Kodak NovaJet 850 Training manual

Technical Support Department

Revision 12_12_2005

NovaJet 850/880 Printer

T

r

a

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n

i

n

g

G

u

i

d

e

Printer Installation

2

Ink Installation

6

Printer Calibrations

11

Networking

18

Routine Maintenance

19

Preventive Maintenance

23

Cartridge Checklist

24

Common Problems

25

Technical Bulletins

- Available Ink Configurations

- Dry Time Guidelines

- Routine Printer Maintenance

- NJ880 Rigid/Textile Print Ops

- Printer Grounding, ESD

Control, & Output Symptoms

34

35

38

43

NovaJet 800 Series Training Guide

2

A. Printer Installation

1. Verify all boxes have been received.

Box 1 contains the printer head and customer documentation (includes the System

CDs, Quick Start Guide, screws, and screwdriver). Also enclosed are 12

reservoirs, 12 cartridge tubing needles/septum

connectors.

Box 2 contains the stand legs, stand feet,

takeup and feed system media rollers, media

core, 2 media adapters, dryer, 2 dryer brackets,

dryer logic cable and Ink Prime box.

Box 3 is the accessory box which contains the ink

and cartridges, sample roll of media, cutters,

and all versions of power cords).

NOTE: You will need to provide an RJ45 Ethernet cable to connect to the Ethernet

port.

2. Remove all contents from Box 2 (2

nd

largest box).

Box 2 contains the stand legs, stand feet, take-up and feed system, media rollers,

media core, 2 media adapters, dryer, dryer brackets and all screws, dryer logic

cord, and Easy Prime box.

NovaJet 800 Series Training Guide

3

3. Flip Box 1 (largest box) upside down and open.

Remove packaging materials, 12 ink reservoirs, 12 cartridge tubing

needles/septum connectors, network parallel cable, and documentation.

4. Attach legs and feet to printer.

Caution: Do not damage leg harness wiring! Ensure cable is not pinched/twisted.

5. Rotate printer to one side and lift out of box using a two person lift.

Ensure all plug connections are intact.

NovaJet 800 Series Training Guide

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6. Attach dryer brackets and install dryer plenum.

Note: align the dryer plenum guide pins with the dryer brackets.

7. Secure dryer logic cable and power cord. NOTE: If installing the new

universal dryer (black metal) ensure the underside voltage selector switch

is set to either 115VAC or 230VAC depending on region.

8. Activate diagnostics ‘legs test’.

Ensure media rollers and dryer function normally. Both rollers should initially pulse in

one direction. By blocking either the top sensor or bottom sensor path the opposite

roller should reverse direction. Dryer should intermittent pulse every few seconds,

after 5 minutes the air leaving the dryer should be warm.

Prime

Color Calib Menu

Access Cartridge

Display Settings

Service Menu

Print Settings

Calibration Menu

Exit

Utility Menu

Calibration Menu

Diagnostics Menu

About

Exit

Service Menu

Servo PWM Test

Accessory

Menu

Servo Cycle Test

Carriage Test

Exit

Color Test

Continuous Test

Diagnostics Menu

Fan #1 Test

Fan #2 Test

Legs Test

Exit

Accessory Menu

1 Spare

Exit

Legs Test Menu

0 Unwind

0 Wind

1 Interlock

1 +24V Detect

NovaJet 800 Series Training Guide

5

Load Media

Pause

Cut

Feed Media Menu

Utility Menu

Setup Menu

Reset

Main Menu

Print Mode Menu

Paper Option Menu

User Setup Menu

Serial Comm Menu

Ink Option Menu

HP-GL/2 Menu

Setup Menu

Exit

Supply Type

Margins

Media Standard

Auto-Cut

Auto-Wipe

Save Media

Paper Option Menu

Exit

Supply Type

Take-up

Next Option

Cancel

Print Passes

Ok

Prev Option

Press Next Option until “Take-up”

is displayed, select Ok.

Auto-Load Delay

9. Select supply mode

Options include Sheet, Roll, Roll 2 or Take-Up.

