Technical Support Department
Revision 12_12_2005
NovaJet 850/880 Printer
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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
34
35
38
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
4
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
7
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
9
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
10
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
12
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
14
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
15
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
16
7. Image Skew Specifications:
W
L
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
18
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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