Kodak 800 User Manual

NovaJet® 8-Head Family

NovaJet
800 Series

Service Manual

®

NOVAJET®

800 Series

Color Inkjet Printer

Service Manual

Part Number 216520-01

NovaJet 800 Series Service Manual

Copyright Eastman Kodak Company, 2002

®

KODAK, ENCAD

, VinylJet®, VinylJet®, CADJET®,
Extreme Color Printing™, and Graphic Outdoor Matched
System™ (GO) are trademarks of Eastman Kodak
Company.
Other trademarks and registered trademarks are the
property of their respective owners.
No part of this 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 elec­tronic 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 Rev A December 2000
2nd Edition Rev B June 2002

iii

FCC Statement (U.S.A.)

The United States Federal Communications Commision
has specified that the following notice be brought to the
attention of the users of the NOVAJET 800 series printers.

FEDERAL COMMUNICATIONS COMMISION RADIO AND
TELEVISION INTERFERENCE FOR CLASS B DEVICE

This equipment has been tested and found to comply with
the limits for a class A digital device, pursuant to part 15
of the FCC Rules. 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 in­stalled and used in accordance with the instructions, may
cause harmful interference to radio communications.

NovaJet 800 Series Service Manual

iv

User Instructions:

If the equipment does cause harmful interference to radio
or television reception, which can be determined by
turning the equipment off and on, the user is encouraged
to try to correct the interference by one of the following
measures:

− Reorient or relocate the receiving antenna.

− Increase the separation between the equipment and

receiver.

− Connect the equipment into an outlet on a circuit

different from that to which the receiver is connected.

− 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

v

VDE Statement

Hiermit wird bescheinigt, daß die NOVAJET 800 Serie
von Drucker in Übereinstimmung mit den Bestimmungen
der BMPT-AmstbIVfg 234/1991 funkentstört ist. Der
vorschriftsmäßige Betrieb mancher Geräte (z.B.
Meßsender) kann allerdings gewissen Einschränkungen
unterliegen. Beachten Sie deshalb die Hinweise in der
Bedienungsanleitung.

Dem Zentralamt für Zulassungen im Fernmeldewesen
würde dan Inverkehrbringen dieses Gerätes angezeigt und
die Berechtigung zur Überprüfung der Serie auf die
Einhaltung der Bestimmungen eingeräumt.

ENCAD, Inc. U.S.A

NovaJet 800 Series Service Manual

vi

Material Safety Data Sheet

ENCAD QIS (Quality Imaging Supplies) ink is nonhazard­ous, requiring no special disposal handling. It can be
harmful if swallowed and should be kept away from
children.

To obtain a Material Safety Data Sheet, contact ENCAD,
Inc. at:

6059 Cornerstone Court West
San Diego, CA 92121-3734
[phone]

International users should contact their local dealer or
distributor.

NovaJet 800 Series Service Manual

vii

NovaJet 800 Series Service Manual

Warranty or Damage Claims

United States

ENCAD®, Inc., warrants its printers ("PRODUCT") to be free from defects in
workmanship and materials for a period of one year from the date of
purchase. In order to submit a Warranty claim, please contact the
ENCAD Help Desk at [phone].

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 specifically disclaims
any and all other warranties, expressed or implied, including but not limited
to, implied warranties of merchantability and fitness for a particular pur­pose. 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 autho­rized 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

Introduction .................................................................................. 1-1

Overview ....................................................................................... 1-3

Related Publications..................................................................... 1-3

Electrostatic Discharge (ESD) Sensitivity ...................................... 1-3

Warnings, Cautions and Notes......................................................1-4

Printer Specifications .................................................................... 1-5

Contents of this Service Manual .................................................... 1-6

Technical Support ......................................................................... 1-8

Chapter 2 Theory of Operation.......................................2-1

Introduction .................................................................................. 2-1

NovaJet 800 Series Printers General Block Diagram ......................2-2

Paper (Media) Axis Drive............................................................... 2-4

The Carriage Axis Drive ................................................................. 2-5

Media Feed and Take-Up System..................................................2-6

Main PWA (Printed Wiring Assembly) ...........................................2-7

Main PWA LED Status Indicators............................................ 2-8

Microprocessor (CPU) ............................................................ 2-8

Gate Array ............................................................................. 2-9

Digital Signal Processor (DSP) ............................................... 2-9

Memory Circuits................................................................... 2-10

