carriage PWA for single or multiple color firing related problems Note The carriage PWA is responsible for printing all test patterns calibrations and prime patterns i e a defective carriage PWA with a defective cyan driver will cause all printed cyan patterns to be incorrect Only replace if this is the case Refer to Disassembly a ol 2 RUE Figure 4 10 Defective Carriage PWA If the color test appears like this example and other printing is faulty then the carriage PWA is defective Troubleshooting 4 24 NovaJet 800 Series Service Manual 1 4 Left 1x4 Right 4 3 2 1 1 8 2 4 Figure 4 11 Stall Configuration Ensure the left or right Carriage PWA is tested properly 15 Replace the Main PWA only if a specific test pattern calibration or jet sequence fails to print Magnetic tipped screwdrivers are known to have caused these types of Main PWA failures in the past Please exercise caution when handling circuit assemblies and always att
82. ailure causes 97 of the symptoms observed um m m mc cua e Figure 4 99 Defective Main PWA 14 For specific test or calibration functions that fail to print or execute replace the Main PWA Caution do not use magnetic tipped screwdrivers around circuit assemblies as this is known to have caused Main PWA failures in the equipment Refer to Main PWA removal procedures in DISASSEMBLY Troubleshooting 4 92 15 16 17 NovaJet 800 Series Service Manual Figure 4 100 Corrupted Code Main PWA Figure 4 101 Microbanding Corrupted Flash ROM First reload Firmware direct connect a PC via a 6 foot 2 meter IEEE 1284 compliant parallel printer cable then reload Boot Code and finally replace the Main PWA to check the Flash ROM for the following problems if issue cannot be solved by any other means Horizontal banding 1cm spacing Microbanding 5 to 2mm banding For printers which cease printing during overnight print runs ensure the room lights remain on or is consistent from the time media was measured as this may affect paper sensor performance leading to incomplete print jobs For O R Error Messages ensure both L and R values indicate numerical ranges of 107800 through 1082000 Any other numerical range could indicate a failure of the respective carriage PWA Atarget range is typically displayed as P10 800 indicating the target
83. aintenance 3 NovaJet 800 Series Service Manual Clean and Inspect Stepper Motor Gears The stepper motor gears can become dirty after time typically after 4 5 years of operation if not cleaned Dirty gears can cause microbanding in the print This will reduce the quality of the output Clean the motor gears with a stiff brush to knock off any debris A cotton swab soaked isopropyl alcohol can be used to remove any ink that may have accumulated on the gears Clean and Inspect Main PWA Foreign material on the Main PWA could short out electrical signals being developed on the Main PWA and cause erroneous prints or even damage to the Main PWA electrical circuits should be free of foreign material especially those materials with conductive properties Clean the Main PWA by blowing the objects away or gently brushing them aside with a soft brush if required Inspect the Main PWA for any damage to the board connections or any of its compo nents Replace the board if inspection reveals any damage or flaws that could affect its function Clean and Inspect Carriage Assembly Foreign material on the carriage assembly could short out signals being developed on the carriage assembly and cause erroneous prints or even damage to the carriage assembly A very common problem occurs when ink has been spilled onto the carriage assembly electrical circuits should be free of foreign material especially those with conductive properties
84. al 1 Place the Top Cover in the open position 2 Move the Carriage Assembly to the left side of the Slide Shaft 3 Reach into the Right Cover and pull back on the Service Station release tab located on the far side of the Service Station See Figure 5 26 4 Raise the right side of the Service Station out of the Platen Assembly Disassembly 5 40 5 NovaJet 800 Series Service Manual Lift out the left side of the Service Station from the Platen and remove the Service Station Moving the Service Station farther to the right might be required to release the left side of the Service Station Install the Service Station 1 To install the Service Station position the Service Station inside the Right Cover and place the left side of the Service Station into the Platen Push down on the right side of the Service Station until the Service Station snaps into place Slide the Carriage Assembly to the right and back into the home position Lower the Top Cover Remove the Trailing Cable Assembly 1 Remove the Top Left and Right Covers following procedures outlined earlier in this chapter Position the Carriage Assembly to the right side of the center of the Slide Shaft Make sure that the Chain Guide on the Chain Support Bracket is not blocking the Floating Carriage Cover or it may be very difficult to perform these procedures Remove the three screws securing the Left Support Bracket to the Floating Cover Slide the
85. ame Tensioner mto E S 5 28 Remove the Carriage 5 31 Installihe PA 5 33 Remove the Paper Sensor or the Encoder Sensor 5 34 Install the Paper Sensor the Encoder Sensor 5 36 Replacing the Floating Carriage Cover Bushings 5 37 Replacing the Carriage 95 5 39 Remove the Service Station 5 40 AStalliihe Service Stato Y t t vts 5 41 Remove the Trailing Cable Assembly 5 41 Install the Trailing Cable Assembly 5 42 Remove the Stabilizer Bracket and Encoder Strip 5 43 Install the Stabilizer Bracket and Encoder Strip 5 44 Remove the Y Arm Assembly Pinch Rollers Slide Shaft and PUOL OAC SSIS Ole e 5 44 Install the Y Arm Assembly Pinch Rollers Slide Shaft and AUIOL OAC 12141579 5 47 Remove the Gap Sensor NovaJet 880 only 5 48 xiii NovaJet 800 Series Service Manual Table of Contents cont Chapter 5 Assembly Disassembly cont Remove the Lower Roller Assembly Stepper Motor and Vacuum Fan 1850 5 48 Install the Lower Roller Assembly Stepper Motor and
86. an external areas weekly or as required Clean slide shaft weekly Clean service station daily Clean encoder strip weekly Clean trailing cables bi weekly Clean platen surface vacuum holes monthly Clean cartridge dimples if prime fails Clean flex cable contacts if prime fails or cartridge is replaced Clean and inspect motor gears annually Clean and inspect Main PWA annually Clean and inspect carriage assembly annually Clean dryer assembly monthly connectors on Main PWA annually Reseat connectors on carriage boards annually Replace trailing cables every 2000 plot hours Replace carriage cover bushings 2 total every 2000 plot hours Replace carriage bushings 4 total every 4000 plot hours 3 1 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 Damage to the surface may result The exterior surfaces of the printer may be cleaned with a soft cloth which has been dampened For more persistent stains a small amount of liquid detergent may be used Cleaning intervals are determined by the environment in which the printer is used Slide Shaft Cleaning Use only isopropyl alcohol on the slide shaft of the printer Dam
87. ance 3 13 NovaJet 800 Series Service Manual Servo Motor Winding Resistance Check Figure 3 7 Servo Motor 1 Disconnectthe servo motor connection from J12 on the Main PWA 2 Using standard ohmmeter or multimeter connect the meter leads to the two wires going to the motor 3 While manually rotating the servo motor monitor the readings on the meter The acceptable range is 2 12 ohms Typically the reading is 3 8 ohms 4 Ifthe measurement is found to be unsatisfactory replace the servo motor Maintenance 3 14 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 Usinga 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 The reading should indicate 7 2 8 0 ohms 4 Continue by measuring between pins 4 and 6 Point B in Figure 3 8 5 Heading should also indicate 7 2 8 0 ohms 6 If either measurement is out of tolerance replace the stepper motor Maintenance 3 15 NovaJet 800 Series Service Manual Power Feed and Take Up Motor Winding Resistance Check 6 Figure 3 9 Power Feed and Take Up Motor Remove the feed and or take up roll from the printer Using Phillips screwdriver remove the four screws that secure the cradle idler from the right leg Ease the cradle idl
88. are Download Upgrade 1 Ensure customer wishes to upgrade to select firmware version All new printers or Main PWAs are shipped with the latest firmware installed Some functionality is usually gained with each successive firmware version Use an IEEE 1284 compliant parallel printer cable for the download from a PC via the ECP parallel port Power off printer first or damage may occur to printers Main PCB U9 U17 U22 buffer IC s Connect an IEEE 1284 compliant parallel printer cable 6 feet 2 meters in length or less is preferred 10 feet 3 meters is suggested to printer s parallel port Obtain the firmware file xxxxxxx EXE firmware Copy to hard drive Double click on exe file at explorer winfile to extract 3 files Troubleshooting 4 103 NovaJet 800 Series Service Manual INTERNET http www encad com Downloads Software Extract 2 files from the executable xxxxxx rom and readme txt 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 Using the EFPU send the XXXX ROM file to the printer Open the EFPU and press the Add button in the Folders section of the dialog box Give the new folder a name and press OK 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 fi
89. at you can see the Belt Clamp See Figure 5 17 Assembly Disassembly 5 26 NovaJet 800 Series Service Manual CARRIAGE BELT RIGHT POST OF BELT CLAMP LEFT POST OF BELT CLAMP Figure 5 17 Carriage Belt Clamp 13 To disengage the Carriage Belt from the Belt Clamp push the Carriage Belt away from the left post of the Belt Clamp and gently lift up until the bottom edge of the Carriage Belt clears the top of the left post 14 Push the Carriage Belt away from the right post of the Belt Clamp and gently lift up to finish removing the Carriage Belt from the Belt Clamp Failure to use an approved antistatic bag for storage or shipment may cause damage to the 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 5 27 NovaJet 800 Series Service Manual Install the Carriage Assembly Carriage Belt and the Frame Tensioner 1 6 To install the Belt onto the right Carriage the bumps on the belt where the ends of the belt are joined together to make the belt continuous must be positioned between the left and right posts of the Belt Clamp See Figure 5 17 Slide the Carriage Belt between the right post and the middle post and guide it down into the Belt Clamp Then slide the Carriage Belt between the left post and the middle post and finish placing
90. auge Kit Obtain the Head Height Alignment Plate Assemble the tools as shown in Figure 3 15 Lo SPIN HEAD ON MICROMETER GAUGE MES TO FACE BACKWARDS M TIGHTEN SET gt SCREWS TEST CARTRIDGE MEASURING TIP EXTENDER ENSURE TIP EXTENDS BELOW CARTRIDGE 1 4 6mm Figure 3 15 Setting Up Tools from Height Gauge Kit Maintenance 3 28 NovaJet 800 Series Service Manual 3 Placethe 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 ENSURE PRESSURE IS PLACED ON THE REAR OF THE CARTRIDGE Figure 3 16 Zeroing the Micrometer Gauge 4 Remove the Cyan ink cartridge Snap the test cartridge with the micrometer gauge into the position vacated by the Cyan ink cartridge See Figure 3 17 Ensure that the micrometer can be read from the BACK of the printer Figure 3 17 Test Cartridge Installed 5 Slightly loosen the 6 screws located on the back of the Y arm that secures the stabilizer to the Y arm Maintenance 3 29 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 While lifting up the measuring tip of the micrometer slide the Car
91. ay through and does not curl under the Carriage PWA c Grasp the Paper Sensor between thumb and index finger and guide the sides of the board into the grooves on each side of the opening See Figure 5 22 d Pushthe Paper Sensor board down into the Carriage Assembly until it snaps firmly into place Assembly Disassembly 5 36 NovaJet 800 Series Service Manual e Turnthe Carriage over and insert the Paper Sensor flex cable into the connector at J3 f Push both sides of the connector lock shut at the same time 2 Toinstall the Encoder Sensor a Turn the Carriage so that the bottom side of it is facing up b Push down on the plastic clip and slide the back of the Encoder Sensor over it c Push the Encoder Sensor in past the ridges until the Encoder Sensor snaps into place d Turnthe Carriage over and insert the Encoder flex cable into the connector at J2 e Push both sides of the connector lock shut at the same time 3 Install the Carriage Assembly and Ink Delivery System following procedures outlined earlier in this chapter 4 Install the Top Left and Right Covers following procedures outlined earlier in this chapter Replacing the Floating Carriage Cover Bushings 1 Position the Carriage Assembly to the right side of the center of the Slide Shaft Make sure that the Chain Guide on the Chain Support Bracket is not blocking the Floating Carriage Cover or it may be very difficult to perform these procedures 2
92. bly and the Left Frame Assembly from the rest of the printer With a flathead screwdriver press the left tab on the left Electronics Cover through the left Carriage Frame Assembly and remove the Electronics Cover Perform the same procedure on the right Electronics Cover by pressing the right tab on the right Electronics Cover See Figure 5 15 Assembly Disassembly 5 24 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 Assembly Disassembly 5 25 NovaJet 800 Series Service Manual Figure 5 16 Strain Relief Removal Installation 9 Slide the Carriage Assembly to the left edge of the Slide Shaft while taking up the slack of the Belt at the same time NOTE The Belt is connected to the right Carriage only The left Carriage is directly connected to the right Carriage The left Carriage moves with the right Carriage which is driven by the Belt 10 Slide the Carriage Assembly slowly off the left side of the Slide Shaft until the left Carriage slides off of the Slide Shaft and disconnects itself from the right Carriage Place the left Carriage aside 11 Slide the right Carriage and Drive Belt off the left side of the Slide Shaft 12 Once the right Carriage is removed from the Slide Shaft turn it over so th
93. cap Assembly away from the main body of the Thermal Dryer Assembly until access is gained to disconnect the connections going to the Printed Wiring Assembly Assembly Disassembly 5 63 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 During assembly ensure that all internal con nections are good including connections located at the left side of the dryer Disconnect the ground connection from the power cord to the main body of Thermal Dryer Disconnect all other connections going from the main body to the printed wiring assembly Install the Thermal Dryer Right Endcap Assembly 1 NOTE Some of the units may have very small servicing loops in the wiring of the Dryer Assembly When removing the Right Endcap the possibility exists that a connection may have been pulled loose elsewhere within the body of the dryer if extreme force is used to pull the endcap away from the main body During assembly ensure that all internal con nections are good including connections located at the left side of the dryer Assembly Reconnect all the connections going from the main body to the printed wiring assembly on the Right Endcap A
94. cause apparent overspray like symptoms when printed 2 Arethe color deadband and color calibrations correct Refer to Printer Calibrations 3 Checkthe ink cartridge jet plate for buildup and ink residue Refer to Scheduled Maintenance 4 Cleanthe encoder strip top and bottom slide shaft and inside of carriage belt with isopropyl alcohol Refer to Scheduled Maintenance 5 Check carriage cover bushings 2 bushings for wear and for cleanliness Refer to Scheduled Maintenance Check carriage bushings 4 inner bushings for wear Refer to Disassembly 6 Ensure vacuum fan is providing adequate suction for media Head strike is a leading cause of inconsistent horizontal banding and reported poor line quality The carriage bushings may need replacement if worn out thus a lower carriage head height 7 Change media to see if electrostatic discharge from media is causing the banding to occur Add 3rd party protection if required a static eliminator strip with carbon fibers running the length of the strip may be necessary to dissipate discharge values in excess of 25KV If 3rd party protection is added to the printer ensure the strip is grounded to the Main PWA ground properly 8 Perform the carriage vibration test under Diagnostics Menu the lines should print fine lines with no jagged edges 9 Printatest plot off the Demo Images CD If no overspray or similar problems show then check the software driver or original file Draw a s
95. ce Manual Table of Contents cont Chapter 4 Troubleshooting cont 176 a 4 28 Banding Differences 4 30 FOnZOMtalBandiniG naa ee 4 31 Vertical Banding 4 43 Line Quality Problems Overspray 4 46 Cartridge Warranty 4 47 Cartridge Maintenance amp Testing 4 48 In Starvation 4 52 nio E 4 57 Color Test Problems 4 60 Unrecognized Cartridge Error Message 4 63 Paper Sensor 2 4 65 Encoder Sensor EMOT deo ono Un 4 68 AutoLoad Paper Sensor Error 4 69 cama gAs Eror acd op RE PUGNO 4 70 Initialization Failure 4 75 Media Sensor Reference Points Not Initialized 4 79 Hardware Failures Diagnostic Tests 4 79 Dryer Failure Sensor Error 4 81 Intermittent Problems Continuity 4 86 Reinitializing the Printer 4 95 Printer Hesitation Networking Problems 4 96 Parallel TOS a od du cud o 4 100 Firmware Downloading Procedures 4 101 P FIDES si 4 101 880
96. cessed before printing each pass Troubleshooting 4 97 NovaJet 800 Series Service Manual Suggest increasing memory to 256 MB for low pass print mode opera tions Typically this only affects CAD computer aided design users that send HP GL 2 files vector to the printer File format examples include plt and hp2 Miscellaneous Notes Note NT does not support ECP parallel port mode an additional parallel port PCI card must be installed or a configuration with a network and print server is suggested Also turn off the Video ROM shadow in the BIOS as this can cause a 20 overhead on the CPU Verify the Win dows Screen Saver is always turned off as this may cause hesitation as well 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 this elimi nates the hesitation For hesitation associated with only vector files such as plot or hp2 files the problem could be insufficient memory Increase printer memory from 64MB to 256MB To prove printer performance select the Pause feature and wait 20 to 30 seconds before de selecting Pause If printer is working properly the carriage head should stop hesitating and production performance should increase for a short period of time Network Connectivity The printer comes with a built in 100 network board which inter faces via two cables an SEH server or an onboard built in Ethernet port If you are u
97. coder strip replace encoder sensor replace outrigger bushings Troubleshootina 4 4 NovaJet 800 Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Internal ERROR Encoder Sensor Failure WOrn carriage bushings loose trailing cable connections cutter assembly malfunction damaged carriage drive belt system faulty trailing cable e encoder sensor cable unseated bad encoder sensor main PWA encod er sensor jack defective replace carriage bushings remove power and reseat trailing cable connections at the MPWA and the carriage assemblies replace cutter assembly 1 check idler tension assembly 2 check carriage belt replace trailing cable assembly reseat encoder sensor cable replace encoder sensor replace main PWA Troubleshootina 45 NovaJet 800 Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Internal ERROR Sensor Failure Internal ERROR Auto Load Paper Sensor Failure servo motor and vaccuum fan connections to MPWA are switched paper sensor cable unseated bad trailing cable assembly bad paper sensor e servo motor disconnected trailing cable connection 15 faulty eauto load paper cable unseated bad auto load paper sensor reattach connections correctly use Figure 3 4 for reference reseat paper sensor cable replace trailin
98. d Cartridge Failure Analysis Steps 1 Besurethe cartridge is the correct cartridge for your printer model Your printer will not work with cartridges from other models Remember the printer is reading the value programmed into the chip on the cartridge it is not actually detecting the cartridge type Replace the cartridge to verify a failure 2 Check MSB version Select Utility Menu Service Menu About 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 Replace Main PWA Troubleshooting 4 63 NovaJet 800 Series Service Manual Figure 4 67 Cartridge Identification Chip Itis possible the ID chip on the rear of the cartridge may have slipped from its original position Verify the double dimples 2 small circles on flex cable have been penetrated at or near the center of each circle If not the chip is out of position or is not mating correctly within the carriage assembly After correcting reattach cartridge message should clear automatically after selecting OK To clear the error turn the printer off and then on again Press Utility Menu Service Menu Cartridge Info to determine the cartridge for which the error message is displayed The incorrectly registered cartridge will have two asterisks displayed Press Utility Menu Access Menu Access Right to
