NovaJet 750 Printer

Training Guide
Ink Installation
Printer Calibrations
Routine Maintenance
Preventive Maintenance
Cartridge Checklist
Advanced Troubleshooting
Print Server Networking
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A. Ink Installation
1. ‘Plug and Play Cartridge’ characteristics

Installed needle assembly

Do not break connection when installing
new cartridge

25 ml inside - preprimed

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.

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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

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down a solid band of color with 33% ink load.

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: To install ink into a cartridge or to verify proper cartridge ink level obtain syringe
with tube extension from accessory kit. Pull 20 ml of ink into syringe. Lift cartridge stall
position valve to up position to cut off ink flow. 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.

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.

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6. Cartridge Jet - Manual Bypass Feature

Example: to manually bypass a clogged black (K) jet, perform the following steps:

Main Menu Open Jet Menu

Load Media Feed Media Menu Black Edit List Print Jet List
Cut Setup Menu Cyan Edit List Clear List Menu
Pause Utility Menu Magenta Edit List
Reset Yellow Edit List Exit

Utility Menu Black Edit List

Prime Display Settings Paper Axis Toggle Jet

Access Cartridge Print Settings Next Option
Color Calib Menu Service Menu # 1: On
Calibration Menu Prev Option Ok
Exit

Calibration Menu Press Next Option until

Use Calib X/Y Open Jet Menu clogged jet number is
Paper Axis Test Paper Axis displayed, press Toggle Jet
Color Db Menu to turn jet OFF, press OK.
Exit

Jet is bad; jet re-

addressed
Jet manually automatically Jet manually bypassed,
bypassed, jet clogged
jet good

Jet is clogged (Jet

electronics are
good though)

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B. Printer Calibrations

A. 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 33.00 inches
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 Distance between the two
length accuracy; printer accuracy is
“T’s” should be 33.00” +/-
guaranteed to +/- 0.2%. Cut off and measure
the distance between the two T's using a 0.05” (inches)
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.

B. Slow Deadband
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; for CAD operations mainly.

C. Color Deadband
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 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.

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D. Color Calibration
To activate the Color calibration select Utility Menu - Color Calib. Menu – Calib Test
(NJ850: Both Vert Calib Test and Horiz. Calib. Test.) 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.

E. Deadband Check
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.

F. Controlling Image Skew (not media skew as this is mechanical).

The NovaJet 750/800 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.

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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.

G. ACCEPTABLE IMAGE SKEW:

PERFECT REFERENCE
RECTANGLE

L2 L1

L
ACTUAL
OUTPUT

LW MEDIA PERIMETER

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 = (L1 - L2) – except for NJ880 (no skew specification has been
designated)

Example: If LW = 59.61 inches (1.51 m.), L = 48.00 inches (1.22 m.)

Then: L1 should equal L2 = 76.53 inches (1.94 m.)

The actual permissible skew (L1 - L2) = (.003) (76.53) = .229”

(5.82 mm.)

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

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C. Routine Maintenance
1. Perform routine maintenance at
recommended plot time hours and in
accordance with prescribed
documentation.
NOTE: The NovaJet printer must be cleaned and
serviced routinely or print output anomalies or
printer failures may occur during normal
operations. It is strongly suggested to take 15
minutes once a week (i.e. every Monday morning) and
perform printer cleaning rather than attempt to remember each cleaning cycle as listed below.

INTERVAL COMPONENT CLEANING AGENT

25-50 Hours Platen/External Surfaces NovaKlean solution on Lint-Free Towel

Can cause paper sensing errors;

resulting in ‘no printing’ symptoms.

INTERVAL COMPONENT CLEANING AGENT

10-20 Hours Service Station NovaKlean or Distilled Water

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INTERVAL COMPONENT CLEANING AGENT

10-20 Hours Cartridge Jet Area NovaKlean on lint-free Towel

50-75 Hours Encoder Strip NovaKlean on cotton swab, followed by

Isopropyl Alcohol on cotton swab (perform every 25 plot hours for GO ink printing)

INTERVAL COMPONENT CLEANING AGENT

50-75 Hours Trailing Cable NovaKlean on lint-free Towel

INTERVAL COMPONENT CLEANING AGENT

50-75 Hours Slide Shaft NovaKlean on lint-free Towel

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INTERVAL COMPONENT CLEANING AGENT

50-75 Hours Flex Driver Cables NovaKlean on lint-free Towel

Ensure cables are dry.