Flash EEPROM ............................................................. 2-10

SDRAM ......................................................................... 2-11

Serial EEPROM ............................................................. 2-11

Stepper Motor Controller ....................................................... 2-11

Servo Motor Controller .......................................................... 2-13

Interface Circuits: Serial & Parallel ........................................ 2-15

ix

NovaJet 800 Series Service Manual

Table of Contents (cont)

Chapter 3 Maintenance ...................................................3-1

Introduction .................................................................................. 3-1

Scheduled Maintenance................................................................ 3-1

Cleaning Procedures ..............................................................3-2

External Cleaning ............................................................. 3-2

Slide Shaft Cleaning ......................................................... 3-2

Service Station Cleaning ................................................... 3-3

Linear Encoder Strip Cleaning ........................................... 3-4

Trailing Cables Cleaning ................................................... 3-5

Platen/Vacuum Hole Cleaning........................................... 3-5

Cartridge Dimples Cleaning .............................................. 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 ................................................................. 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 & Quick Analysis........................................ 3-19

Horizontal Banding Problems.......................................... 3-19

Vertical Banding Problems.............................................. 3-22

Line Quality Problems (Overspray) .................................. 3-23

Alignments/Adjustments............................................................. 3-24

Slide Shaft Profile Adjustment ............................................... 3-24

Head Height Alignment Procedure ......................................... 3-27

Color Calibration ................................................................... 3-31

Deadband Alignments ........................................................... 3-34

Color Deadband Alignment.............................................. 3-37

Paper Axis Calibration .......................................................... 3-39

Diagnostics Menu....................................................................... 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

x

NovaJet 800 Series Service Manual

Table of Contents (cont)

Chapter 4 Troubleshooting.............................................4-1

Introduction .................................................................................. 4-1

No Power ............................................................................... 4-1

No Power ............................................................................... 4-2

Initialization Failure................................................................. 4-2

Media Does Not Move............................................................. 4-3

Internal ERROR “Carriage Axis Failure” ...................................4-4

Internal ERROR “Encoder Sensor Failure” ............................... 4-5

Internal ERROR “Paper Sensor Failure” ................................... 4-6

Internal ERROR...................................................................... 4-6

Auto-Load Paper Sensor Failure” ............................................4-6

Internal ERROR “MPCB Failure” ............................................. 4-7

Unrecognized Cartridges Error ................................................4-7

Media Sen Ref. Pts Not Initialized (NJ880 only) ....................... 4-8

Image Skews or Moves........................................................... 4-8

Does Not Print ....................................................................... 4-8

Ink Cartridge Misfiring ............................................................. 4-9

Paper Skewing ..................................................................... 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 Operation ................................................................... 4-13

Line Quality Degraded .......................................................... 4-14

Fan Does Not Power Up ....................................................... 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 Working.......................................................... 4-17

Media Feed or Take-Up Sensor(s) Not Operating ................... 4-17

Print Quality Issues .............................................................. 4-19

Cartridge Misfires (Intermittent Banding) ................................ 4-19

Failure Analysis - Print Misfires............................................ 4-20

Common Misfire Problems.............................................. 4-25

Clearing Cartridge Misfires.............................................. 4-26

Multiple Cartridge Failures .............................................. 4-26

xi

Table of Contents (cont)

Chapter 4 Troubleshooting (cont)

Microbanding............................................................. 4-28

Banding Differences................................................... 4-30

Horizontal Banding .................................................... 4-31

Vertical Banding ........................................................ 4-43

Line Quality Problems (Overspray) ............................. 4-46

Cartridge Warranty .................................................... 4-47

Cartridge Maintenance & Testing................................ 4-48

Ink Starvation............................................................. 4-52

Ink Dropout ............................................................... 4-57

Color Test Problems .................................................. 4-60

“Unrecognized Cartridge” Error Message .................... 4-63

Paper Sensor Error.................................................... 4-65

Encoder Sensor Error ................................................ 4-68

AutoLoad Paper Sensor Error .................................... 4-69

Carriage Axis Error .................................................... 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 Port Test ..................................................... 4-100

Firmware Downloading Procedures........................... 4-101

NJ850 Printer .......................................................... 4-101

NJ880 Printer .......................................................... 4-102

Media Handling System Failure................................ 4-104

NovaJet 800 Series Service Manual

xii

NovaJet 800 Series Service Manual

Table of Contents (cont)