99. default setting Magenta M 0 default setting Cyan C 0 default setting Black K 0 default setting 1 0 default setting 2 0 default setting 3 0 default setting 4 0 default setting Troubleshooting 4 58 NovaJet 800 Series Service Manual As mentioned above the ambient or surrounding temperature does have an effect on the heating of the ink ENCAD has established that these settings will be adequate for most installations However if the printer is in an environment that is hot or that the temperature changes a lot throughout the day you may have to modify the settings to compensate for your own individual circumstances The preheat settings are factory set to aid in the minimizing of ghosting and or ink density issues With this in mind lowering the settings could cause improper output to appear The settings of the preheat will be dependent upon your environmental condition as well as the type of image and the colors that you are repro ducing One particular setting of the preheat may not be correct for every print application To check the preheat settings for the problem color i e Cyan dropout problem 1 From the main menu select Setup Menu 2 Fromthe Setup Menu select Ink Option Menu 3 Fromthe Ink Option Menu select Ink PreHeat Menu 4 Fromthe Ink PreHeat Menu select Cyan Preheat 5 Presseither Prev Option or Next Option until the value 0 zero is displayed 6 Press to accept the selecti
100. dules The printer will accept 64 MB 128 MB or 256MB DIMMs Serial EEPROM Serial EEPROM is an Electrically Erasable Programmable Read Only Memory which provides storage for calibration constants and user configuration data entered from the host computer An 8K bit serial nonvolatile EEPROM stores calibration and configura tion information It retains data while the unit is off Stepper Motor Controller af ARRAY WAvE C Ih 2j ES CLUE FEHIT a AFFE MBE MOTOR Figure 2 7 Stepper Motor Controller The media is driven by a Stepper Motor which drives the media in a direction perpendicular to the width of the printer The media the printer can advance forward and backward depending upon the Theory of Operation 2 11 NovaJet 800 Series Service Manual commands which the Stepper Motor receives from the microprocessor The Stepper Motor Controller contains two identical circuits one for each winding of the stepper motor The circuit is a combination of two simpler types of circuits and can be thought of as a variation of either one A waveform generator receives digital data from the gate array and generates a sine wave output This signal is fed into a comparator circuit that is measuring the current through the winding of the stepper motor If the current is too low a pulse of 24V is generated When the current goes above the output of the waveform generator the pulse turns off Ev
101. e Left and Right Covers following procedures outlined earlier in this chapter 2 Remove the Ink Delivery System Carriage Assembly and Trailing Cable Assembly following procedures outlined earlier in this chapter 3 Remove the Chain Support Bracket by slightly tilting the top of the Chain Support Bracket towards the front of the printer and lifting it straight up See Figure 5 27 CHAIN SUPPORT BRACKET RESTS ON THE TOP OF THE Y ARM ASSEMBLY Figure 5 27 Stabilizer Bracket Installation Removal Assembly Disassembly 5 43 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 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 Install the Stabilizer Bracket and Encoder Strip 1 Install the Stabilizer Bracket Assembly with Encoder Strip onto the Y Arm Assembly using the four alignment Allen screws and washers Hand tighten only 2 Install the Chain Support Bracket onto the Stabilizer Bracket Assembly by placing the Chain Support Bracket onto the Stabilizer Bracket with a slight forward tilt 3 Install the Carriage Assembly Trailing Cable Assembly and Ink Delivery System following procedures outlined earlier in this chapter 4 Install the Top Left and Right Cover
102. e Manual Figure 4 14 Service Station If failures are occurring within 40 ml of ink throughput improper cleaning of electrical contacts on carrier or a connectivity problem probably exists Driver chips on the carriage PCB are known to have blown multiple cartridges in a row and vice versa Some cartridges can affect other cartridges via the flex driver cable connectivity Use post it note trick attach a post it note to the electrical contacts on rear side of print head or cartridge but do not cover the two identification circuit chip contacts to diagnose the defective cartridge in these cases Figure 4 15 Defective Cartridge Power Lines Initially cartridges should be replaced but further investigation 1 required Troubleshooting 4 27 NovaJet 800 Series Service Manual Some types of address line and power line failures are below Figure 4 17 Power Line Failure Figure 4 18 Address Line Failure iit id i 7 Figure 4 19 Multiple Address Line Failure Microbanding Minimal microbanding normally occurs in the production modes 1 2 and sometimes 3 pass print modes with dense images and depending on the color fill it may occur in the photo mode but should never occur in the enhanced modes The lighter pastel shades quite often exhibit microbanding Troubleshooting 4 28 NovaJet 800 Series Service Manual Figure 4 20 Microbanding Refer to the following table for the differences between quality
103. e calculations are being performed to time the release of the ink drop so that they land on the media at the correct location Differences in media thickness make the distance that the ink has to fall vary and this variable needs to be compensated for in the calculations To perform the Color Deadband Alignments 1 Select Utility Menu from the Main Menu This brings up the Utility Menu as shown in Figure 3 19 Select the Calibration Menu from the Utility Menu This brings up the Calibration Menu as shown in Figure 3 25 Use Paper Calib Open Jet Menu Paper Axis Test Paper Axis Color Db Menu Figure 3 25 Calibration Menu Select the Color Db Menu from the Calibration Menu Maintenance 3 37 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 Color Db Test Figure 3 26 Color Db Menu Select Color Db Test to run the color deadband test The test consists of 12 default calibration settings When the test is run it will print out a pattern of 5 calibration lines for each of the 12 settings It will print this pattern for 1 C 2 M 3 Y 4 Also printed will be the current settings for each of the four six or eight cartridges as well as the slow deadband setting 5 When the plot is complete select Left at the Color Db Menu then 4 Deadband This brings up the options menu as shown in Figure 3 21 to perform the
104. e is unable to read the plenum temperature for one minute or longer Typically a negative temperature indicates a broken connection in the thermistor to main board connection If unable to read the tempera ture the firmware is receiving bad data from the Dallas Bus The dryer firmware will shut down the dryer by switching to OFF mode turning the heater power off and turning the fans on automatically The dryer will remain in this shutdown state until power is recycled Additional information will be displayed if the F6 panel button is se lected second button down on the right side of control panel and held down If Dryer Mode displays OFF or AUTO the target heater temperature will be displayed in degrees C In addition if the heater power is on a character will also be displayed If Dryer Mode displays DISABLED the error temperature will be displayed on the Plenum T line immediately after either Hdw Fault or T Error This error temperature value indicates the plenum thermister Troubleshooting 4 83 NovaJet 800 Series Service Manual reading that was sampled when the detected error occurred Failure Analysis 1 2 4 Ensure all logic cable and power cable connections are intact Check lower leg harness cable plug connections between right stand leg and platen plug and connection between upper leg harness cable and Main PWA Perform electrical pin out to verify c
105. e 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 Move the Carriage Belt to the left so it is out of the way of the Servo Motor pulley Move the Carriage Assembly to the left end of the Slide Shaft Lift up gently and hold the right end of the Trailing Cables Remove the back screw on the Servo Motor The screwdriver will be held at a slight angle Be careful not to strip the head of the screw or to cause damage to the Encoder Strip Assembly Disassembly 5 19 NovaJet 800 Series Service Manual 11 Lower the Trailing Cable back into place 12 While holding the Servo Motor remove the front screw on the Servo Motor 13 Lower the motor to clear the platen and carefully bring the motor out of the printer Install Servo Motor 1 Reinsertthe Servo Motor under the Platen with the connector facing the FRONT side of the Platen Guide the pulley up through the opening in the Platen 2 Oncethe Servo Motor pulley is through the Platen push up on the Servo Motor and align the screw holes with the screw hole openings Insert the front screw into the Servo Motor and tighten it almost all the Way 4 Liftup gently and hold the right end of the Trailing Cables Make sure the screw does not go into the motor at an angle and be careful not to strip the head of the screw or to cause damag
106. e power supply is used for cooling the power supply Air blows over the power supply and the heated air 15 forced out the back of the printer It also blows air on the temperature and humidity sensors so they can measure ambient conditions more accurately A fan 15 located inside the platen with its fan vent seen from under the platen on the right side of the printer This fan provides suction on the platen bed and holds the paper media flat during the printing process The 60 inch model has an additional suction fan located near the center of the printer inside the platen Two fans are located inside the dryer plenum body to draw ambient air inside to be heated These fans are tested when power is applied to the printer Theory of Operation 2 21 Maintenance 3 Introduction This chapter contains general maintenance and cleaning instructions for the NovaJet 800 series printers Scheduled Maintenance Scheduled maintenance consists of a list of checks that are planned to be performed on a regular basis or when conditions warrant it Scheduled maintenance can be thought of as preventive maintenance since its purpose 1 to prolong the life of the printer It is not intended to repair or isolate an existing problem though it can sometimes be helpful in detecting a condition due to a weakened component that has not yet completely failed Below is a list of scheduled maintenance checks and their recom mended periodicity Cle
107. e preheat settings under the Ink Option Menu Symptoms include horizontal bands that recover in all cases and the typical banding pattern can either be consistent or inconsis tent Please refer to the illustration below of the typical symptoms encountered Note the vertical edges of the print are not skewed or exhibit swath shift If swath shifts are observed then this 1s a servo motor or bushing problem NOTE The horizontal bands do not extend beyond the page layout or edges of the print Troubleshooting 4 57 NovaJet 800 Series Service Manual Figure 4 61 Excessive Ink PreHeat Settings The preheat settings are factory set to default settings of O zero and are dependent upon the installed ink set These settings are to aid in the minimization of ghosting and or ink density issues The preset heater settings in conjunction with the ambient or surrounding temperature could be causing the cartridge to get too hot This could cause the ink to boil inside the jetplate and create air bubbles Air bubbles in the ink will result in ink starvation and dropout problems Excessive heat also causes the viscosity to reduce gets thinner which can create pooling or puddling on the jetplate This in turn can result in random spitting and burping due to excessive accumulation of ink on the jet plate The following preheat settings are recommended for each stall position to prevent ink starvation and dropout from occurring Yellow Y 0
108. e to the Encoder Strip 5 Insert the back screw into the Servo Motor and tighten it 6 Tighten both screws on the Servo Motor to 15 in lb of torque 7 Slide the Carriage Belt over the Servo Motor pulley Make sure that the guides on the inside of the belt are inserted in the pulley grooves and that the belt is not twisted 8 Turnthe Belt Removal Tool to tighten the belt around the Servo Motor pulley 9 Move the Carriage Assembly back and forth to check the Carriage Belt tension Remove the Belt Removal Tool Assembly Disassembly 5 20 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 Ibs 11 Connect the Servo Motor connector to J12 on the Main PWA 12 Install the E Connect Network Assembly and the Top Left and Right Covers following procedures outlined earlier in this chapter Remove the Ink Delivery System 1 Remove the Top Left and Right Covers following procedures outlined earlier in this chapter Remove the screw securing the Chain Guide to the Chain Support Bracket See item A in Figure 5 11 Figure 5 11 Chain Guide Removal Remove the screw securing the back part of the Ink Delivery System to the Chain Support Bracket See item B in Figure 5 11 Hemove the screw securing the Ink Delivery System Bracket to the Left Frame See item A in Figure 5 12 As
109. ead screwdriver into the gap between theLeft Cover and the Left Frame as shown in the lower portion of Figure 5 2 and twist Insert and twist into as many gaps as necessary to loosen the cover from the frame 5 Carefully lift the Left Cover up and off the printer Assembly Disassembly 5 4 NovaJet 800 Series Service Manual Install the Left Top and Right Covers To install the Left Cover 3 Position the Left Cover over the Left Frame and while depressing the retracting stop assembly on the Support Bracket lower the Left Cover into position onto the Left Frame Release the retracting stop assembly 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 Using a 2 Phillips screwdriver secure the Left Cover with two screws located under the frame torque to 8 in Ibs Heinstall the ink reservoirs and reservoir door To install the Right Cover Assembly 1 Position and hold the Right Cover Assembly over the Right Baseplate and reconnect the Display data ribbon cable to J10 on the Main PWA the Keypad flex cable to J9 on the Main PWA Ensure that the caution label on the flex cable is facing the DIMM slot While depressing the retracting stop assembly on the Support Bracket lower the Right Cover Assembly into position onto the Right Baseplate Release the retracting stop assembly Assembly Disassembly 5 5 N
110. eft Frame Assembly Install the Ink Delivery System following procedures outlined earlier in this chapter Install the Top Left and Right Covers following procedures outlined earlier in this chapter Assembly Disassembly 5 53 NovaJet 800 Series Service Manual Remove the Lower Roller Assembly Stepper Motor and Vacuum Fan NovaJet 880 1 10 11 12 13 14 To remove the stepper motor lower roller first remove power from the printer Unplug the dryer power cord and disconnect the dryer logic cable Remove dryer by pulling locking pins and lifting straight up Remove the flattening roller thumb screws and remove the flattening rollers Disconnect the SEH print server from the parallel port if connected Remove all cartridges from the printer by lifting the valve actuator and pulling the septum needle free Remove all ink reservoirs by depressing on the valve tabs Remove the top cover by pulling on the retracting stop at the left end remove by pulling cover to left slightly to dislodge tab at the right end To remove the right cover locate and remove the 2 inside right cover screws Locate and remove the 3 bottom right cover screws Disengage the retracting latch between right cover and rear cover pull up and ease right cover over on one side Remove two control panel connections to the Main PWA Remove the right cover To remove the left cover remove the two bottom screws securing the left cover
111. ensor This could also be due to a faulty power supply The paper sensor should sense the platen on the return trip but may fail to do so no error code given Replace paper sensor on the right carriage in this situation unless the power supply is proven defective first Disconnect the servo motor and stepper motor connections at Main PWA Check for proper voltages with the various loads isolated Replace motor as necessary Refer to Disassembly Replace the memory module if not already performed Refer to Disassembly Replace the Main PWA in all other cases Refer to Disassembly Troubleshooting 4 78 NovaJet 800 Series Service Manual Media Sensor Reference Points Not Initialized Hardware Failures Diagnostic Tests Quick Troubleshooting List 1 6 Send atest image PRT or RTL directly to printer to verify a hardware failure If the carriage stops during normal travel clean encoder strip slide shaft bushing belt reseat trailing cable connections if necessary Check feed take up modes and operation Run a legs test under Diagnostics Reseat all printer cable connections Refresh the printer firmware Figure 4 81 Main PWA LED Operation Check Main PCB LED s light emitting diodes 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 1 e during paper sensing operations D10 Normally
112. ent in the spring Perform steps 4 and 5 for all pinch rollers Secure the Y Arm Assembly to the Platen Torque to 15 in lbs Install the Stabilizer Bracket Carriage Assembly and Trailing Cable Assembly following procedures outlined earlier in this chapter Install the Ink Delivery System following procedures outlined earlier in this chapter Install the Top Left and Right Covers following procedures outlined earlier in this chapter Perform the Head Height Adjustment procedures found in Chapter 3 of this service manual Assembly Disassembly 5 47 NovaJet 800 Series Service Manual Remove the Gap Sensor NovaJet 880 only To remove the print gap sensor 1 Remove the top cover by pulling on the retracting stop at the left end remove by pulling cover to the left slightly to dislodge tab at the right end 2 Locate and remove the 2 inside right cover screws 3 Locate and remove the 3 bottom right cover screws 4 Disengage the retracting latch between right cover and rear cover pull up and ease right cover over on one side 5 Remove two control panel connections to the Main PWA 6 Remove the right cover 7 Disconnect print gap sensor from J3 wiring harness extension plug Remove 2 screws securing sensor Twist sensor slightly and remove Remove the Lower Roller Assembly Stepper Motor and Vacuum Fan NovaJet 850 The Inner Platen contains the Lower Drive Roller Assembly the Vacuum Fan Assembly ies the Stepper M
113. eplace outrigger bushings Troubleshootina 4 13 NovaJet 800 Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Line Quality Degraded carriage bushings worn e debris or obstruction in fan drive belt slipping on idler hardware or assemblies loose carriage height too low lower drive shaft gears are dirty or misaligned e noisy Servo motor e noisy stepper motor ink cartridges dirty or clogged cartridge dimple region dirty or damaged replace carriage bushings 4 clean fan assembly replace frame tensioner spring or idler tighten hardware or assemblies perform Carriage Head Height Adjustment clean and or realign lower drive shaft gears replace servo motor replace stepper motor clean and prime ink cartridges clean or replace cartridge Troubleshootina 4 14 NovaJet 800 Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms color calibration needed deadband calibration needed in bidirectional printing mode debris or lubrication on slide shaft leaks or bubbles in ink delivery lines dirty encoder strip eoutrigger bushings worn carriage bushings worn e drive belt worn e drive belt slipping on idler vacuum fan not operating perform Color Calibration perform Deadband Calibration clean slide shaft 1 reseal prime ink delivery lines on both sid
114. er off of the leg enough to disconnect the motor wires from the leg harness Using a standard ohmmeter or multimeter measure between the and connections on the motor While manually rotating the servo motor monitor the readings on the meter The acceptable range is 25 40 ohms Typically the reading is 29 36 ohms If the measurement is found to be unsatisfactory replace the motor Perform the same procedure on the remaining motor Banding Hardware vs Software The technician must be able to identify whether the banding that is being observed 15 related to either a hardware or a software problem The two examples in Figure 3 10 represent classic types of hardware and software banding errors Maintenance 3 16 NovaJet 800 Series Service Manual Banding Differences Consistent horizontal banding is usually hardware related Normally horizontal microbanding is caused by improper color deadband or color calibrations dirty cartridges or service station Inconsistent banding is usually software related However electrostatic discharge ESD from media i e Backlit Duratrans films can also cause inconsistent horizontal banding While minimal microbanding in an image typically occurs due to cartridge jet failures and clogs dirty service station or an improper calibra tion of the printer gross microbanding can be caused by a dirty encoder strip causing image skew or real hardware failures Vertical banding is always hardware rela