10. Load media into printer. Ensure alignment guides are set properly.

Note: maximum weight of media roll is 60 pounds.

Verify media loads correctly and is measured properly.

Check UTILITY MENU – DISPLAY SETTINGS for proper media measurements.

NovaJet 800 Series Training Guide

6

Installed needle assembly

Do not break connection when installing

new cartridge

25 ml inside - preprimed

B. Ink Installation

1. ‘Plug and Play Cartridge’ characteristics

2. Installing ink into reservoirs

It is suggested to fill reservoirs over a table to prevent spills on printer; fill to a

maximum of 400 ml (50 ml minimum).

3. Attach septum fitting to valve body. Prime line (and cartridge if

necessary).

NOTE: When the valve body is raised to the up

position ink flow is cut off, when the valve body (latch)

is closed then the ink line is open.

NovaJet 800 Series Training Guide

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a) Prime line using the short needles

(purple in color); attach short needle

to each of the 4 valves. Connect

septum needle to EasyPrime by

inserting into female receiver.

Depress and hold EasyPrime

activation button to provide a solid

burst, wait 20 seconds, or until ink

line is full.

b) Lift valve actuator (to up postion)

and remove purple septum needle

assembly.

c) Connect cartridge’s septum needle to valve and close valve – wait 60 seconds,

then remove the blue tape from cartridge jet plate!!

NOTE: If attempting to recharge an

existing cartridge, then disconnect

cartridge from stall position and

prime cartridge (print head) using

multiple sets of one-second bursts

until ink is visible in the ink line.

This may take 1-2 minutes to

accomplish depending on the

prime of entire ink line. Ensure

EasyPrime adapter is flush to

cartridge jet plate – a siphoning

sound (slight sucking) should be

heard when priming the cartridge

properly.

4. Activate the color test pattern for ink starvation problems.

Select: SETUP MENU – PRINT MODE MENU – PRINT PASSES – SELECT 3, OK.

Select: UTILITY MENU – SERVICE MENU – DIAGNOSTICS – COLOR TEST MENU –

STALL SELECT (or ALL COLORS)– choose color. Select DENSITY SELECT to 100%.

Select COLOR TEST PRINT. Verify color bar is printed without ink starvation.

Ink Test/Recovery Procedure

(Color Test Print)

This is a pressure test of the

system, so please disregard the

two-pass quality. Each pass of

the carriage assembly should lay

down a solid band of color with

33% ink load.

NovaJet 800 Series Training Guide

8

Color Test Failures:

- Example A above depicts

complete ink starvation in magenta.

This problem may be corrected by

using the EasyPrime and

establishing the required pressure

inside the cartridge. Replace

septum connector/needle if repeated

attempts continue to fail.

- Example B above depicts partial

ink starvation in magenta (ink fires

at 100% at the beginning of each

pass but then starves). This

problem can be corrected by

ensuring 19 ml of ink is present

inside the cartridge (level must be between 8 ml and 35 ml for proper operation – refer to

NOTE below).

NOTE: If you are installing a new Warranty print head (empty), need to revive a

deprimed cartridge due to ink starvation problems (see H-11 on page 30 for example) or

to verify proper cartridge ink levels, obtain syringe with extension tube from accessory kit.

Pull 20 ml of ink into syringe from ink reservoir or new ink bottle. Lift cartridge stall

position valve to up position to cut off ink flow (NJ700-800 series only). Temporarily

remove septum connector from cartridge. Install ink into cartridge by depressing syringe

plunger; pull back on plunger to remove excess ink (if any). Reconnect septum needle to

cartridge and close valve actuator (lower) to restore ink flow to cartridge. The cartridge

will need to be primed to restore negative pressure inside cartridge – refer to step 3

above.

NovaJet 800 Series Training Guide

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Jet is bad; jet re-

addressed

automatically

Jet is clogged (Jet

electronics are

good though)

Jet manually

bypassed,

jet good

Jet manually bypassed,

jet clogged

5. Activate the Prime pattern.

Select UTILITY MENU – PRIME. Verify all colors are printed. Verify no clogs are

present in the prime pattern. Manual or automatic jet compensation is provided up to 20

jets in each cartridge. Ensure the integrity of the diagonal lines are consistent and

smooth. Clean or replace cartridge if unsatisfactory.