Chapter 5 Assembly\Disassembly................................5-1

Introduction .................................................................................. 5-1

Remove the Left, Top, and Right Covers......................................... 5-2

Remove the E-Connect Network Assembly .................................... 5-6

Install the E-Connect Network Assembly ....................................... 5-7

Remove the Keypad and Display ................................................... 5-8

Install the Keypad and Display ...................................................... 5-9

Remove Memory Module............................................................. 5-10

Install Memory Module................................................................ 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 AC Entry Module .......... 5-15

Install the Power Supply, Cooling Fan, and AC Entry Module........ 5-17

Remove Servo Motor ................................................................... 5-18

Install Servo Motor ...................................................................... 5-20

Remove the Ink Delivery System ................................................. 5-21

Install the Ink Delivery System .................................................... 5-23

Remove the Carriage Assembly, Carriage Belt, and the Frame

Tensioner.................................................................................... 5-23

Install the Carriage Assembly, Carriage Belt, and the

Frame Tensioner ......................................................................... 5-28

Remove the Carriage PWA.......................................................... 5-31

Install the Carriage PWA............................................................. 5-33

Remove the Paper Sensor or the Encoder Sensor........................ 5-34

Install the Paper Sensor or the Encoder Sensor........................... 5-36

Replacing the Floating Carriage Cover Bushings .......................... 5-37

Replacing the Carriage Bushings................................................. 5-39

Remove the Service Station......................................................... 5-40

Install the Service Station ............................................................ 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

AutoLoad Sensor........................................................................ 5-44

Install the Y-Arm Assembly, Pinch Rollers, Slide Shaft,

and AutoLoad Sensor.................................................................. 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 (NovaJet 850).......................................................... 5-48

Install the Lower Roller Assembly, Stepper Motor and

Vacuum Fan (NovaJet 850).......................................................... 5-51

Remove the Lower Roller Assembly, Stepper Motor and

Vacuum Fan (NovaJet 880).......................................................... 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

Sensors ..................................................................................... 5-58

Install the Media Take-Up and Feed Sensor Brackets and

Sensors ..................................................................................... 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-

64Assembly\Disassembly............................................................. 5-1

Introduction .................................................................................. 5-1

Remove the Left, Top, and Right Covers......................................... 5-2

Remove the E-Connect Network Assembly .................................... 5-6

Install the E-Connect Network Assembly ....................................... 5-7

Remove the Keypad and Display ................................................... 5-8

Install the Keypad and Display ...................................................... 5-9

Remove Memory Module............................................................. 5-10

Install Memory Module................................................................ 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 AC Entry Module .......... 5-15

Install the Power Supply, Cooling Fan, and AC Entry Module........ 5-17

Remove Servo Motor ................................................................... 5-18

Install Servo Motor ...................................................................... 5-20

Remove the Ink Delivery System ................................................. 5-21

Install the Ink Delivery System .................................................... 5-23

xiv

NovaJet 800 Series Service Manual

Table of Contents (cont)

Chapter 5 Assembly\Disassembly (cont)

Remove the Carriage Assembly, Carriage Belt, and the Frame

Tensioner.................................................................................... 5-23

Install the Carriage Assembly, Carriage Belt, and the

Frame Tensioner ......................................................................... 5-28

Remove the Carriage PWA.......................................................... 5-31

Install the Carriage PWA............................................................. 5-33

Remove the Paper Sensor or the Encoder Sensor........................ 5-34

Install the Paper Sensor or the Encoder Sensor........................... 5-36

Replacing the Floating Carriage Cover Bushings .......................... 5-37

Replacing the Carriage Bushings................................................. 5-39

Remove the Service Station......................................................... 5-40

Install the Service Station ............................................................ 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

AutoLoad Sensor........................................................................ 5-44

Install the Y-Arm Assembly, Pinch Rollers, Slide Shaft, and

AutoLoad Sensor........................................................................ 5-47

Remove the Gap Sensor (NovaJet 880 only)................................. 5-48

Remove the Lower Roller Assembly, Stepper Motor and

Vacuum Fan (NovaJet 850).......................................................... 5-48

Install the Lower Roller Assembly, Stepper Motor and Vacuum

Fan (NovaJet 850) ....................................................................... 5-51

Remove the Lower Roller Assembly, Stepper Motor and

Vacuum Fan (NovaJet 880).......................................................... 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

Sensors ..................................................................................... 5-58