115. eration 6 If ink cannot be pulled through the line using the EasyPrime device ensure the device is functioning correctly by verifying suction and check the 4 AA batteries in the unit Replace the 4 AA batteries in the EasyPrime unit Troubleshooting 4 55 NovaJet 800 Series Service Manual 7 Always run a color test 10096 in the 2 pass print mode to verify the proper pressure levels have been achieved within the cartridge 8 Replace the septum connector and attached cartridge tubing needle 9 Replace reservoir tubing needle 10 Replace the blue or gray valve in the floating carriage cover Refer to Disassembly 11 Replace the blue or gray female valve near reservoir 12 Replace the ink reservoir ni bh PuEUmpER pee E Figure 4 59 Reservoirs and Ink Delivery System 13 Replace the ink delivery system Troubleshooting 4 56 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 Ink Dropout If the printer is experiencing ink dropout or temporary ink starvation conditions it can be improved by modifying th
116. ervice Menu Cartridge Info There is a 500 ml warranty on the print heads the cartridge shuts off at 1280 ml NJ850 or 1500 ml NJ880 with a tridge End of Life message and the cartridge must be replaced Note replace defective cartridge with a warranty cartridge if less than 500 ml throughput and a problem cannot be corrected with cartridge cleaning or manual jet bypass see Cartridge Maintenance amp Testing below Troubleshooting 4 47 NovaJet 800 Series Service Manual Perform Cartridge Maintenance 4 Testing before calling technical support or your service representative These steps must be performed before cartridges will be replaced in any event Cartridge Maintenance amp 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 10096 or 500 ml of ink throughput the cartridge has reached its warranted life ENCAD s cartridge management system assures the highest quality and reliable productivity through the useful life of the cartridge which may extend beyond the cartridge warranty period In order to ensure the quality of output the cartridges will shut off after 1280 ml NJ850 or 1500 ml NJ880 of ink throughput If the cartridge has reached the end of its life it should be
117. ery time the output of the waveform generator is changed by the micropro cessor the motor moves 1 micro step Each circuit contains four main functions see Figure 2 7 1 Reference waveform generator the gate array uses a D A digital to analog converter to set the desired level for the current in the stepper motor winding The output of the D A converter varies in time to create a reference waveform This reference waveform is centered around 2 5V 2 Motor current sense the voltage across a series current sense resistor 1 mea sured and level shifted so that it 15 centered around 5 3 Comparator this portion divides the output of the reference waveform generator by two and compares it to the output of the motor current sensor Logic inside the gate array generates the control signals for the power driver that applies voltage across the motor winding in order to make the actual current match the reference waveform 4 Power driver an H bridge allows the supply voltage to be applied across the winding in either polarity used to drive the current level to the desired value Theory of Operation 2 12 NovaJet 800 Series Service Manual Servo Motor Controller mm ii i i i MOTOR SERVO DRIVER CONNECTOR CARRIAGE CONNECTOR MAIN PWA i bi CARRIAGE Figure 2 8 Servo Motor Controller The Carriage Assembly is driven by the Servo Motor The speed of the Carriage A
118. es 2 replace ink delivery lines clean encoder strip replace outrigger bushings replace carriage bushings replace drive belt replace frame tensioner spring or idler replace fan assembly Troubleshootina 4 15 NovaJet 800 Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Fan Does Not Power Up Media Take Up Motor Not Operat ing Sensor Works MPWA has 24 VDC at J3 pins 1 2 power not being applied to fan printer not in Take Up Mode bad connection to the motor bad Take Up motor faulty wiring leg harness bad MPWA 1 reseat connection at MPWA to fan 2 replace fan 1 reload firmware 2 replace MPWA put in Take Up Mode under Supply Type from Paper Option Menu reconnect Take Up motor replace Take Up motor reseat or replace leg harness replace MPWA Troubleshootina 4 16 NovaJet 800 Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Media Feed Motor Not Operating Sensor Works Media Feed and Take Up Motors Not Operating Both Sensors Working Media Feed or Take Up Sensor s Not Operating bad connection to the motor bad Feed motor faulty wiring leg harness bad MPWA printer is in Sheet Mode reflective decal is dirty or blocked reconnect Feed motor replace Feed motor reseat or replace leg harness replace MPWA put in Take Up Mode
119. es Clean the bushings with a dry lint free towel if necessary Replace both carriage bushings Refer to Disassembly 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 3 Replace the trailing cable prior to any circuit assembly replacement Replace trailing cable for vertical jumps in color i e one color does not print through one part of the print the image appears to have a vertical pattern or for vertical white spaces down a print Replace the trailing cable if 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 4 Clean or replace encoder strip for image skewing image walking or skipping Typically characterized as horizontal banding often a walking image can also Maintenance 3 22 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 Checkthe print mode normally quality is achieved in the draft normal or best mode The Super Draft mode is 600 x 300 not 600 x 600 like the other modes any compression utilities being used Avoid embedding text onto a layer that is compressed this is known to
120. ewing image walking or skipping Whether the image skews slights or off the page the encoder strip is at fault Typically images which skew will have some horizontal banding often a walking image can also Troubleshooting 4 40 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 oam m n m sums m mom culis n Figure 4 41 Main PWA Failures 21 Replace Main PWA for severe horizontal and vertical banding patterns Also replace Main PWA or for specific internal file failures i e Prime pattern displays a pattern where the same jets in all colors fail to fire even after thorough cleaning and cartridge replacement or if only half of the color calibration prints Refer to Disassembly Troubleshooting 4 41 NovaJet 800 Series Service Manual If the color in an output image tends to vertically shift in color over 1 meter slowly then the Main PWA is suspect of having a problem Figure 4 42 RIP Problem Figure 4 4 Bent Servo Motor Pulley 22 For phantom images in output verify RIP is not causing the problem by performing a demonstration print from the Support or Customer s Demo Image CD Additional problems such as diagonal banding could be due to a defective Servo Motor pulley Troubleshooting 4 42 NovaJet 800 Series Service Manual 23 Di
121. f 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 If the carriage stops at front edge and the media rolls out in front of the printer continuously then the paper sensor is malfunctioning This is probably due to ink covering the platen surface or the sensor optics either on the LED XMTR or Sensor RCVR Clean the platen surface thoroughly or the sensor optics located directly behind the right carriage magenta cartridge flex cable or remove the carriage assemblies and replace the paper sensor Failure Analysis 1 Ink on platen surface is typically the cause of sensing failures Switch to take up mode to verify failure If take up sensing is OK then the platen is the problem The platen may have ink on surface or the surface is damaged tiny cuts in the painted surface exposing the shiny metal underneath 2 Curlin media at left or right edge vinyl canvas exposed to high humidity Certain types of translucent bond media cannot be detected properly 3 Scratches or ink dirt or debris on platen surface Often the printer suffers cuts in the painted surface from the use of a knife to cut media 4 Buffed platen surface some textile and heavy bond media is known to have caused this problem which creates a shiny surface and interferes with normal sens
122. 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 ENCAD Website http www encad com Additional information 15 available though our Technical Support and Service Department s Help Desk ENCAD Inc Technical Support amp Service Dept 6059 Cornerstone Court West San Diego CA 92121 Help Desk Telephone 858 452 4350 or 877 ENCAD TS 362 2387 Help Desk FAX 858 558 4672 International users contact your local ENCAD service provider See details on your ENCAD registration card General Description 1 8 Introduction This chapter explains the mechanical and electrical theory of operation of the ENCAD NovaJet 800 Series Color Inkjet printers The NovaJet 800 Series V 8 print engine has eight ink cartridges eight 500 milliliter ink reservoirs and 12 independent ink lines cartridges are housed in a torque free floating carriage assembly that eliminates micro banding by providing vibration free printing To ensure that prints are dry for unattended printing the printer has a dynamic thermal drying system The printer includes an optically controlled take up and feed system as standard equipment Printer hardware features also include an easy to read LCD display An integrated 100BaseT network connectio
123. g 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 Maintenance 3 43 NovaJet 800 Series Service Manual 4 Select the firmware file in the Files section of the dialog box and press the Print button The firmware file is sent to the printer as a normal print job Approxi mately 20 40 seconds later a single beep should be heard indicating the update was successful After a one second delay the printer will auto matically reboot The printer should come up normally Verify the new firmware revision by sequencing through Utility Menu Service Menu About Menu If multiple beeps are heard reboot printer and reseat your connection to the printer network cable or parallel cable Resend the firmware file to the printer Firmware Download Upgrading for the MAC The normal method of downloading new firmware is to send the file as if it was a standard print job 1 2 Power OFF printer wait 15 seconds Connect an Image Writer cable between the printer and MAC Turn the printer ON 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 Click on File Click on Preferences Select the appropriate port that your printer is connected to either Modem or Printer Drag and Drop the XXXX ROM file or the latest version
124. g cable assembly replace paper sensor check servo motor connections reseat trailing cable right carriage reseat auto load paper cable replace auto load paper sensor Troubleshootina 4 6 NovaJet 800 Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Internal ERROR MPCB Failure Unrecognized Cartridges Error e bad MPWA e faulty connection of cartridge ID chip to flex cable wrong cartridges installed incorrect version e carriage flex cable disconnected e trailing cable connections e faulty trailing cable assembly e faulty carriage PWA replace MPWA check cartridges check cartridges verify MB version MB 87 27 0 and replace MPWA if 27 0 is not displayed check flex driver cable connections reseat trailing cable replace trailing cable assembly replace carriage PWA ensure both boards are the same version Troubleshootina 4 7 NovaJet 800 Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Media Sen Ref Pts Not Initialized NJ880 only Image Skews or Moves Does Not Print reference points were accidentally cleared dirty encoder strip defective encoder strip bad connection between computer and printer e firmware 15 corrupted defective trailing cable assy faulty quad flex cable either left or right carriage assembly reset all eleven refer ence p9o
125. h the quick disconnect assembly behind the Power Supply Bracket and out of sight 7 Install the Main PWA Top and Right Covers following procedures outlined earlier in this chapter Remove Servo Motor 1 Remove the Top and Right Covers and the E Connect Network Assembly following procedures outlined earlier in this chapter 2 Disconnectthe Servo Motor connection red and blue wires at the J12 location on the Main PWA by grasping the Servo Motor connector with thumb and forefinger and pulling straight out 3 Remove the E Connect Plate located below the Servo Motor Move the E Connect power cable into the platen and out of the way 4 Obtain the Belt Removal Tool spin the movable side to shorten the distance between the two brass pieces 5 Insertthe Belt Removal Tool between the Left Frame Assembly and the Frame Tensioner See Figure 5 10 Ensure that the movable side is against the Left Frame Assembly and the non movable side is against the Frame Tensioner Assembly Disassembly 5 18 NovaJet 800 Series Service Manual 10 0 gt Figure 5 10 Using the Belt Removal Tool Turn th
126. he Frame Tensioner Insert the Compression Spring into the opening in the back of the Frame Tensioner so that the end of the spring fits over the post inside the opening Fit the Compression Spring over the post at the back of the Y Arm Assembly Fit the notch in the front end of the Frame Tensioner over the notch in the front of the Y Arm Assembly Obtain the Belt Removal Tool spin the movable side to shorten the distance between the two brass pieces While holding the Frame Tensioner in place insert the Belt Removal Tool between the Left Frame Assembly and the Frame Tensioner See Figure 5 10 Ensure that the movable side is against the Left Frame Assembly and the non movable side is against the Frame Tensioner 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 over the Servo Motor pulley Slip the Carriage Belt over the Servo Motor pulley Make sure that the guides in the Carriage Belt are properly fitted over the Servo Motor pulley and that the belt is not twisted Assembly Disassembly 5 30 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
127. he gate array contains the hardware logic for dot firing monitoring changes in the Carriage Assemblies position controlling DMA through the parallel port and generating the PWM Pulse Width Modulation waveforms for the servo controller It also controls the stepper motor LCD and keypad The gate array is a Xilinx device It is a static RAM based field pro erammable gate array This means that the logic that it implements 15 determined by configuration information in internal RAM storage Each time power is turned on this information must be downloaded from the system ROM This type of gate array allows for the flexibility of upgrading the logic by simply downloading the new system software Digital Signal Processor DSP The DSP converts raster data into the head buffer data format used by the printheads The gate array tells the DSP when to send data to the carriage The DSP runs at 192 MHz It has 32M of dedicated SDRAM that 15 separate from the DIMM the PowerPC uses Theory of Operation 2 9 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 1s as follows SDRAM 256 MB Flash EEPROM 2 MB Serial EEPROM IKB Flash EEPROM Flash EEPROM is Electrically Erasable Programmable Read Only Memory used to store
128. hen using this table Ensure that all applicable software diagnostic tests have been properly executed all visual indications including LED status have been observed and all applicable pushbuttons have been depressed to obtain a complete list of symptoms to be applied to the table below Use the table in conjunction with Chapter 3 Maintenance whenever the table prompts you for additional information This information may be in the form of an illustration additional data or a procedure that needs to be performed Table 4 1 Troubleshooting Table Symptoms No Power printer not ON depress power switch faulty power replace power cord cord AC input not replace AC entry Troubleshooting 4 1 NovaJet 800 Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms No Power Initialization Failure e printer not ON faulty power cord AC input not present at power supply DC output voltage not present see Figure 3 32 for pin out DC voltage present at MPCB e DIMM unseated defective or missing e faulty take up or feed motor if installed faulty leg harness cable power supply defective depress power switch replace power cord replace AC entry module replace power supply replace MPCB reseat or replace DIMM replace motor disconnect at J3 on MPWA to test replace as necessary replace power supply Troubleshootina 4 2
129. hooting 4 1 Chapter 5 Assembly Disassembly 5 1 Thermal Dryer PWA Connections 5 65 XXIII NovaJet 800 Series Service Manual General Description 1 Figure 1 1 NovaJet 800 Series Inkjet Printer Introduction This manual provides service information for the ENCAD Inc NovaJet 800 Series Color Inkjet Printers The NovaJet 850 printer is available in two sizes a 42 inch model and a 60 inch model The NovaJet 880 printer is available in a 60 inch model It is written for service personnel who possess analog and digital circuitry experience Chapter 2 Theory of Operation should be read and thoroughly understood before troubleshooting calibrating the printers The printers support pre cut and roll media Media size 15 automatically determined hardclip limits are set accordingly Pre cut media uses different maximum plotting areas than roll media See the Printer Specifications in the User Reference Guide for more details on the media size printable area General Description 1 1 NovaJet 800 Series Service Manual A Centronics parallel connection 1 provided to interface with the host computer Commands sent from the host computer can be in several forms including HP GL 2 HP RTL and Encad RTL formats Drivers are supplied to support Windowse based PCs 95 98 ME NT and 2000 as well as Macintosh and Power PC computers These printers expand upon ENCAD
130. ice Manual FIGURE ITEM PART NAME PART 6 6 1 ACTUATOR VALVE eee eee 214886 01 6 6 2 214521 00 6 6 3 VALVE ASSEMBLY BLUE 215703 01 GRAV 215702 01 6 6 4 CARRIAGE COVER ASSY 215663 03 P O INK DELIVERY SYSTEM 60 217294 00 P O INK DELIVERY SYSTEM 42 217295 00 6 6 5 SUPPORT LEFT CARRIAGE aS 214922 01 6 6 6 SUPPORT RIGHT CARRIAGE CONV BR TEN 214923 01 6 6 7 CARRIAGE BUSHING SET Q 209568 6 6 8 KIT CARTRIDGE SEPTUM A 215505 01 6 6 9 WHEEL CARRIAGE COVER ASSY 217233 01 Parts List 6 12 NovaJet 800 Series Service Manual Figure 6 6 Floating Carriage Cover Parts Breakdown 6 13 Parts List NovaJet 800 Series Service Manual FIGURE ITEM PART NAME PART SERVICE STATION ASSY eee 214393 03 Parts List 6 14 NovaJet 800 Series Service Manual Figure 6 7 Service Station Parts Breakdown 6 15 Parts List NovaJet 800 Series Service Manual FIGURE ITEM PART NAME PART 6 8 1 SHAFT ASSY W FIXED RT SIDE GUIDE ADJ 2 AND CLAMP 3 207657 1 207657 2 6 8 2 GUIDE PAPER ADJUSTABLE 207644 6 8 CLAMP GUIDE PAPER e 207659 6 8 4 SENSOR 207727 6 8 5 SENSOR BRACKET TOP ASSY 207656 1 6 8 SENSOR BRACKET BTM ASSY 207752 1 6 8 7
131. ies prints up to 100 sq ft hr 250 ink saturation The dryer system easily mounts to the stand assembly The dryer logic cable connects the dryer to the right leg logic jack The dryer power cord plugs into the power entry module at the rear of printer The thermal drying system is composed of the dryer plenum logic cable and Main PWA humidity and temperature sensors The dryer typically stays on for approximately 3 minutes following a print job when the Dryer is in the on mode Auto Cut Delay is the time set between successive print jobs dry time between prints The Dryer PWA has two thermistors which provide feedback to the Main PWA firmware to raise or lower temperature inside the plenum The firmware in turn drives the dryer PWA Triac attached to heatsink to deliver the current to the two 1200 watt heating elements The dryer may be turned on off or placed into the auto mode The maximum temperature obtainable is approximately 52 degrees Celsius The 60 unit runs a little cooler than the 42 platform due to the additional length of the 1200 watt heating elements twin 500 to 600 watt elements The glass fuse on the Dryer PWA will normally fail before an active component due to an overcurrent condition Theory of Operation 2 19 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 operatio
132. image may also be pushed slightly to the left side of the printing area Refer to Disassembly CARRIAGE ASSEMBLY Position 15 MATCHED TO VERTICAL BANDING Figure 4 47 Dirty Encoder Strip Clean and or replace encoder strip for image skewing image walking or skipping Typically characterized as horizontal banding often a walking image can also create vertical bands to appear in the print Refer to Routine Maintenance for cleaning or Disassembly for encoder strip replacement Figure 4 48 Defective Teflon Strip Troubleshooting 4 45 NovaJet 800 Series Service Manual 5 Check pinch roller for proper height and encoder stabilizer bracket teflon strip for bubbles Replace teflon strip encode stabilizer bracket assembly if problems persist Line Quality Problems Overspray 1 Check the print mode The enhanced modes should not exhibit any overspray problems Are any compression utilities being used Avoid embedding text onto a layer that is compressed or resized within the application This is known to cause apparent overspray like symptoms when printed Figure 4 49 RIP Error Page Layout Violation NOTE corrupted files during RIP processing or insufficient memory i e at NT workstation particularly can cause a single line to project from an image Are the color deadband and color calibrations correct Refer to Printer Calibrations Check the ink cartridge jet plate for buildu