6. Manually Bypassing Cartridge Jets

A manually bypassed jet appears as an 80% filled block

in the prime pattern (see jets at left and right below).

Perform manual jet bypass whenever a jet illustrates

degraded performance (i.e. clogging or fire misdirection).

In the example at right the magenta cartridge is severely

misfiring – the cartridge will most likely need to be

replaced.

NovaJet 800 Series Training Guide

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Prime

Color Calib Menu

Access Cartridge

Display Settings

Service Menu

Print Settings

Calibration Menu

Exit

Utility Menu

Use Calib X/Y

Paper Axis Test

Open Jet Menu

Exit

Paper Axis

Color Db Menu

Calibration Menu

Load Media

Pause

Cut

Feed Media Menu

Utility Menu

Setup Menu

Reset

Main Menu

Black Edit List

Magenta Edit List

Yellow Edit List

Cyan Edit List

Print Jet List

Exit

Open Jet Menu

Clear List Menu

Paper Axis

# 1: On

Prev Option

Next Option

Toggle Jet

Ok

Black Edit List

Press Next Option until

clogged jet number is

displayed, press Toggle Jet

to turn jet OFF, press OK.

Blown Jets

To manually bypass a clogged black (i.e. K) jet, perform the following steps:

In the example below the Magenta jets are illustrated completely blown (100%

filled blocks), but are being automatically bypassed by the printer. There is no

need to manually bypass any of the jets seen here. As long as the printer still

supports a desired print pass mode (refer to top of Prime pattern) then printing

may continue as normal. If the cartridge is still under warranty (<500 ml) and

more than 10 jets are blow, as observed in the Prime pattern, then this qualifies

as a cartridge replacement.

NovaJet 800 Series Training Guide

11

Use Calib X/Y

Paper Axis Test

Open Jet Menu

Exit

Paper Axis

Color Db Menu

Calibration Menu

Paper Axis

33.00

Prev Option

Next Option

Cancel

Exit

Paper Axis

Prime

Color Calib Menu

Access Cartridge

Display Settings

Service Menu

Print Settings

Calibration Menu

Exit

Utility Menu

Use Calib X/Y

Paper Axis Test

Open Jet Menu

Exit

Paper Axis

Color Db Menu

Calibration Menu

Load Media

Pause

Cut

Feed Media Menu

Utility Menu

Setup Menu

Reset

Main Menu

33.00 inches

Distance between the two

“T’s” should be 33.00” +/-

0.05” (inches)

C. Printer Calibrations

All calibrations should be performed in accordance with user documentation or

refer to steps below.

1. Paper Axis Test.

Prior to running a Paper Axis Test ensure a minimum of 36 inch media is loaded. To

activate the Paper Axis Test select Utility Menu - Calibration Menu - Paper Axis Test.

An upside-down "T" will be printed in the center

of the media, the media will advance

approximately 33 inches or 838 mm and another

"T" will be printed. This calibration is extremely

important for paneling and framing operations to

ensure proper line length accuracy; printer

accuracy is guaranteed to +/- 0.2%. Cut off and

measure the distance between the two T's using

a draftsman ruler, enter the true value under

under 'Paper Axis'. Select Utility Menu,

Calibration Menu, Paper Axis, enter the true

value once only. Note: the display will always

indicate 33" or 832.2 mm as the zero reference

position but the printer is now adjusted for this

media type.

Two “T’s” will be printed about 33.00 inches vertically

apart. Cut the media off and lay on a flat surface.

Measure the TRUE measured vertical distance

between the horizontal lines on the two printed “T’s”

using a steel drafting ruler or the 35inchruler.rtl file

(printed on NovaJet printer via EFPU print utility).