Install the Media Take-Up and Feed Sensor Brackets and

Sensors ..................................................................................... 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)

Chapter 6 Parts List........................................................6-1

xvi

NovaJet 800 Series Service Manual

List of Illustrations

Figure Page

Chapter 1 General Description

1-1. NovaJet 800 Series Inkjet Printer .................................................1-1

Chapter 2 Theory of Operation

2-1. General Block Diagram. .............................................................. 2-3

2-2. Paper (Media) Axis Drive. ............................................................2-4

2-3. Carriage Axis Drive. ..................................................................... 2-5

2-4. Power Feed and Take-Up System................................................ 2-6

2-5. Main PWA (Printed Wiring Assembly).......................................... 2-7

2-6. Gate Array. ................................................................................. 2-9

2-7. Stepper Motor Controller. ........................................................... 2-11

2-8. Servo Motor Controller. .............................................................. 2-13

2-9. Quadrature Signal Generation.................................................... 2-14

2-10. Interface Circuits. .................................................................... 2-15

2-11. Carriage Assembly Circuits. ..................................................... 2-16

2-12. Main Menu. ............................................................................. 2-18

Chapter 3 Maintenance

3-1. Encoder Strip Cleaning. ............................................................... 3-4

3-2. Cartridge Dimple Region. ............................................................. 3-6

3-3. Flex Cable Contacts.................................................................... 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

3-7. Servo Motor............................................................................... 3-14

3-8. Stepper Motor. .......................................................................... 3-15

3-9. Power Feed and 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. ........................................................... 3-29

3-18. Vert. and Horiz. Color Calibration. ............................................ 3-32

3-19. Utility Menu. ........................................................................... 3-33

xvii

NovaJet 800 Series Service Manual

List of Illustrations (cont)

Figure Page

Chapter 3 Maintenance (cont.)

3-20. Color Calib Menu..................................................................... 3-33

3-21. Vertical Options Menu. ............................................................ 3-34

3-22. Slow Deadband. ...................................................................... 3-35

3-23. Service Menu. ......................................................................... 3-36

3-24. Calibration (Deadband) Menu. .................................................. 3-36

3-25. Calibration Menu. .................................................................... 3-37

3-26. Color Db Menu. ....................................................................... 3-38

3-27. Paper Axis Test....................................................................... 3-40

3-28. Diagnostics Menu. .................................................................. 3-41

3-29. Accessory Menu. .................................................................... 3-41

3-31. Carriage PWA Connections Diagram........................................ 3-46

3-32. Leg Harness Connections Diagram. ......................................... 3-47

Chapter 4 Troubleshooting

4-1. Cartridge Misfire. ..................................................................... 4-19

4-2. Excessive Ink Pressure. .......................................................... 4-20

4-3. Dirty Service Station. ............................................................... 4-21

4-4. Septum and Valves. ................................................................. 4-21

4-5. Unseated Flex Driver Cable. ..................................................... 4-22

4-6. Septum Connector. .................................................................. 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

4-11. Stall Configuration.................................................................... 4-25

4-12. Magenta Cartridge Misfires. ..................................................... 4-25

4-13. Adjacent Jet Misfire (Cyan). ..................................................... 4-26

4-14. Service Station. ....................................................................... 4-27

4-15. Defective Cartridge Power Lines. .............................................. 4-27

4-16. Catastrophic Jet Failure. ........................................................... 4-28

4-17. Power Line Failure. .................................................................. 4-28

4-18. Address Line Failure. ............................................................... 4-28

4-19. Multiple Address Line Failure. .................................................. 4-28

4-20. Microbanding. .......................................................................... 4-29

4-21. Quality Print Modes. ................................................................ 4-29

4-22. Ink Cartridge Configurations. .................................................... 4-30

4-23. Defective Magenta Cartridge..................................................... 4-31

4-24. AutoWipe Interference. ............................................................ 4-32

4-25. Improper Grounding. ................................................................ 4-32

xviii

NovaJet 800 Series Service Manual

List of Illustrations (cont)

Figure Page

Chapter 4 Troubleshooting (cont)

4-26. Unseated or Defective Trailing Cables. ...................................... 4-33

4-27. ESD Problems. ........................................................................ 4-34

4-28. Defective Carriage PWAs. ........................................................ 4-34

4-29. Carriage Head Strike. ............................................................... 4-35

4-31. Low Data Transfer Problem. ..................................................... 4-35