133. imple box and send to print from application default line thickness should be 0 008 AutoCAD Check printed output for correct line thickness Obtain the Demo Maintenance 3 23 NovaJet 800 Series Service Manual Images CD and refer to Demonstration Print for proper procedures Alignments Adjustments ENCAD NovaJet 850 printers are designed with a minimum of maintenance requirements in mind Calibrations include color calibration deadband alignment and X axis calibration The mechanical adjustment requirements include the slide shaft profile and cartridge head height adjustments They do not require any electrical alignments Slide Shaft Profile Adjustment The NovaJet 850 printers Slide Shaft height is factory set and is firmly mounted on the outer sides and only has adjustments in the middle portion of the shaft to remove any bowing of the shaft s profile The following procedure is to ensure that the Slide Shaft is relatively perpendicular to the surface of the Platen and to remove any bowing that may be present in the shaft s profile The Slide Shaft is set to 1 418 36cm from the top of the Slide Shaft to the Platen surface for the NovaJet 50 printer The normal operating range for the height of the Slide Shaft is between 1 390 35 3cm to 1 440 36 6cm You will need the following Height Gauge Kit Assembly P N 209996 1 4 open and box end wrench 110 thick Head Height Alignment Plate provided with
134. in Figure 3 21 to perform the vertical adjustment on the cartridge located in slot 4 Maintenance 3 33 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 Press Ok to accept the selection and return to the Color Calib Menu 6 Continue until all seven vertical calibrations on the Color Calib Menu have been accomplished 7 Tomake adjustments to the horizontal alignments follow similiar procedures as those above but replace vertical with horizontal The Horizontal Color Calibration printout is shown on the lower half of Figure 3 18 Deadband Alignments Deadband calibration compensates for minute differences created when bidirectional printing is used Unidirectional printing 1s not affected by deadband There are four types of deadband tests Deadband Slow Deadband All Lines Tests Single Line Test Maintenance 3 94 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 15 only a series of vertical lines printed No difference between the top and bottom set of lines to the center set
135. in place Install the Top and Right Covers following procedures outlined earlier in this chapter Remove the Main Printed Wiring Assembly PWA Integrated circuits may become weakened or damaged by electrical discharge Do not touch or work near integrated circuits without wearing an ESD wrist strap Remove the Top and Right Covers following procedures outlined earlier in this chapter Put on an ESD wrist strap Remove memory module following procedures outlined earlier in this chapter Disconnect the Power Supply connection at the J8 location by grasping the Power Supply connector with thumb and forefinger and pulling straight out See Figure 3 4 for jack locations Disconnect the Stepper Motor connection at the J7 location by grasping the Stepper Motor connector with thumb and forefinger and pulling straight out Disconnect the Servo Motor connection red and blue wires at the J12 location by grasping the Servo Motor connector with thumb and forefinger and pulling straight out Assembly Disassembly 5 11 10 11 12 13 14 15 16 NovaJet 800 Series Service Manual Disconnect the Leg Harness connection at the J6 location by grasping the Leg Harness connector with thumb and forefinger and pulling straight out 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 Disconnect the T
136. int 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 Are the ink cartridges contact points flex contacts dirty Clean with isopropyl alcohol Does the Prime pattern print correctly Refer to Routine Maintenance For spitting or random ink droplets landing on the media ensure the cartridges are only half full 20 ml and that humidity ranges 10 to 70 RH non condensing are adhered to Figure 4 2 Excessive Ink Pressure Is the service station clean and working properly Are the seals or wipers worn Clean the service station under running water Ensure all wipers stand up straight in the station Replace service station as necessary Troubleshooting 4 20 NovaJet 800 Series Service Manual Figure 4 3 Dirty Service Station 5 Arethere any signs of leaking ink on or below the inkjet carrier assembly This would indicate an air leak is in the ink delivery system Ensure the septum connector fittings 3 parts make up the septum connector are tight Check all fittings Replace cartridge septum connector and tubing needle reservoir tubing needle and female valve as necessary Figure 4 4 Septum and Valves 6 Replace cartridge printhead and re prime according to the Priming Procedures 7 Is the flex driver cable connections seated properly at ca
137. ints by per forming the Media Ref Pts Alignment clean encoder strip top and bottom replace encoder strip reseat cable connections on computer and printer refresh EEPROM firmware with new download in contin uous run state replace trailing cable assy replace quad flex cable or complete carriage assembly Troubleshootina 4 8 NovaJet 800 Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Ink Cartridge Misfiring bad MPWA cartridge low on ink defective septum needle e ink drop out ink starvation resembling intermittent banding flex contacts dirty or damaged cartridge dimple area dirty or damaged cartridge not seated correctly bad cartridge replace MPWA refill or replace cartridge replace cartridge tubing needle septum assy lower ink pre heat settings 1 perform Flex Cable Contact Cleaning procedures 2 replace carriage flex cable quad 1 perform Cartridge Dimple Cleaning procedure 2 replace cartridge reseat cartridge replace cartridge Troubleshootina 4 9 NovaJet 800 Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Ink Cartridge Misfiring cont Paper Skewing Printer Output is Banding Horizontal service station dirty or not properly sealing cartridge jet area bad carriage PWA bad MPWA paper guides not installed stepper motor geari
138. ion Menu as shown in Figure 3 25 From the Calibration Menu select Use Paper Calib Ensure that Use Paper Calib is set to ON and press Ok This allows the printer to store the data that is entered in step 7 From the Calibration Menu select Paper Axis Test This runs the paper axis test which prints out two T figures that are mirrored from each other and about 33 83 82 cm apart See Figure 3 27 Maintenance 3 39 NovaJet 800 Series Service Manual 33 or 83 82 Figure 3 27 Paper Axis Test 5 With a precision drafters measuring stick measure the exact distance from each of the T intersections 6 Select Paper Axis at the Calibration Menu This brings up the options menu for the paper axis adjustment This menu 1 similiar to the menu depicted in Figure 3 21 7 Using either Prev Option or Next Option rotate through the selections until the exact value of the measurement found in step 5 is selected Press Ok to accept the selection and return to the Calibration Menu Diagnostics Menu The Diagnostics Menu is located in the Service Menu shown in Figure 3 23 and is seen Figure 3 28 Maintenance 3 40 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
139. is insufficient typically 256 MB is suggested Non IEEE 1284 compliant parallel printer cable used for non net Troubleshooting 4 96 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 For NT systems suggest using a unique PCI card to ensure a 1 MB per second data transfer rate APP und al HB IEEE Pai allel 2 3 Parallel Peet J E Connect AN ins ruis Bound nmberpneber 1 Pena Firing gt Butters Ink Speed RTL Causes of Printer Hesitation Figure 4 108 Printer Hesitation Causes Compute Bound When the printer becomes compute bound the print head will hesitate between print passes This occurs when the printers processor cannot keep up with the print swath requirement could occur normally in the one or two pass print modes In the one or two pass print modes all the ink is fired in one pass or two passes to complete a print swath Since a large amount of data has to be computed to complete that swath the print head may have to wait between swaths and depending on the amount of memory in the printer 1 for a plot file stored in memory the printer may have to wait for all instructions to be pro
140. is not binding 25 Install the Ink Delivery System following procedures outlined earlier in this chapter 26 Install the Top Left and Right Covers following procedures outlined earlier in this chapter Remove the Carriage PWA Integrated circuits may become weakened or damaged by electrical discharge Do not touch or work near integrated circuits without wearing an ESD wrist strap 1 Remove the 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 Puton an ESD wrist strap 4 Unlock the connectors and remove all flex cables on the Carriage PWA Assembly Disassembly 5 31 NovaJet 800 Series Service Manual L lt gt Figure 5 20 Carriage PWA Removal installation 5 32 Assembly Disassembly 7 NovaJet 800 Series Service Manual Unlock the latch on the right end of the Carriage and lift up the right end of the Carriage PWA See Figure 5 20 Slide the Carriage PWA to the right to remove the tab on the left end of the Carriage PWA from the slot in the Carriage Failure to use an approved antistatic bag for storage or shipment may cause damage to the Carriage PCB and affect the Warranty Place the Carriage PWA in an ESD bag antistatic bag in preparation for shipment to ENCAD for replacement or repai
141. it Settings A single beep will sound indicating all printer settings have been returned to the printer defaults Always perform a reinitialization Init Settings after conducting a firm ware download This will ensure the cartridge print head preheat settings have been reset to default Troubleshooting 4 95 NovaJet 800 Series Service Manual keda h Sefun Menu Litilitw Menu User Mer Paper ptinz Monu ink Option Menu Boral Camm Menu Ce it dit Seings Setup Menu tility Menu Figure 4 107 Initialization Menu Location Printer Hesitation Networking Problems Hesitation of the printer carriage is normally caused by the parallel port data rate not being optimized Ensure the ECP parallel port mode is utilized or better network the printer Data Starvation Data Starvation normally occurs when the printer has to wait for additional data from the host computer to complete another print pass This phenomenon is due to data not being transferred fast enough from the host computer Several junctions between the computer and the printer can affect the data transfer rate Most common causes of data starvation Computer CPU may be too slow less than a 450 MHz processor Operating System complexity Hard drive space non partitioned drive affects RIPping perfor mance Driver sending file may be too slow must use high speed driver setting on host workstation
142. ivery system 5 21 J jack connections carrier 3 11 3 10 L linear encoder strip 3 4 3 5 M main printed circuit board 2 7 3 8 media feed and take up system 2 6 memory SIMMs 2 11 installation 5 10 menu accessory 3 41 calibration 3 37 calibration deadband 3 36 color calib 3 83 diagnostics 3 41 main 2 18 service 3 36 utility 3 33 motor media feed take up resistance check 3 16 Servo controller 2 13 Index 1 removal installation 5 18 resistance check 3 14 stepper media controller 2 11 removal installation 5 48 5 54 resistance check 3 15 MPCB 5 6 5 7 5 11 N notes 1 4 optical encoder strip 2 5 2 13 P pinch rollers 5 44 power supply 2 19 5 15 H related publications 1 3 S scheduled maintenance 3 1 service station 3 3 5 40 signal flow 3 45 specifications 1 5 technical support ENCAD website 1 8 help desk FAX 1 8 telephone 1 8 test carriage 3 42 color 3 42 continuous 3 42 fan 3 43 NovaJet 800 Series Service Manual legs 3 43 loopback 3 42 parallel port 3 42 serial port 3 42 servo cycle 3 42 servo PWM 3 41 tools required 5 1 trailing cable 5 41 troubleshooting 4 1 banding 4 10 4 12 degraded line quality 4 14 does not print 4 8 fan not operating 4 16 fa
143. k the Trailing Cable A connector to J1 on the Main PWA Connect and lock the Trailing Cable B connector to J2 on the Main PWA Connect the Leg Harness connector to J6 on the Main PWA Connect the Servo Motor connector to J12 on the Main PWA Connect the Stepper Motor connector to J7 on the Main PWA Connect the Power Supply connector to J8 on the Main PWA Reinstall the Memory Module into U24 by following procedures outlined earlier in this chapter Install the Top and Right Covers following procedures outlined earlier in this chapter Remove Power Supply Cooling Fan and AC Entry Module 1 Remove the Top and Right Covers and the Main PWA following procedures outlined earlier in this chapter Ensure that the Main PWA is placed in an ESD bag antistatic bag for protection Reach between the Power Supply Bracket and the AC Entry Module and carefully pull out the quick disconnect assembly attaching the Power Supply input to the AC Entry Module Disconnect the Power Supply input from the AC Entry Module Disconnect the clip securing the power supply wires to the top of the support bracket While holding the Power Supply in place remove the four screws securing it to the Power Supply Bracket See Figure 5 8 Slide the Power Supply out of the Power Supply Bracket Assembly Disassembly 5 15 NovaJet 800 Series Service Manual Figure 5 8 Power Supply Removal To remove the Cooling Fan and AC Entry
144. l be displayed in the printer s control panel display Troubleshooting 4 86 NovaJet 800 Series Service Manual Blue test button g SEH IP ADDRESS 192 168 2 10 Figure 4 89 SEH Activated Test Pattern Figure 4 90 E Connect LEDs 4 For data or communications problems to the printer check parallel port interface by running a E Connect Test quickly depress Test Button at rear of printer at E Connect Box or run a continuous test with loopback cable attached not provided with printer Refer to the Parallel Port Test The Semi Circular Nook test pattern will print This will ensure the network server parallel printer ports the short parallel printer cable 15 39 cm and the Main PWA processor are functioning correctly NOTE The yellow 100 LED should be illuminated indicating a 100baseT network is online As long as the green LED is illuminated printer operations should be successful Troubleshooting 4 87 NovaJet 800 Series Service Manual Figure 4 92 Inadaquate Network Data Transfer Rate Check with the RIP or Print Driver vendor for the latest software upgrades to ensure no conflicts exist with currently loaded firmware To check current firmware version from Main Menu select Utility Menu select Service Menu select About The display will indicate the firmware version as follows MB xx 27 0 where xx is the model type 2 indicates the printer is an ENCAD model 0 indicates that printing is auth
145. l the lower roller stepper motor assembly 1 Place all assemblies on a flat surface Ensure the vacuum fan openings are facing away from the stepper motor Fan 1 should be between rollers 1 amp 2 while fan 2 should be between rollers 3 amp 4 2 Install assemblies into printer together and lock vacuum fans in place first before attaching other assemblies NOTE The thick arm of the center support bracket faces towards the front of the printer on reinstallation Y Arm Assembly Installation Tip NovaJet 880 Before installing the Y Arm assembly loosely attach the right fixed platen end screws do not tighten NOTE When installing the Y Arm assembly alignment of the print head is referenced to the left fixed platen end Install Y Arm by tightening the 4 screws on the left side first followed by the right side screws Ensure the cutter groove is straight across all three platen sections Assembly Disassembly 5 57 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 Ensure that the bracket is being replaced with the correct bracket 1 Remove all media and media rollers from the printer 2 Disconnect the senso
146. lical two beep sequence from step 2 above if successful Cycle power and retest Call technical support if unfamiliar with this procedure Check the AC power entry module continuity and switch operation Ensure plug between power supply and power entry module is intact and connected properly Caution even with the power switch in the off position AC power is still being applied to the dryer plenum Refer to Disassembly Verify the fuse at the Power supply is good 0 5 ohms or less Verify the wire plugs at power supply jack on the Main PWA are properly connected with the plug Retest Check power supply output voltages to Main PWA using a digital voltmeter or hand held voltage meter Select DC measuring scale Ensure Main PWA LEDs are displaying 08 24V available D13 5V available Replace the power supply if the 5VDC or 24VDC levels are absent from power supply output Verify the power source is isolated prior to checking output and also check for grounding of 24VDC signal lines If all voltages are absent replace the power supply If only one voltage is absent then replace Power supply Refer to Disassembly Troubleshooting 4 77 8 10 11 NovaJet 800 Series Service Manual Figure 4 80 Paper Sensor 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 s
147. lways turn the printer OFF remove the power cord and the interface cable before beginning any disassembly pro cedures An electrical shock hazard may be present if these precautions are not followed Remove the Left Top and Right Covers Removing the Left Cover allows access to the left side of the Platen for removal of the Carriage Assembly Carriage Drive Belt Tension Assem bly and the Cutter Activator Also located on this side is the ink reservoirs and the Ink Delivery System portion that is connected to the reservoirs Removal of the Left Cover is a requirement to remove the Lower Roller Assembly and the Vacuum Fan s from inside the Platen Removing the Right Cover provides access to the Main Printed Wiring Assembly PWA Display and Keypad circuits Servo Motor AC Entry Module Power Supply and the Power Supply Cooling Fan The Top Cover needs to be removed before any of the other covers can be removed It also gives access to the Carriage Assembly and the Service Station when in the open up position and the Carriage is at the Carriage Access position To remove the Top Cover 1 Putthe Top Cover in the open position by lifting the front of the Cover to the full upward position 2 Depress and hold the retracting stop assembly located on the left side of the Top Cover to disengage it from the Left Cover Assembly Disassembly 5 2 NovaJet 800 Series Service Manual 3 Lift up on the left side of the Top Cover until it
148. ly 10 For erratic carriage movement at power up reseat the trailing cable and encoder sensor cable connections at the Right carriage PWA Reseat inner trailing cable connection at the Main PWA Ensure all ZIF zero insertion force connections are locked securely Troubleshooting 4 90 NovaJet 800 Series Service Manual Figure 4 96 Servo System Synchronization Error 11 Verify the servo motor resistance values with an ohmmeter or multimeter should be 2 8 ohms 1 5 30 ohms acceptable Replace servo motor if values are out of tolerance Check outrigger bushings followed by the carriage bushings 12 Replace trailing cable assembly Figure 4 97 Probable Defective Main PWA Troubleshooting 4 91 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 or driver most likely Ensure the 1x4 right and 1x4 left cartridge sets are utilized for isolating the defective carriage PWA If problem shows up in both modes then the Main PWA or firmware is at fault Both examples above are extremely rare NOTE Do not replace electronic assemblies for microbanding symptoms Normally the printer calibrations select print mode or cartridge f
149. m the motor 5 Fromthe back of the Cradle ldler disconnect the tension spring from the post located on the Cradle Idler 6 Remove the screw and washer holding the motor mount to the Cradle Idler Carefully remove the motor motor mount and motor gear subassembly from the Cradle Idler 7 Remove the C clamp that is securing the motor gear to the motor 8 Remove the three screws washers and lock washers from the motor mount to remove the motor Install the Media Take Up and Feed Motors 1 Install the three screws washers and lock washers that secures the motor to the motor mount 2 Install the motor gear to the motor Secure with a C clamp 3 Insertthe motor motor mount and motor gear subassembly into the back of the Cradle ldler Tilt the subassembly slightly while installing to align the motor gear with the opening on the top of the Cradle Idler 4 Screw in the screw and washer that secures the motor mount to the Cradle ldler 5 Attach the tension spring to the post on the Cradle Idler 6 Position the Cradle Idler assembly in front of the hole in the leg assembly Attach the wire connectors to the motor red to the positive terminal black to the negative terminal 7 Insert the Cradle Idler Assembly into the leg and secure with four screws Assembly Disassembly 5 60 NovaJet 800 Series Service Manual MOTOR MOTOR MOTOR MOUNT GEAR Gy C CLAMP P CRADLE IDLER Figure 5 33 Media Take Up a