INTERVAL COMPONENT CLEANING AGENT

20-30 Hours Carriage Bushings NovaKlean on cotton swab

50-75 Hours Cutter Groove Toothpick or small wooden tool

INTERVAL COMPONENT CLEANING AGENT

25-50 Hours Pinch/Lower Roller NovaKlean on lint-free Towel

INTERVAL COMPONENT CLEANING AGENT

50-75 Hours Platen Vacuum Holes Toothpick or small wooden tool

80-100 Hours Y-Arm Surface NovaKlean on cotton towel

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INTERVAL COMPONENT CLEANING AGENT

As Required Paper Sensor Isopropyl Alcohol on cotton swab

The Paper Sensor is located directly behind the Right Carriage magenta
cartridge approximately 4 mm. Spin cotton swab at an upward angle of 30 degrees.

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D. Preventive Maintenance
Perform preventive maintenance at recommended plot time hours
and in accordance with prescribed documentation (authorized
service providers only!).
At 2000 plot hours replace both Carriage Bushings, Trailing Cable, Service Station and
thorough perform cleaning (including carriage paper sensor and encoder sensor).

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E. Cartridge Checklist (for warranty replacement)

1. Electrically bad jets (100% filled block) in the Prime pattern (10 nozzle failures for 20 Jet (red-top)
cartridges and <500 ml throughput (see UTILITY MENU – SERVICE MENU – CARTRIDGE INFO)
warrants a cartridge replacement. Manually bypass clogged jets as necessary (clogged jets, misfires,
are not covered by the warranty.) Clean the jet plate thoroughly by blotting with a water dampened
lint-free towel to clear clogs.

Catastrophic Failure (more than 35 jets)

Faulty Power Line; check compensation list

to verify photo mode is still supported.
Clean rear electrical contacts and reseat
cartridge to verify problem is not
intermittent.

Faulty Address Line; check compensation

list to verify photo mode is still supported.
Clean rear electrical contacts.

Multiple Power and Address line failures;

one cartridge is defective (use post-it note
technique to isolate defective cartridge.)

A clogged jet is illustrated as jet 111; jets 105 and 108 are
manually bypassed (80% filled blocks only.) Jet 114 is defective
and is automatically being bypassed. Between 20 and 35 jets, in
each color, may be defective or bypassed to maintain photo quality
printing.

2. Microbanding is typically caused by the low pass modes or improper color deadband and color
calibrations. If not, then jet degradation of one color
probably exists. Inspect prime pattern for diagonal line
integrity and consistency (line should be perfectly straight
with no misfires).

Faulty K line; shifts up and down randomly

Microbanding Example; check pass mode

3. Ink Starvation (caused by the Cartridge and not the Ink

Delivery System); defective jet plate seal or top lid seal. Test
alternate ink delivery lines and tubing needles before cartridge
replacement. Swap cartridge positions to check electrical
connectivity.

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F. Advanced Troubleshooting
1. Skewing of the output image is normally a dirty or defective encoder
strip/sensor. Clean encoder strip thoroughly top and bottom using Windex
or NovaKlean solution. Clean encoder sensor by spraying Windex directly
onto sensor; blow dry with canned air – refer to NJ1000i Technical Bulletin
5. Replace encoder strip (service required) if problem cannot be corrected.

2. Missing data in an image is typically a print server or network traffic

problem. Increase data port rate or reconfigure print server.

3. Multiple lines throughout a print typically indicates a problem with the

connectivity to the printer. Ensure only an IEEE compliant parallel printer
cable (if used) and/or switchbox are used. One protruding line or an area
showing over spray is typically a RIP problem and not necessarily a
connectivity issue.

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4. Faint cut lines or heavy lines which angle slightly on one end are caused
by the carriage head hitting the media surface. Media up to a 20 mil
thickness can pass through the printer. Ensure media has not been
exposed to humidity for long periods as this will cause media to become
stiff. Check with technical support for media types which can pass
through the printer.

5. Printer carriage hesitation. Hesitation of the carriage assembly during

printing can be due to various factors; i.e. Slow processor in workstation
for Software RIPs, screen saver turned on, improperly configured parallel
port for non-networked environments, incorrect speed setting for driver
data transfer rate, print server setup (untested print server used/incorrect
SEH setup), other network traffic, etc.

6. Horizontal bands which extend the width of the image and repeat at a
relatively consistent rate are usually caused by the Autowipe feature being
turned on or improper ink pre-heat settings.

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7. Larger than normal ink droplets (0.5- 2 mm) on the media are caused by
excessive pressure in the cartridge. Ensure the cartridge only has 20 ml
of ink inside and the ink reservoirs do not have more than 400 ml of ink
inside. Printer stand surface or floor area must be level and flat.

8. Microbanding is typically caused by incorrect printer calibrations or low

pass printing. Print pass mode of 4 or lower may cause banding. Ensure
all calibrations are performed correctly. Defective or clogged cartridges
may also cause microbanding. Perform printer calibrations and replace
associated cartridge (s) to verify.