4-32. Test Print. ................................................................................ 4-36

4-33. Misfiring Jet.............................................................................. 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

4-38. RIP Error. ................................................................................. 4-39

4-39. Connectivity Problem . .............................................................. 4-40

4-40. Dirty or Defective Encoder Strip. ............................................... 4-40

4-41. Main PWA Failures. ................................................................. 4-41

4-42. RIP Problem. ........................................................................... 4-42

4-4. Bent Servo Motor Pulley........................................................... 4-42

4-44. Dirty or Worn Carriage Bushings. ............................................. 4-43

4-45. Worn Bushings or Bushing Pads. ............................................ 4-43

4-46. Defective Trailing Cable Examples. ........................................... 4-44

4-47. Dirty Encoder Strip. ................................................................. 4-45

4-48. Defective Teflon Strip. .............................................................. 4-45

4-49. RIP Error (Page Layout Violation)............................................. 4-46

4-50. ESD Problem. ......................................................................... 4-47

4-51. Jet Out Detection. ................................................................... 4-48

4-52. Cartridge Cleaning. .................................................................. 4-50

4-53. Service Station Cleaning. ......................................................... 4-51

4-54. Magenta Ink Pressure Failure. ................................................. 4-52

4-55. Ghosting. ................................................................................ 4-53

4-56. Cartridge Tubing Needle and Septum. ...................................... 4-54

4-57. 208 Jet Cartridge. .................................................................... 4-55

4-58. EasyPrime Operation. ............................................................. 4-55

4-59. Reservoirs and Ink Delivery System.......................................... 4-56

4-60. Excessive Ink Pressure. .......................................................... 4-57

4-61. Excessive Ink PreHeat Settings. .............................................. 4-58

4-62. Dirty Service Station Problem................................................... 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

4-66. Ink Starvation. ......................................................................... 4-63

4-67. Cartridge Identification Chip. .................................................... 4-64

4-68. Flex Driver Cable. .................................................................... 4-65

4-69. Paper Sensor. ......................................................................... 4-66

4-70. Paper Sensor Location. ........................................................... 4-68

4-71. Encoder Sensor. ..................................................................... 4-68

4-72. AutoLoad Paper Sensor. .......................................................... 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 Operation. ...................................................... 4-76

4-79. Memory Module. ..................................................................... 4-76

4-80. Paper Sensor. ......................................................................... 4-78

4-81. Main PWA LED Operation. ...................................................... 4-79

4-82. Functional Problem................................................................. 4-80

4-83. Connectivity Problem............................................................... 4-80

4-84. ESD Problem.......................................................................... 4-81

4-85. Main PWA Humidity Sensor..................................................... 4-82

4-86. Dryer LEDs. ............................................................................ 4-85

4-87. Dryer Connectivity. .................................................................. 4-85

4-88. Internal Test Print. ................................................................... 4-86

4-89. SEH Activated Test Pattern...................................................... 4-87

4-90. E-Connect LEDs. .................................................................... 4-87

4-91. Driver/RIP Problem. ................................................................. 4-88

4-92. Inadaquate Network Data Transfer Rate................................... 4-88

4-93. ESD Problems. ....................................................................... 4-89

4-94. Servo Cycle/PWM Menu. ........................................................ 4-90

4-95. Carriage Bushings. ................................................................. 4-90

4-96. Servo System Synchronization Error. ...................................... 4-91

4-97. Probable Defective Main PWA. ............................................... 4-91

xx

NovaJet 800 Series Service Manual

List of Illustrations (cont)

Figure Page

Chapter 4 Troubleshooting (cont)

4-98. Probable Defective Carriage PWA........................................... 4-92

4-99. Defective Main PWA. ............................................................. 4-92

4-100. Corrupted Code - Main PWA................................................... 4-93

4-101. Microbanding.......................................................................... 4-93

4-102. Apparent Ink Overspray. ......................................................... 4-94

4-103. True Type Font Problem.......................................................... 4-94

4-104. Print Settings Not Printing in Black. ........................................ 4-94

4-105. Text Field Problem. ................................................................ 4-95

4-106. Dirty or Defective Encoder Strip. .............................................. 4-95

4-107. Initialization Menu Location. .................................................... 4-96

4-108. Printer Hesitation Causes. ...................................................... 4-97

4-109. E-Connect LEDs. ................................................................... 4-99