150. move the carriage assembly to the service position to allow replacement of the appropriate ink cartridge Check to make sure you have the correct cartridge for your printer model installed in each position Install new cartridges if necessary Reseat both large flat white trailing cables at the Main circuit board if the above steps do not work Reseat both cables at the carriage PWA s Reseat all flex driver cables at rear side of carriage PWA s Troubleshooting 4 64 8 9 NovaJet 800 Series Service Manual Figure 4 68 Flex Driver Cable Test dc voltage across the 2 IC integrated circuit identification dimples on carriage flex driver cable using a DVM digital multimeter In the DC scale verify that the voltage is jumping from 0 to 5Vdc If the voltage is fairly steady at 5V then the respective carriage PWA is defective Replace both Trailing Cables Replace the Main PWA Refer to Cartridge Warranty Paper Sensor Error The paper sensor error typically happens when a break in continuity occurs in the flexible printed circuit FPC line at the paper sensor assembly The paper sensor assembly 15 the most fragile of the electronic components in the printer exercise caution when installing or the assem bly may break Troubleshooting 4 65 NovaJet 800 Series Service Manual 2 m m LA Figure 4 69 Paper Sensor Initialization Failure One symptom of a defective pape
151. n 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 The printer will normally spit into the service station every 15 seconds GO or GX ink loaded or every 2 minutes GS ink loaded to keep nozzles clear but will not interfere with print and dry time to cause banding of any nature Maintenance 3 19 10 11 NovaJet 800 Series Service Manual Clean the cartridge electrical and carriage flex driver cable contacts with isopropyl alcohol Refer to Scheduled Maintenance 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 Clean the encoder strip top and bottom and inside of carriage belt with distilled water Clean the slide shaft with isopropyl alcohol Change media to see if electrostatic discharge from media is causing the banding to occur Add 3rd party protection if required Ensure vacuum fan is providing adequate suction for media It is possible that binding of the feed roller may also occur leading to microbanding and abnormal print anomalies if the stand legs are not secured to the printer head securely A rocking motion from the weight of the carriage assembly movement during printing is crea
152. n provides seamless network and workstation communication The printer power switch is located at the right rear of the printer The NovaJet 800 Series is a PowerPC 48MHz microprocessor based digital printer that receives plotting instructions from a host computer through the Centronics parallel interface 2 1 NovaJet 800 Series Service Manual NovaJet 800 Series Printers General Block Diagram Figure 2 1 illustrates the major functional areas of the printers The NovaJet 800 Series printers consist of three mechanical assem blies 1 Paper Media Axis Drive 2 Carriage Axis Drive 3 Media Feed and Take Up System and five main electrical assemblies 1 Main PWA Printed Wiring Assembly 2 Carnage Assemblies 2 3 Control Panel 4 Power Supply 5 Thermal Dryer Assembly Theory of Operation 2 2 NovaJet 800 Series Service Manual EIN CARRIAGE AXIS DRIVE PAPER PARRALL PORT ENCODER DIGITAL SIGNAL SENSOR PROCESSOR ETHERNET Bs aaa E Se ue mat ns gt RIGHT CARRIAGE i 55 de PROCESSOR CARRIAGE i PIWS 2 LEFT CARRIAGE ASSEMBLY GATE a POWER ARRAT FEED SUPPLY SENSCR i FEED MOTOR 7 i MEMORY MIECHA x GROUTS TAKE UP ae ae MOTOR MAIN TAKE UP SENSCR mu LOWER 5 STEPPER PAPERASISORIVE DRIVE MOTOR ASSEMBLY LEGEND ELECTRICAL CONNECTION
153. nd Feed Motor Removal Remove the Thermal Dryer Assembly Once the dryer is plugged in there is continuous power being applied to the dryer even when the printer is turned off DISCONNECT POWER CORD BEFORE SERVICING 1 Liftthe entire drying fan assembly off of the printer Assembly Disassembly 5 61 NovaJet 800 Series Service Manual Install the Thermal Dryer Assembly 1 Carefully place the Thermal Dryer Assembly onto the support brackets See Figure 5 34 Secure and torque to 15 in lbs 2 Attach the data cable to the right side of the Thermal Dryer Assembly 3 Attach the Thermal Dryer Assembly power cord the to back of the printer Remove the Thermal Dryer Right Endcap Assembly NOTE The Thermal Dryer Right Endcap Assembly contains the Printed Wiring Assembly for the Dryer Once the dryer is plugged in there is continuous power being applied to the dryer even when the printer is turned off DISCONNECT POWER CORD BEFORE SERVICING Assembly Disassembly 5 62 NovaJet 800 Series Service Manual This assembly emits heat by radiation Disconnect the Thermal Dryer Assembly power cord from the back of the printer Disconnect the data cable from the right side of the Thermal Dryer Assembly Locate and remove the four screws securing the Thermal Dryer Right Endcap Assembly See Figure 5 35 EUER I Q im Figure 5 35 Dryer Right Endcap Removal Installation Carefully pull the Right End
154. ng dirty or damaged lower roller loose lower roller defective if banding is consistent 1 perform Service Station Cleaning procedures 2 replace seal on service station replace carriage PWA replace MPWA install paper guides perform Clean and Inspect Stepper Motor Gears procedure tighten screws securing lower roller replace lower roller assembly 1 inspect and or replace stepper motor perform Stepper Motor Winding Resistance Check Troubleshootina 4 10 NovaJet 800 Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Printer Output is Banding Horz cont insufficient ink in cartridges normally 1 3 full cartridges need to be primed color calibration required paper axis calibration required faulty or corrupt firmware cartridge dimple area dirty or damaged flex cable contacts dirty or damaged 2 inspect and or replace stepper motor gears and or lower roller assembly 3 replace MPWA replace or refill cartridges perform Prime perform Color Calibration perform Paper Axis Test Calibration reload firmware while in continuous run state 1 perform Cartridge Dimple Cleaning procedure 2 replace cartridge 1 clean Flex Cable Contacts Troubleshootina 4 11 NovaJet 800 Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Printer Output is Banding Horizontal co
155. ning Clean the trailing cables bi weekly or as necessary to remove any buildup of debris Distilled water should be used Do not pull too hard on the trailing cables or damage may occur To clean the Trailing Cables 1 Disconnect the power cord and interface cable 2 Slightly dampen a lint free cloth with water and wipe along the length of the trailing cables on both sides Ensure the encoder stabilizer bracket surface is thoroughly cleaned Clean the lower surface of the rear cover on the left side of the printer Reconnect the power cord and interface cable Platen Vacuum Hole Cleaning To clean the external surfaces of the printer Dampen a lint free cloth with water and wipe all surfaces of ink and debris Ensure the platen surface 15 thoroughly cleaned To clean the platen vacuum holes obtain a toothpick and gently remove lint and media fiber from platen holes Caution do not push lint through platen holes or problems with the stepper motor gearing may eventually occur leading to microbanding in image output If the platen holes are not cleaned periodically then adequate vacuum suction be not be available to pull media down during print operations Maintenance 3 5 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 cau
156. ns the printer should be allowed to acclimate to the environment for at least 15 minutes The plenum may be preheated using the F6 key 2nd key from the top at right side of control panel under the Sensor Status Menu The Dryer PWA is internal to the right side of the dryer plenum The green LED D2 on the Dryer PWA indicates that the triac is functioning properly and that power is applied to the two heating elements Sensor Status Menu From the top level menu of the printer navigate the menu tree as follows Utility Menu Service Menu Diagnostic Menu Accessory Menu Sensor Status The printer LCD will display the following information Dryer Mode Plenum T deg C MBoard T deg C MBoard H pct RH Available mode readouts include On Off Auto and Disabled The optical sensors are designed to inform the Main PWA when there is not a proper amount of slack in the media by sensing the curl of the media at the bottom of its loop This method is used so that all approved forms of media including transparent backlit media is able to take advantage of the power feed and take up system Theory of Operation 2 20 NovaJet 800 Series Service Manual Beeper and Fans The beeper contains built in driver circuitry so that 1 beeps under firm ware control The beeper alerts the user to error conditions There exists three types of fans that can be on these printers A single fan located below th
157. nsed the paper sensor sends this information to the Main PWA which immediately begins an out of paper subroutine This subroutine stops the printer from printing until more media 1 loaded NOTE Space lighting must be at a constant level or the paper sense circuitry will create an error and print operations will cease The sensor also checks for the size of the media loaded so it can determine the proper printing parameters The Green LED on the Right Carriage and Left Carriage PWA indi cates the proper drive voltage is available for the driver ICs It is dim when the printer is idle but becomes bright during printing Theory of Operation 2 17 NovaJet 800 Series Service Manual Control Panel The Control Panel is located on the right side of the printer and consists of 8 variable action control buttons and an LCD graphics display The control buttons are assigned to different functions and are dependant upon the selections that were previously selected There are four buttons on the left of the display and four buttons on the right with the display showing up to eight possible selections Load Media Feed Media Menu Cut Setup Menu Utility Menu Figure 2 12 Main Menu Figure 2 12 shows the keypad after the printer has been turned on and finished the start up process As seen in the figure the control buttons are assigned to the corresponding command that is displayed closest to the physical location of the button
158. nt Printer Output is Banding Vertical Printer Output is Banding Horizontally and Vertically carriage assembly obstructed carriage belt is loose too tight worn or damaged outrigger bushings worn or damaged carriage bushings worn or damaged loose trailing cable connections faulty trailing cable assembly dirty encoder strip dirty encoder strip 2 replace carriage quad flex cable check carriage assembly for proper movement along Y arm reinstall check tension assembly and or replace belt replace outrigger bushings and clean slide shaft replace carriage bushings 4 reseast trailing cable replace trailing cable assembly clean encoder strip clean encoder strip Troubleshootina 4 12 NovaJet 800 Series Service Manual Table 4 1 Troubleshooting Table cont Symptoms Keypad Locked Up or Not Functioning Properly Noisy Operation defective encoder strip bad MPWA firmware problem keypad assembly damaged faulty connection between MPWA and keypad bad MPWA e ink or paper debris in printer obstruction in path of carriage outirgger bushings worn clean encoder strip replace MPWA 1 reset printer 2 refresh or up grade firmware while in continuous run state replace keypad assembly reseat or replace connector replace MPWA clean printer remove obstruction clean printer r
159. nt adjustments recommended to perform on the printers Diagnostics and a signal flow diagram are also listed Chapter 4 TROUBLESHOOTING A table containing problems that could occur and possible causes and repairs is found in this chapter This table is not intended to be a complete listing of troubleshooting procedures It will isolate the problem down to the lowest replacable assembly If the problem happens to be the wiring between assemblies standard troubleshooting techniques will have to be implemented to correct the problem Chapter 5 ASSEMBLY DISASSEMBLY Contains detailed procedures to remove and replace printer parts and assemblies Chapter 6 PARTS LIST Contains a complete listing of all field replacable parts and assemblies for the color inkjet printers Illustrated parts breakdown drawings are included to help clarify and identify parts for ordering Special kits and adjustment jigs may also be required ORIENTATION Instructions this manual are based the assumption that the service person is facing the front of the printer References to top view back view and so forth are consistent with this engineering standard References to the X Axis and Y Axis Paper Axis and Carrier Axis respectively follow the standard of AutoCAD absolute coordinates up and down for X left to nght for Y General Description 1 7 NovaJet 800 Series Service Manual Technical Support ENCAD offers full technical support and service
160. nt then starves the second swath prints and then also starves then the cartridge most likely does not have enough ink inside typically the cartridge should have between 15 and 30 ml of ink car tridge ink level will eventually stabilize at 19 ml Check cartridge ink level using the syringe and syringe tip provided with the printer For all other color test printing failures please refer to the failure analysis checks below Figure 4 54 Magenta Ink Pressure Failure Troubleshooting 4 52 NovaJet 800 Series Service Manual Ink System Pressure Theory The ink system works on less than 1 10 psi pressure The reservoir caps should remain loose to allow for atmospheric pressure to push down on the ink to provide adequate pressure on the ink The purpose of the cartridge priming procedure is to establish 2 to 5 inch head pressure in the upper chamber of the cartridge The cartridge must have between 15 and 40 ml of ink inside the cartridge for adequate printing pressure Proper cartridge pressure and ink level is required for long print opera tions Figure 4 55 Ghosting Ghosting is a phenomena of inkjet technology Adjust pre heat levels to help correct The temperature control mode on the NJ880 is the default setting by may be changed to preheat to help offset the ghosting effects observed Troubleshooting 4 53 NovaJet 800 Series Service Manual Failure Analysis 1 Ensure the cartridge is properly primed and pressure
161. nted The available are 10 25 3596 50 65 75 and 100 Continuous Test The Continuous Test sends the printer into a test loop that will perform a series of tests continuously Powering down and restarting the printer or selecting RESET is will exit this test loop The Continuous Test will first prime the cartridges followed by a serial port test parallel port test a fast deadband display and a color calibration display The deadband and color calibration displays are used only as a visual inspection of the operating condition of the printer No adjustments can be performed while in the Continuous Test mode A loopback test cable is required to correctly accomplish the serial and parallel port tests This part of the test is not necessary to perform because the serial port is not used and the parallel port can be tested using the E Connect TEST button The TEST button on the E Connect assembly on the rear of the printer when depressed quickly causes a Semi Circular Nook Test pattern to be printed This will effectively test the parallel ports E Connect and Main PWA parallel port After completing the deadband display the test will begin again with the prime and continue until power is removed Maintenance 3 42 NovaJet 800 Series Service Manual Fan 1 and Fan 2 Tests Tests the operation of the fans on the printer Fan 1 Test while depressed turns on the power supply cooling fan and the suction fan inside the platen
162. o Cartridge Ink Level Check For all other color test printing failures please refer to the troubleshooting failure check below Troubleshooting 4 60 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 1s to check for ink pressure and not the quality of the printed pattern Verify all bars print at 100 ink saturation Abnormal Color Tests Figure 4 64 Abnormal Test Examples A Total ink starvation recheck using the EasyPrime B Partial ink starvation check ink level in cartridge ensure 20 ml installed using the syringe provided Failure Analysis Color Test Incorrect 1 Ensure the cartridge is properly primed and pressure has been established inside the cartridge see Set Up procedures Note when priming the cartridge it is important to ensure the suction end of the EasyPrime assembly is flush against the cartridge jet plate Prime the cartridge using 3 consecutive one 1 second bursts and then wait 3 4 seconds repeat 4 6 times over a 1 minute period A sucking noise should be heard from the EasyPrime when procedure is performed correctly Troubleshooting 4 61 NovaJet 800 Series Service Manual 2 Ensurethe reservoirs are attached to female valves properly at left end of printer or this may cause ink starvation in the ink delivery system af
163. o the folder you created 8 Select the firmware file in the Files section of the dialog box and press the Print button The firmware file is sent to the printer as a normal print job Approxi mately 20 40 seconds later a single beep should be heard indicating the update was successful After a one second delay the printer will auto matically reboot The printer should come up normally Verify the new firmware revision by sequencing through Utility Menu Service Menu About Menu If multiple beeps are heard reboot printer and reseat your connection to the printer network cable or parallel cable Resend the firmware file to the printer Note the parallel cable should not exceed 6 feet or 2 meters NT workstations do not support the required ECP parallel port mode unless a PCI card has been installed and configured for ECP parallel port data transfer Caution Turn off printer before connecting the IEEE 1284 compliant parallel printer cable to printer or damage to Printer s Main circuit board may result Troubleshooting 4 102 NovaJet 800 Series Service Manual Figure 4 113 Firmware Download Procedures NJ880 Printer 1 Place printer into continuous run mode two beep sequence by holding down the top left and the bottom left keys on the keypad and powering on the printer until the two beep sequence is heard after approximately 6 seconds 2 Perform steps as listed for the NJ850 Expanded Instructions for Firmw
164. o use an approved antistatic bag for storage or shipment may cause damage to the Main PWA and affect the Warranty 17 Place the Main PWA in an ESD bag antistatic bag in preparation for shipment to ENCAD for replacement or repair or if it is to be stored at your facility for repair Install the Main Printed Wiring Assembly PWA Integrated circuits may become weakened or damaged by electrical discharge Do not touch or work near integrated circuits without wearing an ESD wrist strap 1 Puton an ESD wrist strap 2 Remove the Main PWA from the ESD bag 3 Align the Main PWA so that the serial and parallel connections protrude out of the back of the printer and that the screw holes are aligned to the holes on the power supply bracket 4 Fasten the Main PWA to the power supply bracket with 8 in lb of torque Ensure that the ground straps from the side plate and baseplate are secured to the Main PWA by the screw located beside the side plate nearest to the parallel port 5 Connect the E Connect Power connector to J18 on the Main PWA 6 Connectthe Power Supply Cooling Fan connector to J17 on the Main PWA 7 Connect the Vacuum Fan 2 60 inch only connector to J4 on the Main PWA Assembly Disassembly 5 14 10 11 12 13 14 15 16 17 NovaJet 800 Series Service Manual Connect the Vacuum Fan 1 connector to J15 on the Main PWA Connect the AutoLoad Sensor connector to J13 on the Main PWA Connect and loc
165. on and return to the Ink PreHeat Menu 7 HReprintthe image to verify problem has been corrected NOTE 1 When performing a firmware download it is important to reinitialize the printer Refer to Printer Initialization Reinitializing the printer sets all user settings back to their default values If the printer 15 not reinitialized then the preheat values will be altered when the firmware Troubleshooting 4 59 NovaJet 800 Series Service Manual is downloaded and can only be corrected with a reinitialization of the printer The reinitialization can be performed prior to or immediately after a firmware download Figure 4 62 Dirty Service Station Problem NOTE 2 The symptoms of this problem could be easily confused with dirty service station autowipe feature activation servo motor failure or firmware related problems Please verify by checking all Microbanding and Horizontal banding causes first Color Test Problems Symptom After initiating the Color Test in a 2 pass mode one or more of the printed colors suffers ink starvation Refer to Ink Starvation If the starvation stops and starts as the color test progresses 1 the first swath starts to print then starves the second swath prints and then also starves then the cartridge most likely does not have enough ink inside typically the cartridge should have between 15 and 30 ml of ink cartridge ink level will eventually stabilize at 19 ml Refer t
166. on the right side of the printer Fan 2 Test while depressed turns on the suction fan inside the platen near the center of the printer The 42 inch printer does not have this second suction fan therefore the Fan 2 Test is disabled Legs Test Tests the condition of the leg harness connections and the components of the power feed and take up system and dryer assembly Firmware Download Upgrading for the PC You can download new firmware from Encad s website www encad com The normal method of downloading new firmware sends the file to the printer as a standard print job 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 your printer or you can download the utility from Encad s website Note Firmware cannot be downloaded through a RIP unless the RIP has a pass through feature To download new firmware to your printer 1 Ifyou already have a network connection to your printer you can use that to download the firmware or connect an IEEE1284 compliant parallel printer cable between the printer and computer 2 Open the EFPU and press the Add button in the Folders section of the dialog box Give the new folder a name and press OK 3 Press the Add button in the Files section of the dialo