208 Jet Cartridge

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Ensure the diagonal lines in the prime pattern are solid and exhibit
consistency. Up to 20 jets may be compensated in each cartridge while
maintaining photo pass quality printing.

9. Horizontal bands along the right edge of the media are typically caused by
a dirty service station or cartridge. Curling media (from high humidity) or
media too thick can also cause the banding problem.

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10. Ink over spray can be caused by compression utilities. Electrostatic

discharge from film media has also been known to exceed the printer
specifications and cause inconsistent overspray. Verify the strike-plate
brushes are in good condition before resuming print operations. Do not
use 3-prong to 2-prong adapters when connecting printer to power source;
do not provide additional printer grounding other than through printer’s
standard power cord.

11. Ink Starvation (occurring from 10 minutes to 4 hours) is typically caused

by inadequate cartridge priming or a leak in the ink delivery system.
Ensure the cartridge has been properly primed using the NovaPrime or
EasyPrime device. Ensure all septum connectors are tightened securely.
Refill cartridge to 20 ml of ink and reprime cartridge (establish negative
pressure). Replace septum connectors/tubing needles if cracked/broken;
replace cartridge.

12. Text errors or lines which appear within the text is usually caused by the
application. Delete text box within application and create a new field.
Diagonal banding or horizontal lines extending from the text is normally a
postscript or RIP error. Check workstation memory (minimum 512 MB)
and ensure the RIP workstation has a minimum of 4GB free for processing
files.

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13. Vertical banding through an image can be caused by mottling of the ink on
low saturation media like bond, the carriage bushings are worn out
causing ‘carriage chatter’, or the lower roller is extending too high through
the platen. Vertical banding can also be caused by a defective trailing
cable or when ink saturations are extremely high (>290%) and the dryer is
used with high heat applied.

14. Unusual patterns which print in either the Prime pattern (lower left
illustration) or in normal prints (lower right illustration) are symptoms of a
defective trailing cable. Replace the white trailing cable (service required).
To prevent these failures from occurring ensure the trailing cable is
cleaned every two weeks.

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15. For initialization failures first ensure the memory module is properly seated
at the Main PWA (remove 5 screws to access) and verify the proper LED
states (NJ800 series only):

D1 – Normally flashes; DSP is not active. Steady during print operations.

D9 – Normally flashes; Power PC processor is idle. Stops flashing when processor is
active (i.e. during paper sensing operations).
D10 – Normally OFF; Flashes during initialization, then turns off. LED staying on would
indicate a problem when the FPGA is unconfigured. Ensures the gate array chips have
been properly programmed (one on Main PCB and on each Carriage PCB).
D8 - +24V available.
D13 - +5V available.

Check the Boot Code for proper initialization. While holding down the two
buttons indicated below turn on the printer, a cyclical two-beep sequence
should be heard.

16. For media feed and takeup system failures first ensure the correct supply
mode is enabled (Sheet, Roll, Roll 2, or TakeUp). Check sensor bracket
alignment and motor wiring connections to each motor (remove 4 screws
to access each motor).

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17. For NJ750 and 800 series dryer system failures ensure the logic cable and
power cable are properly secured. Check sensor status for error
messages. Cycle power to verify operation.

From the top-level menu of the printer, check the dryer sensor status (NJ800
only).
Utility Menu
Service Menu
Diagnostic Menu
Accessory Menu

Sensor Status

The printer LCD will display

the following information:

Dryer Mode: cccccccc

Plenum T. = ## deg. C
MBoard T. = ## deg. C

MBoard H. = ## pct. RH

The Dryer Mode: (cccccccc) indicates the current dryer setting. Operational
modes are “OFF”, “ON (Heat), “AUTO”, “FANS ONLY(No-Heat)” or
“DISABLED (error condition)”. Plenum T. and MBoard T. (main-board T.)
indicate temperature and are displayed in degrees C. MBoard H. (main-board
humidity) indicates the ambient relative humidity as a percentage.

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G. Print Server Networking (SEH Intercon print server)

A. The 100baseTX parallel print device allows connection between a 100

baseTX network environment and the NovaJet 750. The SEH print server draws
power directly from the printer’s parallel port.

" High speed print server; 1 Mbytes/sec data rate

(compliant with IEEE 1284)
" Powered by parallel port
" ECP mode support
" Protocols; IPX/SPX, TCP/IP, WINS, BCP/TBCP,
NetBIOS/SMB, IPP, DNS, SLP, SNMP, SMTP,
Ethernet/Token Talk Phase 2, HTTP/HTML
" Operating Systems; Novell Netware 3.x – 5.x, UNIX, BS2000, Apple MacOS 7.x – 9.x,
Microsoft Windows 3.X, 95/98, NT 4.X, 2000, XP
" Easy Installation and Simple Management
" JetAdmin, WebJetAdmin, and EpsonNet Tools Support

B. Depressing the blue test button (located on side of server) sends the currently
loaded IP address to printer to be displayed on the printer’s control panel.