4-110. Semi-Circular Nook Test Pattern. ............................................ 4-99

4-111. Loopback Test Cable............................................................ 4-100

4-112. Demo Print. ......................................................................... 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. .............................. 5-3

5-2. Left Cover Removal/Installation. ................................................ 5-4

5-3. E-Connect Assembly Installation/Removal. ............................... 5-7

5-4. Keypad and Display Installation/Removal. ................................. 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........................................................... 5-16

5-9. Cooling Fan/AC Entry Module Removal................................... 5-17

5-10. Using the Belt Removal Tool. .................................................. 5-19

5-11. Chain Guide Removal. ............................................................ 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. ............................................................... 5-27

xxi

NovaJet 800 Series Service Manual

List of Illustrations (cont)

Figure Page

Chapter 5 Assembly/Disassembly (cont.)

5-18. Carriage Coupler Installation. ................................................... 5-28

5-19. Left Carriage Installation. ......................................................... 5-29

5-20. Carriage PWA Removal/Installation. ......................................... 5-32

5-21. Paper and Encoder Sensor Removal. ....................................... 5-34

5-22. Paper and Encoder Sensor Installation..................................... 5-36

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. ......................................................... 5-40

5-27. Stabilizer Bracket Installation/Removal. .................................... 5-43

5-28. Y-Arm Installation/Removal. ..................................................... 5-45

5-29. Pinch Roller. ........................................................................... 5-46

5-30. Stepper Motor Removal/Installation. ......................................... 5-51

5-31. Inside Platen, Right Side. ........................................................ 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 Breakdown. ....................................................... 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

xxii

NovaJet 800 Series Service Manual

List of Tables

Table Page

Chapter 3 Maintenance

3-1. Main PWA Connections. ............................................................ 3-10

3-2. Carriage PWA Connections. ....................................................... 3-11

Chapter 4 Troubleshooting

4-1. Troubleshooting Table.................................................................. 4-1

Chapter 5 Assembly/Disassembly

5-1. Thermal Dryer PWA Connections................................................ 5-65

xxiii

NovaJet 800 Series Service Manual

General Description 1

Introduction

Figure 1-1. NovaJet 800 Series Inkjet Printer.

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 is automatically
determined and 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 is provided to interface with the host computer.
Commands sent from the host computer can be in several forms including HP-GL/2,
HP-RTL and Encad RTL formats.

Drivers are supplied to support Windows®-based PCs (95, 98, ME, NT and 2000) as
well as Macintosh and Power PC computers.

These printers expand upon ENCAD’s tradition of delivering fast, high-quality color or
monochrome graphics for a variety of applications. 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

Related Publications

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.

The following publication contains additional information which may be
useful in servicing the NovaJet 800 Series Color Inkjet Printers:

? ENCAD NovaJet 800 Series Quick Start Guide,

P/N 215360-XX

? ENCAD NovaJet 800 Series System CD-ROM,

P/N 215363-XX

Copies of these and other ENCAD, Inc. 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

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
indicated by:

Followed by a paragraph describing the concern.

NovaJet 800 Series Service Manual

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:

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:

NOTE

Followed by a paragraph describing the concern.

General Description 1-4

Printer Specifications

The specifications and performance characteristics of the NovaJet
800 Series Color Inkjet Printers are as follows:

NovaJet 800 Series Service Manual

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

100BaseT Interface

Certifications:

Safety

CSA, CSE/NRTL
(equivalent to UL1950)
TUV GS
EN 50 082-1
EN 60 950
UL1950
NOM-019-SCFI-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:

Operating:

65° to 85° F

Weight: NJ850 NJ880

60” 165 lbs 235 lbs

42” 150 lbs
(18° to 30° C)
5% to 80% RH
non-condensing

Storage:

Dimensions:

Height 44”(1.12m) 48” (1.22m)

Width 93” (2.37m)
40° to 95° F
(4° to 35° C)
5% to 80% RH
non-condensing

Depth 28” (0.71m)

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.

42 inch

111” (2.82m) 111” (2.82m)
60 inch

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 alignment/adjustments recommended to perform on
the printers. Diagnostics and a signal flow diagram are also listed.

Chapter 4 TROUBLESHOOTING - A table containing problems that could occur

and possible causes and repairs is found in this chapter. This table is not
intended to be a complete listing of troubleshooting procedures. 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 in this manual are based on 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 right for Y.

General Description 1-7