167. ontinuity of cables refer to service manual Typically for wiring harness and dryer logic cable problems the Dryer will be forced into the Disabled mode and Plenum Temperature Plenum T will change to approx 43 and display a Hardware Fault Hdw Fault Replace the Main PWA the humidity sensor and temperature are attached to backside of Main PWA Refer to Disassembly Replace the Dryer Assembly Note There is a particular sequence of events that could result in a disabled dryer Please be aware that this condition could occur and 1 recoverable The dryer and printer are operating as designed The sequence of events are 1 The Printer has been on and DRYER ON or AUTO for some period of time The printer is turned OFF The printer is immediately turned ON As the Firmware is being initialized power is applied to already warm heating elements The temperature in the plenum rises to the Firmware shutoff point but since the Firmware is still initializing no action can be taken The temperature in the plenum triggers a hardware shutdown the electronics shuts down power to the heating elements and the fans are forced on Troubleshooting 4 84 NovaJet 800 Series Service Manual At this point the printer must be turned OFF and then ON to clear this condition When this condition occurs simply leave the printer on for a period of a minute or two while the heating elements are cooled Figure 4 86 Dryer LED
168. or operation Troubleshooting 4 67 NovaJet 800 Series Service Manual Figure 4 70 Paper Sensor Location 5 Ink on Paper Sensor most common failure 6 Trailing cable connections reseat replace cable outer cable Encoder Sensor Error The encoder sensor error typically happens when a break in continuity occurs in the flexible printed circuit FPC line at the encoder sensor assembly The encoder sensor will need replacement should the error display The encoder sensor assembly is connected to the carriage PCB at an angle and may be difficult to connect During installation the connection must be secured or erratic carriage movement of the carriage assembly may occur at power up Figure 4 71 Encoder Sensor Troubleshooting 4 68 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 carriage in this situation unless the servo motor or trailing cable is proven defective first Another failure is characterized by erratic carriage movement at power up this is usually an unseated connection at the right carriage PWA offering the improper feedback to the servo system loop Carriage Tracking Failure The infrared encoder sensor on the right carriage 15 responsible for reading the encoder strip lines and
169. orized Refer to the Checking Firmware procedure Troubleshooting 4 88 NovaJet 800 Series Service Manual Figure 4 93 ESD Problems 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 Reseat the memory module DIMM at the Main circuit board Power off printer Troubleshooting 4 89 NovaJet 800 Series Service Manual Leto ight FT 3 I L WR sm Figure 4 94 Servo Cycle PWM Menu 8 Runthe 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 Ifthe carriage assembly moves only 1 3 2 to 8 cm from the home position at power up resulting in a Carriage Axis Error occurs value 98 then the servo motor is most likely defective Also see step 10 below Figure 4 95 Carriage Bushings 9 Power off printer move carriage assembly to extreme left hand side of unit Power on printer If the carriage returns to the service station on the first pass then the trailing cable large flat white cable is probably good suspect worn outrigger bushings 2 total or internal carriage bushings 4 total Refer to Disassemb
170. otor Assembly Drive Shaft Supports and two Foam Blocks These parts are collectively referred to as the Inner Platen Parts NOTE The removal of the Lower Drive Roller Assembly and Vacuum Fan s is easier if they are accessed from the left side of the Platen 1 Remove the Top Left and Right Covers following procedures outlined earlier in this chapter 2 Remove the Right Sideplate Assembly following procedures outlined earlier in this chapter Assembly Disassembly 5 48 3 10 NovaJet 800 Series Service Manual Remove the Service Station following procedures outlined earlier in this chapter Be careful when removing any foam blocks so that it does not tear It is very important to have an intact foam block to produce sufficient vacuum inside the Platen This is re quired to properly hold the media down onto the Platen Using the access gained by removing the Right Sideplate and the Service Station remove the right foam block from between the Lower Drive Roller Assembly and the Servo Motor Remove the Ink Delivery System following procedures outlined earlier in this chapter Remove the Left Assembly following procedures outlined earlier in this chapter NOTE The 42 inch model has one Vacuum Fan and Exhaust as sembly while the 60 inch model has two sets of Vacuum Fans and Exhausts Remove the four eight screws on the bottom of the Platen which hold the Fan Exhaust s in place While holding the Vacuum Fan
171. ovaJet 800 Series Service Manual 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 Securethe 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 Ibs To install the Top Cover 1 Insertthe pin located on the right side of the Top Cover into the corresponding hole on the Right Cover Assembly 2 While depressing the retracting stop assembly on the left side of the Top Cover lower the left side of the Top Cover into position and secure itto the Left Cover by releasing the retracting stop assembly Remove the E Connect Network Assembly Integrated circuits may beweakened or damaged by elec trical discharge Do not touch or work near integrated circuits without wearing an ESD wrist strap 1 Disconnect the network cable and the small parallel cable from the back of the E Connect Network Assembly 2 Locate and remove the 4 screws securing the E Connect Network Assembly to the bottom of the Platen See Figure 5 3 Assembly Disassembly 5 6 NovaJet 800 Series Service Manual Figure 5 3 E Connect Assembly Installation Removal Put on an ESD wrist strap Slowly lower the E Connector Assembly until you can disconnect the power cable from the connection located near the center of the circuit board Install the E Connect Network Assembly 1 Connect
172. ovaJet 800 Series Service Manual The Carriage Axis Drive OPTICAL ENCODER OPTICAL SENSOR PAPER SENSOR CARRIAGE RIGHT CARRIAGE TRAILING CABLE TRAILING CABLE ASSEMBLY ONLY FROM MAIN PWA INKJET DRIVERS I LEFT AND RIGHT CARRIAGE ASSEMBLY Figure 2 3 Carriage Axis Drive The Carriage Axis Drive moves the printer s carriage assembly along the length of the printer The drive consists of a servo motor linear encoder strip drive belt and tensioning assembly These items are illustrated in Figure 2 3 The servo motor drive belt and tensioning assembly are the components that actually drive the carriage assembly The servo motor drives the belt back and forth allowing the attached carriage assemblies to be reposi tioned as required The tensioning assembly 1 spring controlled and allows the proper amount of tension on the belt The linear optical encoder strip 1 used to obtain the printers accuracy along the axis of the printer The strip of film has 150 parallel lines per inch printed on it By utilizing two optical encoder sensors that are slightly off set from each other and reading the leading and trailing edges of the lines a resolution of 600 dpi can be obtained The stepper and servo motors are controlled from the main printed circuit assembly by the microprocessor Theory of Operation 2 5 NovaJet 800 Series Service Manual Media Feed and Take Up
173. p and ink residue if streaks occur on the right side of print Refer to Routine Maintenance Clean the encoder strip top and bottom slide shaft and inside of carriage belt with distilled water or isopropyl alcohol Refer to Routine Maintenance Check outrigger bushings and carriage bushings for wear and for cleanliness Refer to Vertical Banding and Routine Maintenance Ensure vacuum fan or fans are providing adequate suction for media or head scrapes will occur Refer to Horizontal Banding Troubleshooting 4 46 NovaJet 800 Series Service Manual i hk ee reda iab is Figure 4 50 ESD Problem 7 Change media to see if electrostatic discharge from media is causing the banding or ink over spray to occur Add 3rd party ESD protection if required static eliminator strip 8 Perform the carriage vibration test under Diagnostics Menu the lines should print fine lines with no jagged edges 9 Print a demo print from the sample images CD If no overspray or similar problems show then check the software driver or original file Draw a simple box and send to print from application default line thickness should be 0 008 AutoCAD Check printed output for correct line thickness Obtain the Servicing Support CD and refer to Demonstration Print for proper procedures Ensure the demonstration print is correct Cartridge Warranty To check cartridge ink throughput select Utility Menu S
174. pecifically disclaims any and all other warranties expressed or implied including but not limited to implied warranties of merchantability and fitness for a particular pur pose In no event shall ENCAD be liable for any loss of profit or other commercial damages special incidental or consequential damages or any other damages or claims whatsoever This Warranty gives Buyer specific legal rights and Buyer may also have other rights that vary from state to state This Warranty applies only to printers purchased from ENCAD or autho rized ENCAD distributors or dealers The intent of this Warranty is to repair or replace defective Products subjected to normal wear and tear when operated according to ENCAD instructions viii NovaJet 800 Series Service Manual Table of Contents Chapter 1 General Description 1 1 1 1 i HR 1 3 Related Publications 1 3 Electrostatic Discharge ESD Sensitivity 1 3 Warnings Cautions and Notes 1 4 SD SCIICA TONS eU 1 5 Contents of this Service Manual 1 6 Technical SUDDON nunna ena E 1 8 Chapter 2 Theory of Operation 2 1 MOGGIO tO TET 2 1 NovaJet 800 Series Printers General Block Diagram 2 2 Paper Media
175. play 5 8 Install the Keypad and Display 5 9 Remove Memory 5 10 Stal WE era cela tia 5 11 Remove the Main Printed Wiring Assembly PWA 5 11 Install the Main Printed Wiring Assembly 5 14 Remove Power Supply Cooling Fan and Entry Module 5 15 Install the Power Supply Cooling Fan and AC Entry Module 5 17 REMOVE Servo 5 18 Install Servo MOO 5 20 Remove the Ink Delivery System 5 21 Install the Ink Delivery System 5 23 XIV 800 Series Service Manual Table of Contents cont Chapter 5 Assembly Disassembly cont Remove the Carriage Assembly Carriage Belt and the Frame TENSIONE 5 23 Install the Carriage Assembly Carriage Belt and the krame TENSIONE 5 28 Remove the Carriage 5 31 Install the Garridge PWA 5 33 Remove the Paper Sensor or the Encoder Sensor 5 34 Install the Paper Sensor the Encoder Sensor 5 36 Replacing the Floating Carriage Co
176. r or if it is to be stored at your facility for repair Install the Carriage PWA 1 Put the tab on the left end of the Carriage PWA into the slot in the left side of the Carriage See Figure 5 20 Ensure that no flex cables are underneath the Carriage PWA Push down the right end of the Carriage PWA until the latch snaps into place Reattach all flex cables on the Carriage PWA Install the Carriage Assembly and Ink Delivery System following procedures outlined earlier in this chapter Install the Top Left and Right Covers following procedures outlined earlier in this chapter Assembly Disassembly 5 33 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 TO REMOVE PAPER SENSOR BOARD GRASP HERE AND PULL UP PUSH DOWN ON CLIP PUSH DOWN ON ENCODER THEN PULL OUT THIS PIECE OF PLASTIC ONE ON SIDE MUST CLEAR THE RIDGES ON THE UNDERSIDE OF THE HOLDER Figure 5 21 Paper and Encoder Sensor Removal Assembly Disassembly 5 34 NovaJet 800 Series Service Manual NOTE The Paper Sensor and Encoder Sensor are only installed onto the right Carriage procedures in this section refer to the right Carriage only
177. r 1 ensure media loops down far enough to block feed sensor In Roll 2 mode the sensor is deactivated Feed Roller 2 or Take Up Roller Take Up Sensor In Roll 1 mode the sensor is deactivated Figure 4 114 Media Handling System Troubleshooting 4 105 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 The following tools are recommended to disassemble and reassemble the printer 1 Phillips Torque Screwdriver 2 Phillips Torque Screwdriver 1 Slotted Torque Screwdriver 2 Slotted Torque Screwdriver 1 Phillips Screwdriver 2 Phillips Screwdriver 1 Slotted Screwdriver 2 Slotted Screwdriver Wrench 1 4 Screwdriver Socket Head 1 4 Wire Cutters Needle Nose Pliers X ACTO Knife ESD Wrist Strap The following materials are also required Isopropyl Alcohol Cotton Swabs Lint Free Cloth or Tissue Double Sided Tape 1 16 thick 3 4 wide Loctite Blackmax P N 200172 5 1 NovaJet 800 Series Service Manual A Hardware Kit 1s available for the printers See Chapter 6 of this manual for the part number A
178. r leads from the printers leg assembly by squeezing the sides of the connector to release the quick disconnect latches With a pair of wire cutters cut the wire tie wraps see Figure 5 32 that is securing the sensor leads to the sensor bracket 4 Remove the sensor by unscrewing the plastic nut off of the front of the sensor Pull the sensor out of the bracket 5 HRemove the two screws securing the bracket to the leg Assembly Disassembly 5 58 NovaJet 800 Series Service Manual assembly Figure 5 32 Media Take Up and Feed Sensor Removal Install the Media Take Up and Feed Sensor Brackets and Sensors 1 Install the two screws securing the bracket to the leg assembly 2 Insert the sensor into the hole on the sensor bracket secure by screwing on the plastic nut onto the front of the sensor 3 Route the sensor wires to the back of the bracket and secure the wires using two wire tie wraps 4 Bringing the wire from under the bracket attach the wire connector to the leg harness plug Push connector in until firmly seated Assembly Disassembly 5 59 NovaJet 800 Series Service Manual Remove the Media Take Up and Feed Motors 1 Remove all media and media rollers from the printer 2 Remove the four screws holding the Cradle Idler to the leg assembly See Figure 5 33 3 Carefully slide the Cradle Idler assembly out of the leg assembly until the wires going to the motor can be removed 4 Remove the wires fro
179. r sensor is when the carriage assembly suddenly stops at left end of unit during initialization initialization does not complete dim or blank control panel display This could also be due to a faulty power supply The paper sensor should sense the platen on the return trip but may fail to do so no error code given Replace paper sensor on carriage in this situation unless the power supply is proven defective first NOTE it is extremely important that the room or area lighting remains consistent during all print operations or the paper sensor may fail often no error message is provided the printer simply stops the print job 1 do not turn lights off in the room after a printer has successfully mea sured the media and then start a print job Ensure the Main PWA LEDs light emitting diodes are properly function ing D1 Normally flashes DSP is not active Steady when printing D9 Normally flashes Power PC processor is idle Stops flashing when processor is active 1 e during paper sensing operations D10 Normally OFF Flashes during initialization then turns off LED staying on would indicate a problem when the FPGA 1 unconfigured Ensures programming of gate array chips 15 successful D 24V available 5V available Troubleshooting 4 66 NovaJet 800 Series Service Manual Loading Media Failure The carriage paper sensor infrared sensor will first obtain a reference at right side o
180. railing Cable A connection at the J1 location Use the thumb and forefinger to pull up on the connector lock and remove the Trailing Cable from the connector Disconnect the Autoload Sensor connection at the J13 location by grasping the Autoload Sensor connector with thumb and forefinger and pulling straight out Disconnect the Vacuum Fan 1 connection at the J15 location by grasping the Vacuum Fan 1 connector with thumb and forefinger and pulling straight out Disconnect the Vacuum Fan 2 connection at the J4 location 60 inch model only by grasping the Vacuum Fan 2 connector with thumb and forefinger and pulling straight out Disconnect the Power Supply Cooling Fan connection at the J17 location by grasping the Power Supply Cooling Fan connector with the thumb and forefinger and pulling straight out Disconnect the E Connect Power connection at the J18 location by grasping the E Connect Power connector with the thumb and forefinger and pulling straight out Disconnect the ground straps going to the side plate and baseplate by removing the screw located near the parallel port on the Main PWA Using care remove the Main PWA by unscrewing the remaining screws securing the Main PWA to the bracket See Figure 5 7 Assembly Disassembly 5 12 NovaJet 800 Series Service Manual 7 Main PWA Removal Figure 5 5 13 Assembly Disassembly NovaJet 800 Series Service Manual Failure t
181. re any signs of leaking ink on or below the inkjet carrier assem bly Is the flex driver cable connections seated properly at carriage PWA Isthe trailing cable damaged Look for black runs or brown freckles in the white cable Is the septum connector or quick connect fitting damaged do reser voir valves snap in securely Is the ink delivery system tubing chain damaged Inspect flex driver cables on carriages has damage ink attack occurred Reseat flex driver connection at Carrier PWA service required Replace the trailing cable assembly service required Common Misfire Problems Cartridge electrical contacts may have oil or ink on surface clean with isopropyl alcohol Carriage assembly flex driver cable may have ink or debris on contacts clean with alcohol Troubleshooting 4 49 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 nsert cartridge and initiate a Color Test 10096 density in a 2 pass print mode For severe jet clogs use ultrasonic cleaner 30 40 sec or warm to hot water 10 15 sec to break down clogging at nozzle Multiple Cartridge Failures Assuming cartridges flex driver cables are clean and connectivity is good recommend to customer to replace service station should be replaced every 1000 print plot hours Troubleshooting 4 50
182. removing 4 securing screws Loosen the ferrite bracket screw to obtain clearance to pull sensor wiring and plugs through opening Remove the right side plate Remove the ink delivery system carriage cover brackets and bushings off the slide shaft on either end of printer Obtain the Belt Spacer Tool provided in the training kit to remove carriage belt Position belt spacer tool in between the frame tensioner and the left side plate While holding the belt spacer tool turn the adjustable bolt to provide adequate tension to the back side of the frame tensioner Remove carriage belt from the servo pulley Avoid damaging the encoder strip Hold the belt spacer tool and turn the adjustable bolt to release tension on the frame tensioner spring Remove the belt spacer tool Remove the service station by pulling on the tab at right side and lifting out Remove the screw securing the torroid Remove the grounding braid securing screw and nut by gaining access to screw through the right fixed end beam Remove the servo motor by first removing the 2 screws securing the servo plate at underside of printer While holding the motor remove 2 securing screws and lower motor through right end platen opening Remove the left side plate by removing the 6 securing screws Assembly Disassembly 5 55 23 24 25 26 27 28 29 NovaJet 800 Series Service Manual Disconnect the 2 carriage electronic covers by pressing in on the inner t
183. replaced If not go to otep 2 Figure 4 51 Jet Out Detection eet aL uL mL Enabling open jet compensation see Manual Jet Bypass will often dramatically improve print quality If enabling open jet detection and or activating the manual jet bypass feature on problem jets clogged misfiring jets found in the Prime pattern does not improve image quality go to Step 3 Cleaning the jet plate with distilled water and a lint free cloth should clear any jets stopped by dust particles or other physical obstructions Vigorously blot the gold jet plate area on the bottom of cartridge with the heavily dampened lint free cloth Repeat several times For cartridges which have not been used for longer Troubleshooting 4 48 NovaJet 800 Series Service Manual than 2 weeks apply hot water towel to jet plate area for 15 to 30 seconds If cleaning the jet plate thoroughly and re priming the cartridge does not improve print quality go to Step 4 4 Runaprime and inspect the printed lines If the photo mode is not supported as indicated by the Prime Pattern jet out detection and the previous three steps have already been performed contact ENCAD Technical Support or your service representative General Print Misfire Analysis Is ink in supply to cartridge jets Are the ink cartridges contact points flex contacts dirty or damaged Is the service station clean and working properly seals wipers worn Are the