Received IP Address
192.168.002.010

Ok

C. The Status and Link LED’s (green in color) should be steady when the printer
has been turned on and a properly configured network connection has been
established. The Status LED will blink until the server is configured properly in
the proper IP range of the device (could be dependent of the HUB’s or Network
Interface Card’s IP range).
The Activity LED (amber in
color) will only blink while
the server receives data
from the host computer
(typically blinks during
printing).

D. Print Server

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Configuration for Windows 2000/XP

Printer Networking is a basically a 3-step Process:

1. Assign TCP/IP address of host computer/server
2. Assign TCP/IP address to print server (may also need to install windows
printer port during this process)
3. Assign TCP/IP address to RIP (same as print server)

For the most recent software version (i.e. InterCon NetTool) go

to the following URL:

http://www.seh.de/

NOTE: The most common download, for PC users, from SUPPORT -

FIRMWARE/SOFTWARE (select IC105 FastPocket-TX) is:

Version 1.8.23 for Win 2000, Win XP, Win 9x

Administration tool for InterCon print servers.

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NOTE: Before you can configure a Windows print queue, you must first configure an IP
address on both your PC and the SEH print server.

1. PC PROTOCOL SETUP
1. 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. Select
Properties from the list. The Network dialog box appears.
2. 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.

3. Once the TCP/IP properties dialog box is open enter the information as follows:
IP Address- 192.168.254.201
SUBNET Mask- 255.255.255.0
DNS Server- 192.168.254.195

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Alternate DNS Server- 192.168.254.190

Leave the Gateway blank. See Figure Below.

NOTE: To configure the SEH print server you will have to load the InterCon
NetTool. Insert the InterCon CD into your CD drive or obtain from:
http://www.seh.de/

2. PRINT SERVER PROTOCOL SETUP

Run the CD.EXE from the Autorun folder. Once started press the top button(British
Flag). Press the InterCon-NetTool button to install. Follow the prompts and finish the
installation.

1. Once loaded activate the InterCon-NetTool. The SEH will Auto-Assign itself an IP
address, using DHCP, within the IP range of your PC. To change the IP address and
Subnet Mask, double click on the IP address or select Properties from the Edit pull down
menu. See figure below.

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2. To assign your IP address and Subnet Mask, choose TCP/IP from the configuration
tree on the left. Assign 192.168.254.200 for the IP address. Assign 255.255.255.0 for the
Subnet Mask. Leave the Gateway blank or zeros, and de-select DHCP at the bottom.
See figure below.

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3. Close the InterCon-NetTool. Your settings will be saved in the print server. You are
now ready to setup the Windows Printer Port.

3. WINDOWS PRINTER PORT SETUP

NOTE: If RIP software has been previously loaded then a hot folder with an assigned
port will have ‘normally’ already been loaded – this step may not be necessary unless
the Windows printer port is to be used for printing purposes. This step will be required if
the EFPU print utility is to be used for downloading firmware or test files however.

1. Select Start, Settings, Printers.

2. Double click on Add Printer, the Add Printer Wizard dialog box appears. Click Next.
3. Select “Local Printer”. Click Next.
4. At the bottom of the dialog box select “Create a new port”. Change selection to
“Standard TCP/IP Port”. Click Next- the TCP/IP Printer Port Wizard will start. Click
Next. See figure below.

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5. Under “Printer Name or IP Address” enter 192.168.254.200. The “Port Name” will
self generate. Click Next. See figure below.

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6. Under “Device Type” select “Network Print Server (1 Port)” the first one in the list.
Click Next, then Finish. See figure below.

7. You will now be prompted for the Manufacture and Printer Type. Select “Generic”
and “Generic/ Text Only”. Click Next, Next again, and Next again. Do not share this
printer. Click Next. Select no to Print a test Page. Click Next and Finish. Your TCP/IP
printer port is now setup.

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4. RASTER IMAGE PROCESSOR (RIP) TCP/IP ASSIGNMENT

1. The last step of the networking setup is to assign an IP address in the RIP software
(this TCP/IP address is the same address assigned to the SEH Intercon print server).
The location of the ‘device’ or ‘TCP/IP setup’ is normally located under the RIP software
‘setup’ drop-down menu or under the ‘Printer Configuration’ folder, depending on the RIP
used.

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