Enter the TRUE measured distance under “Paper

Axis”. For example if the distance was 33.06, then

input 33.06 one time only. CAUTION: If the test is re-

run the value will indicate 33.00 again, do not input

the same value again unless a new measurement is

taken – the system always adjusts reference to zero

(displayed as 33.00”).

NovaJet 800 Series Training Guide

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Prime

Color Calib Menu

Access Cartridge

Display Settings

Service Menu

Print Settings

Calibration Menu

Exit

Utility Menu

Calibration Menu

Diagnostics Menu

About

Exit

Service Menu

Deadband Test

Single Line Test

All Lines Test

Slow Db Test

Deadband

Exit

Slow Deadband

Calibration Menu

A series of vertical lines

will print. The top and

bottom portions print first,

followed by the center

portion. Ensure both

portions line up to each

other vertically.

This printed pattern is incorrectly adjusted.

Deadband Test

Single Line Test

All Lines Test

Slow Db Test

Deadband

Exit

Slow Deadband

Calibration Menu

Slow Deadband

-1

Prev Option

Next Option

Cancel

Ok

Slow Deadband

Press Next Option until

desired value is

displayed, select Ok. Re-

run the Slow Db Test

again to check. Repeat

until pattern is correct.

This printed pattern is correctly adjusted.

Deadband Test

Single Line Test

All Lines Test

Slow Db Test

Deadband

Exit

Slow Deadband

Calibration Menu

2. Slow Deadband Calibration

To activate the Slow Deadband calibration select Utility Menu - Service Menu -

Calibration Menu - Slow Db Test. The Slow dB Test pattern will print very slowly. This

is a mechanical adjustment of the printer servo system and should be performed monthly.

Ensure the vertical lines are straight, if out of alignment, as in this example, then an

adjustment is necessary. Select Utility Menu, Service Menu, Calibration Menu, Slow

Deadband - change the value and rerun the pattern until correct. NOTE: this calibration

is normally not required; mainly perform for CAD print operations.

If the slow deadband pattern is incorrect adjust the values and re-run the Slow Db Test until

the pattern prints correctly:

NovaJet 800 Series Training Guide

13

Prime

Color Calib Menu

Access Cartridge

Display Settings

Service Menu

Print Settings

Calibration Menu

Exit

Utility Menu

Black Deadband

Magenta Deadband

Yellow Deadband

Cyan Deadband

Color Db Test

Exit

Color Db Menu

Use Calib X/Y

Paper Axis Test

Open Jet Menu

Exit

Paper Axis

Color Db Menu

Calibration Menu

Y

M

C

K

84 76 68 60

Black Deadband

Magenta Deadband

Yellow Deadband

Cyan Deadband

Color Db Test

Exit

Color Db Menu

Black Deadband

68

Prev Option

Next Option

Cancel

Ok

Black Deadband

Note the most vertical set

of lines which coorespond

to “K”. In the above

example, 68 appears to be

the most correct value.

Press Next or Prev Option

until 68 is displayed, select

Ok.

3. Color Deadband Calibration

To activate the Color Deadband calibration select

Utility Menu - Calibration Menu - Color dB Menu -

Color dB Test. The Color dB pattern will print.

This is an electronic calibration for compensating

the differences in cartridge resistances. Always

perform this calibration whenever a cartridge is

replaced. To adjust left NJ850/880 print head (i.e.

values 1-4), select Left at control panel. Choose the

best value under each aligning set of colors. To

adjust the right print head (values Y, M, C, and K)

select Right at the control panel. Select the value under the best group of vertical lines in

each color. Please do not choose one value to characterize all colors unless illustrated

by the pattern.

The illustration below shows how to make an adjustment for Black Deadband:

NovaJet 800 Series Training Guide

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Prime

Color Calib Menu

Access Cartridge

Display Settings

Service Menu

Print Settings

Calibration Menu

Exit

Utility Menu

Cyan Vertical

Calib Print Test

Magenta Vertical

Cyan Horizontal

Exit

Magental Horiz.

Yellow Vertical Yellow Horiz.