184. riage to the left side of the stabilizer Position it as close to the screw as possible and drop the measuring tip onto the platen Do this a couple of times to ensure an accurate reading Move the left end of the stabilizer bracket until the reading below is observed Read only the RED numbers on the micrometer gauge For the NovaJet 850 printer adjust for a reading of 67 3 This equates to a head height of 0 065 NOTE The actual measurement is different than the true head height due to the fact that the test cartridge does not contain a jet plate assem bly A difference had to be calculated to compensate for the lack of a Jet plate assembly on the test cartridge Tighten the screw on the left side of the stabilizer While lifting up the measuring tip of the micrometer slide the Carriage to the right until the next stabilizer screw is lined up Position it as close to the screw as possible and drop the measuring tip onto the platen Do this a couple of times to ensure an accurate reading Move the left end of the stabilizer bracket until a correct reading is observed Read only the RED numbers on the micrometer gauge Tighten the screw on the stabilizer that is next to the Carriage Maintenance 3 90 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 ser
185. rite around the Trailing Cable Assembly and insert the right side of the Trailing Cable Assembly through the access hole provided in the Right Side plate 3 Slide the Carriage Assembly and Floating Carriage Cover Assembly to the far left side of the Slide Shaft While ensuring a 5 125mm overhang on the right side position the Trailing Cable Assembly over the Stabilizer Bracket and slowly lower it onto the bracket Ensure that the Trailing Cable Assembly goes on straight and that there are no buckles in the cables Firmly press the Trailing Cable Assembly onto the tape to secure it into position 4 Connect the right end to the Main PWA the right Carriage cable longer cable to the J1 connector and the left Carriage cable shorter cable to the J2 connector 5 Movethe Carriage Assembly and Floating Carriage Cover Assembly to the right Insert the Strain Reliefs with Trailing Cables and ferrite onto the Carriage Assembly by sliding it onto the Strain Relief Supports until it snaps firmly into place Assembly Disassembly 5 42 NovaJet 800 Series Service Manual 6 Reposition the Floating Carriage Cover Right Support Bracket Assembly and the Left Support Bracket around the Carriage Assembly Secure the Left Support Bracket to the Floating Carriage Assembly Torque to 15 in lbs 7 Install the Top and Right Covers following procedures outlined earlier in this chapter Remove the Stabilizer Bracket and Encoder Strip 1 Remove th
186. rlier in this chapter Remove the Carriage Assembly Carriage Belt and the Frame Tensioner Remove the Top Left and Right Covers and the Ink Delivery System following procedures outlined earlier in this chapter Obtain the Belt Removal Tool spin the movable side to shorten the distance between the two brass pieces Insert the Belt Removal Tool between the Left Frame Assembly and the Frame Tensioner See Figure 5 14 Ensure that the movable side is against the Left Frame Assembly and the non movable side is against the Frame Tensioner Assembly Disassembly 5 23 NovaJet 800 Series Service Manual 0 gt Figure 5 14 Using the Belt Removal Tool 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 Turn the Belt Removal Tool in the opposite direction to remove the pressure exerted onto the Frame Tensioner Remove the Belt Removal Tool Remove the Frame Tensioner Assembly Remove the four screws securing the Left Frame Assem
187. rmware file to the folder you created Select the firmware file in the Files section of the dialog box and press the Print button The firmware file is sent to the printer as a normal print job Approximately 20 40 seconds later a single beep should be heard indicating the update was successful After a one second delay the printer will automatically reboot The printer should come up normally Verify the new firmware revision by sequencing through Utility Menu Service Menu About Menu If multiple beeps are heard reboot printer and reseat your connection to the printer network cable or parallel cable Resend the firmware file to the printer After a one second delay the printer will automatically reboot The printer should come up normally Verify the new firmware revision by sequencing through Utility Menu Service Menu About menu Reinitialize the printer Setup Menu User Setup Menu Init Settings A single beep will sound from the printer Cycle power and ensure a normal initialization occurs Run a prime to verify the unit will print Troubleshooting 4 104 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 Media Handling System Feed Rolle
188. rriage Troubleshooting 4 21 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 Referto Disassembly Figure 4 5 Unseated Flex Driver Cable 8 Is the trailing cable damaged Look for black runs or brown freckles in the cable Brown freckles indicate excessive current is passing through the flexible printed circuit a black line indicates severe burning of the line 9 Checkseptum needle fitting or reservoir valve for damage Ensure the three septum parts are securely twisted together Ensure reservoir cartridge tubing needle male valve snaps securely into female valve Figure 4 6 Septum Connector 10 Is the tubing or chain damaged at either end of ink delivery system Switch to another ink line to verify problem Replace female reservoir valve for ink starvation issues Refer to Ink Starvation Troubleshooting 4 22 NovaJet 800 Series Service Manual Hz gp qu r Figure 4 7 Damaged Flex Driver Cable 11 Inspect flex driver cables on carriage Has damage ink attack occurred Look at electrical dimples for charring or burn marks Replace cable if damaged Refer to Disassembly 12 Reseat flex driver cable connection at the appropriate Carriage PWA For Left carriage stalls 1 2 3 or 4 or Right carriage stalls Y M C K Refer to Disassembly Figure 4 8 Defective Tr
189. rt bracket and out the other side 8 Rotate the bushing 180 again and insert it into the Left Support Bracket Assembly Disassembly 5 38 NovaJet 800 Series Service Manual 9 Perform the same procedure to replace the Right Support Bracket bushing Replacing the Carriage Bushings 1 Remove the Top Left and Right Covers following procedures outlined earlier in this chapter 2 Remove the Ink Delivery System and the Carriage Assembly following procedures outlined earlier in this chapter to remove the Carriage Assembly from the Slide Shaft Figure 5 24 Carriage Bushing Removal Use tip screwdriver to push up on the latch which holds the Carriage bushing in place See Figure 5 24 4 Pull the Carriage bushing out of the Carriage 5 Repeat these procedures for the other Carriage bushings Assembly Disassembly 5 39 NovaJet 800 Series Service Manual Figure 5 25 Carriage Bushing Installation 6 Orient the new bushing as shown in Figure 5 25 so that the metal tab on top of the bushing goes into the Carriage Assembly first 7 Push the bushings in until they snap into place 8 Install the Carriage Assembly and Ink Delivery System following procedures outlined earlier in this chapter 9 Install the Top and Right Covers following procedures outlined earlier in this chapter Remove the Service Station SERVICE STATION RELEASE TAB Figure 5 26 Service Station Remov
190. s memo m ie Rame PINE cn ew al Fre i i gees Pr rE Figure 4 87 Dryer Connectivity Troubleshooting 4 85 NovaJet 800 Series Service Manual Intermittent Problems Continuity If the printer experiences intermittent print problems or reboots then ensure all connections at Main PWA are good platen is thoroughly cleaned of ink verify the DIMM module is seated correctly and check for foreign debris in rollers Failure Analysis 1 Reinitialize the printer From the Main Menu select Setup Menu then select User Setup Menu and choose Init Settings The unit will sound one beep indicating the refresh was successful and all user settings have been restored to default Refer to the Printer Reinitialization procedure zb BEER wee Figure 4 88 Internal Test Print 2 Perform the test print Utility Menu Service Menu Test Print Ensure the printer is in the highest print pass mode before printing Five pass for 2x4 cartridge set or 10 pass for 1x4 or 1x8 cartridge sets Verify a similar output to this example is printed The test print is used to verify printer calibrations Refresh the printer firmware Refer to the Firmware Download procedure To test the SEH server and connectivity depress the SEH s blue test button The currently configured IP address wil
191. s different from that of another rasterized print HE OMS BEB x Figure 4 32 Test Print 13 Refer to Cartridge Misfires and Ink Dropout to ensure all other troubleshooting checks have been made Figure 4 33 Misfiring Jet 14 For single color or multiple color print failures replace the carriage PWA If normal test patterns i e Color Test and normal basic test patterns are seriously degraded then replace the carriage PWA Refer to Disassembly Troubleshooting 4 36 15 16 NovaJet 800 Series Service Manual a n Pu po IT i n z fom t L Figure 4 34 Defective Carriage PWA Color Test Inspect and clean stepper motor and lower roller drive gears if printer is older than 5 years Every two years if printer is used for textile printing Other unique microbanding causes include synchronization errors from the stepper drive system due to defects or gear cleanliness Figure 4 35 Defective Stepper Motor Replace stepper motor for consistently spaced horizontal patterns 2 10 mm apart when printer is run in the enhanced modes with a test print Often a lower roller drive noise will accompany the banding Inspect stepper motor gearing lower roller for damage debris ensure screws are tight Check stepper motor winding resistance 7 2 8 0 ohms check full
192. s following procedures outlined earlier in this chapter 5 Perform the Head Height Adjustment procedures found in Chapter 3 of this service manual Remove the Y Arm Assembly Pinch Rollers Slide Shaft and AutoLoad Sensor 1 Remove the Top Left and Right Covers following procedures outlined earlier in this chapter 2 Remove the Ink Delivery System Carriage Assembly and Trailing Cable Assembly following procedures outlined earlier in this chapter 3 Remove the Stabilizer Bracket Assembly following procedures outlined earlier in this chapter Assembly Disassembly 5 44 NovaJet 800 Series Service Manual 4 Disconnect the AutoLoad Sensor connector at the J13 location on the Main PWA Grasp the AutoLoad Sensor connector with the thumb and forefinger and pull straight out 5 Remove the seven screws that secures the Y Arm Assembly to the Platen See Figure 5 28 Figure 5 28 Y Arm Installation Removal 6 The pinch rollers are held on by small C clamp located on the back of the Y Arm Assembly See Figure 5 29 While holding the pinch roller remove the C clamp and move the pinch roller towards the front of the Y Arm Assembly until it clears the back of the Y Arm Bracket Assembly Disassembly 5 45 7 10 11 NovaJet 800 Series Service Manual Figure 5 29 Pinch Roller opin the back of the pinch roller to either side and remove the back spring Carefully tilt the back of the pinch roller upwards This
193. sembly Disassembly 5 21 NovaJet 800 Series Service Manual eec aK SORA 9 F P2 Figure 5 12 Left Side of Delivery System 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 Move the Carriage to the center of the Slide Shaft Figure 5 13 Floating Carriage Cover Removal Assembly Disassembly 5 22 8 NovaJet 800 Series Service Manual 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 Carefully slide the Ink Delivery System out of the left side of the printer Install the Ink Delivery System 1 2 Carefully slide the Ink Delivery System into the printer Secure the Floating Carriage Cover to the Left and Right Support Brackets Torque to 6 in Ibs Secure the Ink Delivery System Bracket to the Left Frame Torque to 15 in lbs Secure the Ink Delivery System to the Chain Support Bracket See item B in Figure 5 11 Torque to 15 in lbs Reattach the Chain Support Bracket to the Rear Support Bracket See item A in Figure 5 11 Torque to 15 in Ibs Secure the Fitting Mount Bracket left portion of the Ink Delivery System to the Left Frame using six screws Torque to 15 in lbs Install the Top Left and Right Covers following procedures outlined ea
194. ses the cartridges to not receive some of the electrical signals for a proper firing of the jets This can be seen as a misfiring of the cartridge NOTE Care should be used when handling the cartridges Avoid touching the cartridges on the dimple area or on the inkjet holes on the bottom The oils and dirt on fingers and hands can contaminate the area and result in misfiring of the inkjets Clean the cartridge dimple area by gently dabbing the area with a lint free cloth or cotton swab saturated with isopropyl alcohol Maintenance 3 6 NovaJet 800 Series Service Manual Be sure to clean the yellow cartridge because it is not readily apparent that it 1s dirty The yellow ink is hard to see and could be overlooked Flex Cable Contact Cleaning Figure 3 3 Flex Cable Contacts Cleaning the flex cable contact area is very important due to the ease with which this area can become dirty The flex for the yellow cartridge 15 deceiving because it is not readily apparent that it is dirty This also causes the cartridges to not receive all of the electrical signals for a proper firing of the jets This can be seen as a misfiring of the cartridge NOTE Be careful when handling the flex cable contact area Avoid touch ing the contact area because oils on your skin can contaminate the area and result in misfiring of the inkjets Clean the flex cable contacts by gently dabbing the area with a cotton swab soaked with isopropyl alcohol M
195. sing the E Connect NJ850 only then attach the provided parallel printer cable 15 39 cm between the upper centronics parallel port and the lower parallel port at right rear of printer Attach an Ethernet cable to the E connect jack Verify the green LED OK illuminates The green LED OK indicates the server is communicating with the network The white LED TEST should illuminate amber in color briefly only at power up and then extinguish The yellow LED 100 indicates a 100baseT network exists and is online E Connect supports high speed ECP enhanced capabilities port parallel port mode with DMA dynamic memory access and Bi directional data transfer up to 1 Megabytes per second A short 15 or 39 cm IEEE 1284 compliant parallel cable must Troubleshooting 4 98 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 The printer will print a Semi Circular Nook test pattern which will verify the E Connect print server network box and parallel ports are working properly Troubleshooting 4 99 NovaJet 800 Series Service Manual Parallel Port Test Attach the service loopback test c
196. ssembly See Figure 5 36 and Table 5 1 5 64 JI J2 J3 JA J5 NovaJet 800 Series Service Manual Figure 5 36 Right Endcap Connector Locations Table 5 1 Thermal Dryer PWA Connections Fan 1 16 Element Right Conn Fan 2 J7 Thermistor Element Left Conn J8 Fuse on back of PWA Power J9 Thermistor Power P1 Data cable the power cord ground to the main body of the Thermal Dryer Attach and secure the Right Endcap Assembly Torque to 15 in lbs Attach the data cable to the right side of the Thermal Dryer Assembly Attach the Thermal Dryer Assembly power cord the to back of the printer Assembly Disassembly 5 65 Parts List 6 This chapter lists the items and their associated numbers for the parts and assemblies of the NovaJet 800 Series printers that are field replace able The list is in order of part name as identified in the assembly disassembly chapter This list is to be used in conjunction with the assembly disassembly procedures to aquire the necessary parts and properly install them into the printer The parts and assemblies may be ordered through your local authorized dealer or ENCAD Inc s Technical Support and Service department FIGURE ITEM PART NAME PART 6 1 COVER LERT s esce enn Dit 214399 00 6 1 2 DELIVERY SYSTEM 60 217294 00 INK DELIVERY SYSTEM 42 217295 00 6 1 o ERAMESLEBLD eddie e 214407 02 6 1 4 TUBE ASSY
197. ssembly is controlled by varying the duty cycle of the signal applied to the controller The microprocessor checks the position of the Carriage Assembly approximately 1 000 times per second during the servo interrupt It then updates the PWM pulse width modulator register in the gate array which sets the duty cycle to make adjustments to the Carriage Assembly speed A linear optical encoder is used to monitor the Carriage Assembly position The optical encoder strip runs the length of the Stabilizer Bracket and contains 150 lines and spaces per inch Thus there are 300 edges per inch The detector circuit actually consists of two optical edge detectors They are separated from each other by one half the width of one of the optical lines on the encoder strip This allows 4 evenly spaced pulses to be developed for each line on the encoder strip This is known as quadra ture signals It gives an effective resolution of 600 lines per inch See Figure 2 9 for a graphical representation of quadrature signals Maximum velocity of the Servo Motor is 46 6 inches per second IPS Servo Motor life is rated to 2 8 million cycles or approximately 2800 plot hours Theory of Operation 2 13 NovaJet 800 Series Service Manual DETECTOR 2 ae DETECTOR 1 OUTPUT OF DETECTOR 1 PLE IJ LIU L4 LJ L OUTPUT OF DETECTOR 2 SUU LU L COMPOSITE TRANSITION TRIGGERED OUTPUT OF BOTH DETECTORS 4 OUTPUT PULSES PER OPTICAL LINE Figure
198. t from 5 mm to 20 mm The servo motor bearings may be faulty normal servo motor life is 1600 to 2500 plot hours Horizontal bands 0 2 mm to 1 mm which extend beyond the page layout are usually caused by the workstation memory or the driver not having sufficient work space Ensure 1GB is free on hard drive at all times 256 MB of memory is suggested Partitioning the hard drive is recommended Refer to Disassembly Maintenance 3 21 NovaJet 800 Series Service Manual 18 Clean or replace encoder strip for image skewing image walking or skipping Whether the image skews slights or off the page the encoder strip is at fault Typically characterized as horizontal banding often a walking image can also create vertical bands to appear in the print Refer to Scheduled Maintenance for cleaning or Disassembly for encoder strip replacement 19 Improper grounding or earthing An improper A C outlet power ground may cause banding due to excessive noise on the line between the neutral and ground Ensure the outlet has a clean zero ground potential with minimal noise between the neutral and ground 20 Replace Main PWA for severe horizontal and vertical banding patterns Refer to Disassembly Vertical Banding Problems 1 Forvertical banding check carriage bushings for wear and ensure the bushings are free of dirt and ink residue buildup Perform the carriage vibration test under Diagnostics Menu the lines should print fine with no jagged edg
199. t side of the Lower Drive Roller Assembly inside of the left side of the Platen until the first roller is inserted Position and hold one of the Fan Assemblies under the Lower Drive Roller Assembly and between the first and second rollers Continue to insert the Lower Drive Roller Assembly into the Platen Position and hold the other Fan Assembly for 60 inch model only under the Lower Drive Roller Assembly Continue to insert the Lower Drive Roller Assembly completely into the Platen Reaching inside the Fan Exhaust hole under the Platen position and secure the Fan Assembly ies Reinstall the Fan Exhaust Assembly ies Install the Lower Drive Roller Assembly Left and Right Support Brackets Install the Center Support Bracket Insert the Platen Plug Assembly Disassembly 5 52 10 11 12 13 14 15 16 NovaJet 800 Series Service Manual Reinsert the right Foam Block Make sure that the Stepper Motor and Fan s cables are exiting out of the back corner of the Foam Block See Figure 5 31 The Foam Block is positioned between the Stepper Motor and the Servo Motor Make sure it is not tilted at an angle SERVICE STEPPER STATION MOTOR P O LEG HARNESS Figure 5 31 Inside Platen Right Side Reinsert the Service Station Reinstall the Right Sideplate Ensure that all cables from inside the Platen are exiting out of the large hole in the Sideplate Reinstall the left Foam Block Reinstall the L
200. ted Diagonal banding could be either hardware or software HARDWARE SOFTWARE Figure 3 10 Examples of Horizontal Banding Hardware banding is usually characterized by consistent banding strips as shown Typically horizontal banding is caused by the cartridge or print head in 95 of the cases It signifies a slippage in the media s normal movement that is possibly due to the stepper motor lower drive shaft assembly pinch rollers or the rollguides on the back of the printer All these possible faulty areas deal with a rotational movement that if faulty will generate a consis tent banding pattern The Main PWA and Carriage PWA can also cause this type of error to occur Software banding is characterized by inconsistent banding lines or lines which violate the page layout extend beyond the print border These Maintenance 3 17 NovaJet 800 Series Service Manual banding lines are generated by the software when the application incorrectly interprets the media advancing ink firing sequence of the expected print file or when text an error occurs within the host application Errors can also be caused by insufficient host workstation or RIP memory or processing power Because it is not directly tied to a mechanical movement the bands become inconsistent in both frequency and duration The possible causes are the printer driver the original software package or the RIP if is used To eliminate the chance that it is the prin