Color Calib Menu

COLOR VERTICAL HEAD-TO-HEAD CALIBRATION

7012 3 456-6 -5 -4 -3 -2 -1

COLOR HORIZONTAL HEAD-TO-HEAD CALIBRATION

0 1234567-8 -7 -6 -5 -4 -3 -2 -1

4. Color Calibration (most important)

To activate the Color calibration select Utility Menu - Color Calib. Menu – Calib Test

(NOTE: the Vert Calib Test and Horiz. Calib. Test. will need to be activated and

adjusted) Seven horizontal patterns followed by seven vertical patterns will print. The

color calibration pattern should be performed whenever a cartridge is removed from the

carriage for cleaning or replacement. Choose the best value under each aligning set of

colors, i.e. yellow to magenta, then magenta to cyan, then cyan to black. Enter the most

correct value for each of the 14 fields. Note: stalls 1 through 4 correspond to the Left 4

cartridges. For the horizontal patterns and vertical patterns select the value which falls

below the best-aligned marks.

NOTE: Use the loupe (enclosed with the printer) and good lighting conditions to choose the

proper calibration value. Always perform this calibration when a cartridge is removed or

replaced.

NovaJet 800 Series Training Guide

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5. Final Calibration Check - Deadband Calibration

To activate the Deadband calibration select Utility Menu - Service Menu - Calibration

Menu - Deadband. The deadband pattern will print very quickly in all color ranges. This

is a final check of printer calibrations to ensure alignment has been achieved. Ensure the

vertical lines are straight with respect to each color, if severely out of alignment, as in this

example, then a re-calibration of the printer is necessary or cleaning of the encoder strip

is necessary. Note: The pattern does not have to be perfect, just close to maintaining

vertical alignments.

6. Controlling Media Skew (not image skew)

The NovaJet 800 series of printers are designed with self-aligning pinch rollers. The

alignment process takes place when media is advancing forward, but not backwards.

Loading media is critical to the media alignment and reducing skew. Many times the

media is loaded at a slight skew and will take several feet of advancing media to get it

aligned properly. This can be improved by following the steps below.

1. Load the media and align the rear media guides.

2. Advance the media though the printer about 1 foot, using the Feed Media Menu/Forward

button.

3. Put the printer media feed in “Sheet” mode (Set-up Menu/Paper Option Menu/Supply

Type/Sheet). Using the media “Forward” button, drive the media forward until it is pulled tight.

4. Change the media feed back to “Roll” or “Take-up” (Set-up Menu/Paper Option Menu/Supply

Type/

5. Roll or Take-up).

6. Advance the media forward three feet to check alignment with the white media guideline.

7. Start printing the image.

NovaJet 800 Series Training Guide

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7. Image Skew Specifications:

W

L

OUT P UT

ACTUAL

MEDI A PERIMETE

R

PERFECT REFERENCE

RECTANGLE

L

12

L

EXHIBIT

A

Assuming the media loading instructions as defined in the user manual

have been followed, Exhibit A describes the maximum permissible

image skew.

The maximum skew is:

0.30% of ∆L = (L

1

- L

2

) – except for NJ880 (no skew specification has been

designated)

Example:

If L

W

= 59.61 inches (1.51 m.), L = 48.00 inches (1.22 m.)

Then: L

1

should equal L

2

= 76.53 inches (1.94 m.)

The actual permissible skew (L

1

- L

2

) = (.003) (76.53) = .229”

(5.82 mm.)

NOTE: This is the only method used to determine skew.

NovaJet 800 Series Training Guide

17

Load Media

Pause

Cut

Feed Media Menu

Utility Menu

Setup Menu

Reset

Main Menu

Print Mode Menu

Paper Option Menu

User Setup Menu

Serial Comm Menu

Ink Option Menu

HP-GL/2 Menu

Setup Menu

Exit

Color Mode

Dots Per Inch

Quality Mode

Print Passes

Print Direction

Carriage Speed

Print Mode Menu

Exit

Print Passes

Ten

Next Option

Cancel

Print Passes

Ok

Prev Option

Press Next Option until “Ten”

is displayed, select Ok.

8. Best Quality Mode

To obtain the highest or optimum print quality mode from the printer, for 1x4 or 1x8 operations, place

the print pass mode to 10, carriage speed of 7 and bi-directional operation. For 2x4 print operations,

place the print pass mode to 5. To set the print-pass mode:

Print pass mode will impact image output quality – refer to the guidelines in the chart

below:

Print Pass Modes: 1, 2, 3, 4, 6, 8, 10 (For 1x4 and 1x8 cartridge sets)

1, 2, 3, 4 ,5 (For the 2x4 cartridge set)

Default print mode shown in RED Quality mode shown in Italics

NovaJet 800 Series Training Guide

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D. Networking

Printer Networking is generally a 3-step process:

1. Assign TCP/IP address of host

computer/server.

a) If you have not already done so, install

the TCP/IP protocol on your PC. This is

done by first RIGHT-CLICKING on the

My Network Places icon on your desktop.

b) Select Properties from the list. The

Network dialog box appears.

Double click on the Local Area

Connection icon. When the Local Area

Connection dialog box opens, double

click on the TCP/IP protocol to activate

the TCP/IP properties. See figure below.

2. Assign TCP/IP address at printer – stay in the same ‘range’ as host computer

from step 1. Select Setup Menu – Network Menu. Ensure DHCP is disabled

unless advised by a network administrator that it is required. (may also need

to install & configure a standard TCP/IP windows printer port during this

process if using EFPU for file downloading/firmware upgrading, etc.).

3. Assign TCP/IP address to RIP (same as printer’s IP address). Test

connectivity and begin print operations.

NovaJet 800 Series Training Guide

19

E. Routine Maintenance (same as

Technical Bulletin 3)

Perform routine maintenance at recommended

plot time hours and in accordance with prescribed

documentation. The printer must be cleaned and

serviced routinely (i.e. weekly or bi-weekly) or

print output anomalies or premature printer

failures may occur during normal operations.

Inkjet Printer Cleaning Kit, part number 216883-

00, is available for order.

It is suggested to remove power from the printer and remove media from the printing

area prior to performing routine maintenance.

INTERVAL COMPONENT CLEANING AGENT

75 Plot Hours Platen/Cutter Groove NovaKlean /Distilled Water

- Apply solution to lint-free towel and thoroughly

clean platen surfaces (printing area) and cutter

groove bottom surface. Use a toothpick to help

remove residue/debris from the cutter groove. If

the cutter groove is not cleaned adequately this

can lead to paper sensing errors, resulting in

‘no printing’ symptoms.

- Using a toothpick ensure the platen vacuum holes are free of obstructions.

INTERVAL COMPONENT CLEANING AGENT

20 Plot Hours Service Station NovaKlean /Tap Water

- Remove the service station by gently

pulling at securing tab at right side of

station. Immerse service station under

warm running tap water for 1-2 minutes.

Wipe residues away from wipers using

solution applied to a lint-free towel. Dry

service station and re-install.

I

NTERVAL COMPONENT CLEANING AGENT

20 Plot Hours/Idle >100 hrs Cartridge Jet Area NovaKlean /Distilled Water

NovaJet 800 Series Training Guide

20

- Apply solution to lint free towel. Blot cartridge jet plate center several times, wipe away

excess residues from sides of jet plate. NOTE: Do not wipe center jet plate area and do

not lift the cartridge up too high or flip cartridge upside down as this may cause the

cartridge to deprime. If deprime occurs the cartridge will need to be re-primed using the

NovaPrime or EasyPrime device.

- Apply solution to a 2

nd

lint-free towel thoroughly wipe the electrical cable contacts at

rear of cartridge. Proceed to flex driver cable cleaning prior to attaching cartridge – see

below.

INTERVAL COMPONENT CLEANING AGENT

75 Plot Hours Flex Driver Cables NovaKlean /Isopropyl Alcohol

- Apply solution to lint free towel. Clean entire

surface area of flex driver cable (for each

cartridge stall); wipe away excess residues from

cable surface.

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