201. ted which can cause shifting of the printer base Turn printer off Slowly move carriage head back and forth manually to ensure no obstructions are causing the print defects observed i e tape on the rear cover tie straps under the electronics cover or low carriage head height Check E Connect Print Server Carriage head hesitation which causes microbanding is normally caused by a low data port rate information cannot get through the print server fast enough While the E Connect is rated for 700 kilo bytes per second fast enough to handle any large format demands at the fastest printer speed available an improperly configured server or a server in a high traffic environment may be the cause of the microbanding Test printer with limited or no network traffic to verify Reconfigure the E Connect if necessary and turn off any redundant or unused protocols Please consult a network administrator for assistance Print a test RTL file to verify banding if banding is absent then check software Obtain the Demo Images CD and refer to the Multimedia Operations CD Demonstration Print for proper procedure Print at least 5096 of the test print 1 2 meter long before deciding the next course of action The Test Print Utility Maintenance 3 20 12 13 14 15 16 17 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 di
202. ter 10 minutes of print operations Figure 4 65 Cartridge Tubing Needle and Septum 3 Ensure the septum connector assembly is tightly secure The assembly is composed of three parts which must be tightly twisted together prior to installation and use 4 Ensurethe septum connector cartridge tubing needle is properly connected between the cartridge and carriage assembly you may have to reseat the assembly at the valve body Replace reservoir tubing needle and or cartridge tubing needle if pressure is lost after the procedure has been performed a leak is present in the line 5 Replace the cartridge with a new one the line 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 7 Always run color test 210096 in the 2 pass print mode to verify the proper pressure levels have been achieved within the cartridge Troubleshooting 4 62 NovaJet 800 Series Service Manual Figure 4 66 Ink Starvation 8 Referto Ink Starvation procedures for any printed output which resembles the following image where one color stops printing completely Unrecognized Cartridge Error Message For an Unrecognized Cartridge error message first ensure the 2 electri cal integrated chip contacts on the rear of the cartridge have been penetrated Replace the cartridge to verify problem Unrecognize
203. ter Calibrations Checking Print Mode Is the high pass mode 5 pass for 2x4 configuration 10 pass for 1x4 1x6 and 1x8 cartridge set configurations printing successful Note 3 pass mode 2x4 configuration or 4 pass mode 1x4 1x6 and 1x8 cartridge set configurations will microband in many of the 2 tone color ranges including some blue gray orange and purple hues Check to see if the media is loaded correctly and is of proper thickness no greater than 20 mil media can pass through the machine Check to see if the media guides are in place and are not defective Check the pinch rollers for alignment damage Are the color deadband and color calibrations correct Refer to Printer Calibrations Inspect the Prime pattern and verify diagonal line in the jet test is consistent throughout The line should not have sections or lighter and darker shades it should not be dissolved or broken Refer to Printer Features Jet Out Detection Clean manually bypass clogged jets or replace the cartridge if any of these abnormal conditions exist Defective or clogged cartridges account for 90 of the banding observed Change the preheat setting for the affected color To gain access select SetUp Menu Ink Option Menu Ink PreHeat Settings choose the appropriate color If this does not help then return settings to zero 0 default at completion of test Ensure the Auto Wipe feature is turned off To gain access select SetUp Menu Paper Optio
204. ter driver 1 Remove RIP or network systems and connect the printer directly to the computer via the printers parallel port 2 Printatest 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 If the test file prints correctly the problem lies in either the software package that generated the print or the RIP if used The problem could also be with the built in E Connect print server or with the workstation transmitting the print data directly to the printer s parallel port To eliminate the E Connect print the Semi Circular Nook test pattern by quickly depressing the TEST button at right rear of printer Ensure the short 157 39 cm parallel printer cable is attached between parallel ports prior to activating the test A simple test to determine if the banding is caused by the computer RIP application or the printer is to rotate the image 90 degrees and see if the banding rotates or remains in the same orientation as the previous print If the banding does not rotate then look for causes in the printer If the banding does rotate with the image then look for causes in the computer RIP or application Maintenance 3 18 NovaJet 800 Series Service Manual Banding Causes amp Quick Analysis Horizontal Banding Problems 1 Check the print mode for the type of image being printed Refer to Prin
205. ter the value below the set of lines that are correctly aligned Be careful that you are aligning the correct color by observing the K black C cyan M magenta Y yellow 1 2 3 and 4 1 4 are assigned colors on the right side of the plot The Color Vertical Head to Head Calibration checks the alignment of the nozzles vertically and allows corrections when required Just enter the value below the set of lines that are correctly aligned Be careful that you are aligning the correct color by observing the K black C cyan M magenta Y yellow 1 2 3 and 4 1 4 are assigned colors on the right side of the plot To perform the Color Calibration 1 Select Utility Menu from the Main Menu This brings up the Utility Menu as shown in Figure 3 19 Maintenance 3 32 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 Vertical Vert Calib Test Horizontal Horiz Calib Test Figure 3 20 Color Calib Menu 3 Select Vert Calib Test to print the vertical color calibration plot as shown in the upper half of Figure 3 18 4 When the plot is complete select Vertical at the Color Calib Menu then select 4 Vertical This brings up the options menu as shown
206. the Belt is not binding on the Carriage Assembly 9 Insert both Strain Reliefs with Trailing Cables onto the Carriage Assembly by sliding it onto the Strain Relief Support until it snaps firmly into place 10 Place the Trailing Cables into the J1 connector locks on each of the Assembly Disassembly 5 29 11 12 13 14 15 16 17 18 19 20 21 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 Position the Electronics Cover over the right Carriage and gently press down on the ends of the Electronics Cover until the latches snap into the right Carriage Perform the same procedure to attach the other Electronics Cover onto the left Carriage Slide the Carriage Assembly to about the middle of the Slide Shaft and stretch out the Carriage Belt Insert the Carriage Belt into the Frame Tensioner so that the belt extends about an inch past the Frame Tensioner Holding the Carriage Belt and Frame Tensioner insert the Idler Pulley Assembly into the loop of the belt Make sure that the side of the Idler Pulley Assembly with the thicker outer ring of plastic is facing up Once the ldler Pulley Assembly is in position pinch the belt to hold the Idler Pulley Assembly in place and pull it into the Frame Tensioner so that the axle rests in the V shaped groove in t
207. the NJ850 Service Training Kit or in the Service CE Kit Height Gauge Alignment Kit Contents are Dial Gauge Micrometer Modified Novajet Cartridge for newer products Modified Novajet 4 Pro Pro 50 Cartridge Not Used Platen Carriage Shaft Mounting Block Maintenance 3 24 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 Slide Shaft Profile Adjustment 2 Carriage Cartridge Head Height Setting 1 Connect the dial gauge micrometer to the Shaft mounting block as shown in Figure 3 11 7 _ GAUGE SHAFT MOUNTING TIGHTEN SET BLOCK SCREW NOT SHOWN Figure 3 11 Dial Gauge Micrometer Assembly 2 Place gauge against left side of shaft assembly allowing micrometer tip to rest directly on top of shaft See Figure 3 12 Zero the gauge this is to become the reference point Maintenance 3 25 NovaJet 800 Series Service Manual MEASURE MEASURE MEASURE FIRST LAST SECOND ADJUST IF NECESSARY Figure 3 12 Measurement Positions for Slide Shaft Measure the right side next to media alignment mark and note the difference Divide this amount by two Measure just off the center of the slide shaft and adjust the center turnbuckle with an open ended wrench if required for the average value the
208. the power cable to the connection located near the center of the circuit board Hold the E Connect Assembly in place and secure using 4 screws Torque to 15 in lbs Connect the small parallel cable and the network cable to the rear of the E Connect Assembly Assembly Disassembly 5 7 NovaJet 800 Series Service Manual Remove the Keypad and Display 1 Remove the Top and Right Covers following procedures outlined earlier in this chapter Turn the Right Cover Assembly over and with a 1 4 socket or wrench remove the four kepnuts securing the ESD Shield and ground connections See Figure 5 4 Remove the ESD Shield With a 1 4 socket or wrench remove the four standoffs and washers that secure the LCD Display Assembly to the Keypad Remove the Display Assembly Figure 5 4 Keypad and Display Installation Removal Assembly Disassembly 5 8 NovaJet 800 Series Service Manual 4 Disconnectthe grounding flex cable from the large standoff before removing the Keypad Assembly See Figure 5 5 for location Remove the Keypad Assembly Figure 5 5 Keypad and Display Grounding Connections Install the Keypad and Display 1 Route the Keypad flex data and ground cables into the Right Cover Assembly through the hole provided for the Keypad 2 Placethe Keypad into position and hold Turn the Right Cover Assembly over and position the Display Assembly onto the threaded studs of the
209. the unit through 7 day 24 hour operation for a minimum of 2 weeks without error Refer to disassembly to replace the encoder stabilizer bracket and the trailing cables Figure 4 75 Dirty or Defective Encoder Strip Inspect encoder strip for damage if error occurs in one spot consistently then the encoder strip could be damaged Replace the stabilizer bracket encoder strip is pre attached to stabilizer bracket and obtain a new trailing cable assembly for installation 2 Check outrigger carriage cover bushings for visible wear and replace outrigger bushings at 400 hours of printing operation To replace the cover bushings refer to disassembly procedures While replacing inspect and verify the internal right and left carriage bushings are not severely worn normally replaced at 2000 plot hours lsthe Slide Shaft clean Check with printer operator to see if lubricants have been applied to slide shaft no lubricants should be applied to any part of the printer Troubleshooting 4 72 NovaJet 800 Series Service Manual 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 Is the Carriage Belt tight Is the carriage belt frayed Check the frame tensioner and idler for damage ensure tension is tight on belt and not loose Clean inside of carriage belt with isopropyl alcohol greater than 70
210. thering properties different from that of another rasterized print Refer to Cartridge Misfires and Ink Dropout to ensure all other troubleshooting checks have been made For single color or multiple color print failures replace the carriage PWA If normal test patterns i e Color Test and normal basic test patterns are seriously degraded then replace the carriage PWA Refer to Disassembly Inspect and clean stepper motor and lower roller drive gears if printer is older than 5 years Other unique causes include synchronization errors from the stepper drive system due to defects or gear cleanliness Replace stepper motor for consistently spaced horizontal patterns 2 10 mm apart when printer is run in the best mode with a test print Often a lower roller drive noise will accompany the banding Inspect stepper motor gearing lower roller for damage debris ensure screws are tight Check stepper motor winding resistance Check lower roller height for head scrapes on media Banding will have jagged or slightly angled lines at the termination points or may even appear as light cuts in the media like a utility knife cut the surface of a print The normal head height range between the bottom surface of the cartridges and the platen surface is 0 062 to 0 068 Use the Carriage Head Height Kit for proper adjustment Refer to Alignments Replace the servo motor for horizontal bands thicker than 2 mm which extend beyond the page layou
211. trieb mancher Ger te z B kann allerdings gewissen Einschr nkungen unterliegen Beachten Sie deshalb die Hinweise in der Bedienungsanleitung Dem Zentralamt f r Zulassungen im Fernmeldewesen w rde dan Inverkehrbringen dieses Ger tes angezeigt und die Berechtigung zur berpr fung der Serie auf die Einhaltung der Bestimmungen einger umt Inc U S A Vi 800 Series Service Manual Material Safety Data Sheet ENCAD QIS Quality Imaging Supplies ink is nonhazard ous requiring no special disposal handling It can be harmful if swallowed and should be kept away from children To obtain a Material Safety Data Sheet contact ENCAD Inc at 6059 Cornerstone Court West San Diego CA 92121 3734 619 452 4350 International users should contact their local dealer or distributor Vil NovaJet 800 Series Service Manual Warranty or Damage Claims United States ENCADS Inc warrants its printers PRopucr to be free from defects in workmanship and materials for a period of one year from the date of purchase In order to submit a Warranty claim please contact the ENCAD Help Desk at 858 452 4350 ENCAD reserves the right to make changes or improvements to Products without incurring any obligation to similarly alter Products previously purchased Buyer s sole and exclusive rights pursuant to this Warranty shall be for the repair or replacement of defective Product ENCAD s
212. ture 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 dry band to appear on the print This feature is normally defaulted off Figure 4 25 Improper Grounding 5 For direct printing environments ensure all switchboxes and cables are IEEE 1284 compliant Troubleshooting 4 32 NovaJet 800 Series Service Manual Figure 4 26 Unseated or Defective Trailing Cables 6 Cleanthe cartridge electrical and carriage flex driver cable contacts with isopropyl alcohol Refer to Routine Maintenance the flex driver cable connection for print images which contain vertical bar patterns along the right edge of print If more than one color represented by the vertical bars is present then the trailing cable is either unseated or defective 7 Clean the encoder strip top and bottom slide shaft and inside of carriage belt with distilled water or isopropyl alcohol Troubleshooting 4 33 NovaJet 800 Series Service Manual T 2 gt Eo TUM iiir gt WE d x ANINO sigure 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 9 10 11 NovaJet 800 Series Service Manual Figure 4 29 Carriage
213. u Service Menu Diagnostic Menu Accessory Menu Sensor Status The printer LCD will display the following information Dryer Mode cccccccc Plenum deg MBoard deg MBoard H pct RH Troubleshooting 4 81 NovaJet 800 Series Service Manual Dre Humidity Sane Figure 4 85 Main PWA Humidity Sensor The Dryer Mode cccccccc indicates the current dryer setting Opera tional modes are OFF AUTO or DISABLED Plenum and MBoard T main board T indicate temperature and are displayed in degrees C MBoard H main board humidity indicates the ambient relative humidity as a percentage If the dryer mode is set to AUTO and the firmware times out trying to read the MBoard or MBoard H a character will appear after Dryer Mode ON to indicate that the dryer mode was automatically switched from AUTO to ON The power supply fan is turned on immediately upon menu selection One of its Jobs is to feed ambient air into the main board chamber where the sensors reside The main board sensors require several minutes mately 5 of this of exposure to the ambient air before they can adjust to room conditions If the printer has been turned off or has been idle for several minutes validation for sensor accuracy must be made after this adjustment period has elapsed Information on this display 1s updated once every five seconds Please
214. ulty keypad 4 13 ink cartridge failure 4 9 internal error auto sensor failure 4 6 carriage axis failure 4 4 encoder sensor failure 4 5 MPCB failure 4 7 paper sensor failure 4 6 media both motors inoperative 4 17 feed motor inoperative 4 17 sensor inoperative 4 17 take up motor inoperative 4 16 media does not move 4 3 no power 4 1 4 2 noisy operation 4 13 paper skewing 4 10 vacuum fan 5 48 5 54 warnings 1 4 Index 2
215. used J6 Leg Harness JI5 Vacuum Fan 1 J7 Stepper Motor notused J8 Power Supply J17 Power Supply Cooling Fan J9 Keypad J18 E Connect Power 024 PC133 SDRAM DIMM socket Maintenance 3 10 NovaJet 800 Series Service Manual JI J2 J3 14 Figure 3 5 Carriage PWA Connection Locations Table 3 2 Carriage PWA Connections Trailing Cable JS Cyan Slot 2 Drivers Paper Sensor J6 Magenta Slot 3 Drivers Encoder Sensor J7 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 The J2 and J3 jack connections shown on Figure 3 5 are used on the right carriage assem bly only To remove the ribbon cables from their connectors lift the connector s ribbon locking mechanism as shown in Figure 3 6 To reattach depress the locking mechanism back into the locking position after inserting the ribbon cable end Maintenance 3 11 NovaJet 800 Series Service Manual RIBBON Br 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 Many factors including but not limited to hours day used cleanliness of the trailing cable surfaces and general ambient
216. value found in step 3 See Figure 3 13 The NovaJet 850 60 inch model has two turnbuckles so both of these need to be adjusted together for the center position Maintenance 3 26 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 IN FRONT OF IT POSITION GAUGE DIRECTLY Figure 3 13 Slide Shaft Profile Adjustment For example If the Left 0 Right 40 004 then the center should be adjusted to 0 002 This will ensure a smooth plane of travel for the carriage assembly There are no adjustments on either end of the shaft in all models Head Height Alignment Procedure Perform this procedure only when the encoder strip stabilizer has been removed from the Y Arm or whenever the alignment is in question carriage head strikes occur or deadband calibrations cannot be achieved The head height alignment procedure is to ensure that the correct amount of distance exists between the cartridge jet plate and the Platen See Figure 3 14 Maintenance 3 27 NovaJet 800 Series Service Manual CARTRIDGE JET PLATE En re ME PLATEN HEAD HEIGHT a 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 G
217. ver Bushings 5 37 Replacing the Carriage 95 5 39 REMOVE TNE Service 5 40 Installthe Service DD NE DUE EN 5 41 Remove the Trailing Cable Assembly 5 41 Install the Trailing Cable Assembly 5 42 Remove the Stabilizer Bracket and Encoder Strip 5 43 Install the Stabilizer Bracket and Encoder Strip 5 44 Remove the Y Arm Assembly Pinch Rollers Slide Shaft and PUTO WO AG SENSOM 5 44 Install the Y Arm Assembly Pinch Rollers Slide Shaft and SENSOM 5 47 Remove the Gap Sensor Novadet 880 only 5 48 Remove the Lower Roller Assembly Stepper Motor and Vacuum Fan Novadet 850 5 48 Install the Lower Roller Assembly Stepper Motor and Vacuum gulis e 7 3 650 PCM 5 51 Remove the Lower Roller Assembly Stepper Motor and Vacuum Fan 880 5 54 Lower Roller Installation Tip NovaJet 880 5 57 Y Arm Assembly Installation Tip NovaJet 880 5 57 Remove the Media Take Up and Feed Sensor Brackets and 5 58 Install the Media Take Up Feed Sensor
218. vice station access hole so the Micrometer measuring tip extends to the head height plate surface Adjust for 67 3 reading the RED number only 13 Continue performing steps 10 through 12 until all six of the stabilizer screws have been adjusted 14 Reposition the Carriage to all of the adjustment positions and verify that the measurements are correct 15 Perform steps 6 through 15 as many times as necessary to correctly accomplish this adjustment Color Calibration This procedure describes how to check that the cartridges are properly aligned for color plotting and should be followed each time the ink car tridges are installed Figure 3 18 1 a representation of how a color calibration looks when printed Maintenance 3 31 NovaJet 800 Series Service Manual SS SE ee ee a SS SS SS SS SS SS SS M SS SSS SS SS SS SS SS COLOR VERTICAL HEAD TO HEAD CALIBRATION tee Mh 6 5 4 3 2 1 0 1 2 3 4 5 6 COLOR HORIZONTAL HEAD TO HEAD CALIBRATION Current Heads Figure 3 18 Vert and Horiz Color Calibration The Current Heads Y M C 1 2 3 4 view represents the alignment of the heads as they are currently entered This is just an overview of all heads and how they are aligned Do not attempt to align the heads using this view The Color Horizontal Head to Head Calibration checks the alignment of the nozzles horizontally and allows corrections when required Just en

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