Laser Wire Markers

Nova 800i Series

The Nova 800i Series is Spectrum’s advanced family of laser wire processing systems, developed for high-performance wire marking and complex harness manufacturing applications. Representing the 6th generation of Spectrum laser wire markers, the series combines advanced UV laser technology with fully integrated mark, measure and cut capability to deliver high productivity, process reliability and exceptional marking quality.

 

Designed for demanding aerospace and high-reliability manufacturing environments, the Nova 800i Series provides fast, accurate and repeatable wire processing across a wide range of wire types and production requirements. Systems are available in both manual and automatic configurations, with scalable dereeling solutions supporting up to 36 wires for high-efficiency production environments.

 

Available models include:

  • Nova 840i – High-performance laser wire marking system for medium-volume production
  • Nova 860i – Enhanced productivity configuration for increased throughput
  • Nova 880i – Advanced high-volume processing system with maximum throughput

 

The Nova 800i Series can also be integrated with Spectrum wire handling and downstream automation systems, including the Nova Pegasus wire coiling and labelling system, enabling fully automated wire processing workflows.

 

Nova wire markers comply with key OEM aerospace specifications and international industry standards, including SAE AS5649 and ASD-EN4650.

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Benefits

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Permanent, High-Quality Marking

Laser marking provides clear, durable, abrasion-resistant identification without inks or consumables.

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Non-Aggressive, Damage-Free Processing

The laser process does not damage insulation or affect the wire’s mechanical or electrical properties.

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Flexible Marking Capability

Supports an unlimited range of characters for clear, permanent identification.

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Maximum Productivity Through Automation

The automated system with wire Auto Select & Load (ASL) enables rapid wire changeover and automated grouping by connector, reducing manual sorting in complex harness manufacturing.

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Scalable Automation Capability

Integrates with downstream automation systems, including Nova Pegasus wire coiling and labelling solutions, for enhanced productivity and process automation.

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Highest Throughput and Performance

The Nova 800i delivers industry-leading laser wire harness processing performance, combining high-speed operation with simplified maintenance and extended service intervals to maximise uptime.

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Low Cost of Ownership

The Nova 800i Series is designed for efficient long-term operation, with a high performance-to-cost ratio and minimal consumable usage.

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Upgradeability

Modular system architecture allows easy in-field upgrades, including increased marking speed and fully automated wire handling for processing up to 36 wire types.

Technical Specifications

*Throughput depends on number of characters per mark and spacing. **Additional wire types supported subject to validation testing.

Product Specifications

Metric Imperial
Processing Specifications
Wire gauge
26 - 6 AWG (additional gauges subject to validation)
26 - 6 AWG (additional gauges subject to validation)
Wire size (OD)
0.8 - 6.4 mm (6.7 mm available on request)
0.031 - 0.252 in (0.264 in available on request)
Throughput (max)
26 m/min* (N840i), 38 m/min* (N860i), 64 m/min* (N880i)
85.3 ft/min* (N840i), 124.7 ft/min* (N860i), 210.0 ft/min* (N880i)
Cable length (min)
150 mm
5.9 in
Wire type
Single core wires, shielded and unshielded multi-conductor cables. Full list available on request.
Single core wires, shielded and unshielded multi-conductor cables. Full list available on request.
Insulation material
PTFE (Teflon®), FEP (Teflon®), ETFE (Tefzel®), XL-ETFE (Tefzel®), PVDF (PVF2)**
PTFE (Teflon®), FEP (Teflon®), ETFE (Tefzel®), XL-ETFE (Tefzel®), PVDF (PVF2)**
Marking specifications
Full uppercase and lowercase alphanumeric (A-Z, a-z, 0-9), extra characters, Barcode (Code 39)
Full uppercase and lowercase alphanumeric (A-Z, a-z, 0-9), extra characters, Barcode (Code 39)
Font sizes
Large Horizontal, Medium Horizontal, Medium Vertical, Small Vertical. See Font Table for full spec.
Large Horizontal, Medium Horizontal, Medium Vertical, Small Vertical. See Font Table for full spec.
System Specifications
Laser type
UV DPSS laser (355 nm)
UV DPSS laser (355 nm)
Beam delivery system
XY galvo scanning system
XY galvo scanning system
Configuration
Floor-standing system, reel-fed with integrated coiling pan or automated wire handling output
Floor-standing system, reel-fed with integrated coiling pan or automated wire handling output
Temperature control
Air-cooled
Air-cooled
Dimensions (W x D x H)
1430 x 1755 x 1845 mm
56.3 x 69.1 x 72.6 in
Weight
350 - 450 kg (dependant on configuration)
772 - 992 lbs (dependant on configuration)
Control and Software
Machine control architecture
Windows-based control software
Windows-based control software
Interface
Height-adjustable 61 cm (24") screen or Height-adjustable 43 cm (17") touchscreen
Height adjustable 24" screen
Communications
RJ45 Ethernet
RJ45 Ethernet
Program configuration
Spectrum Technologies bespoke program
Spectrum Technologies bespoke program
Program recipes
Comma separated value files (.CSV), manual input
Comma separated value files (.CSV), manual input
Environmental and Operational Conditions
Operating temperature
+15°C to +30°C
+59°F to +86°F
Operating humidity
20% - 80%, non-condensing
20% - 80%, non-condensing
Noise level
<70 dB(A)
<70 dB(A)
Power and Utilities
Electrical connection
230 VAC, 50/60 Hz, 1Φ (transformer available for regions without 230 V supply)
230 VAC, 50/60 Hz, 1Φ (transformer available for regions without 230 V supply)
Electrical consumption
6 kVA (8 kVA with transformer)
6 kVA (8 kVA with transformer)
Compressed air
6 bar
87 psi
Fume extraction
External extraction required – 50 m³/hr minimum (ACS4 available)
External extraction required – 29.4 ft³/min (cfm) minimum (ACS4 available)
Compliance and Standards
Aerospace and industry standards
SAE AS5649B; SAE ARP5607B; SAE AIR5468; SAE AS50881 (MIL-W-5088L); ASD-EN 4650; ASD-EN 3838; ASD-EN 3475-100; Boeing BAC 5152; Boeing DR-36911; Boeing HP8-28; Airbus AIPS07-06-001; Airbus AIPI07-06-001; Sikorsky SS7333; Eurofighter J56.714 Edition D
SAE AS5649B; SAE ARP5607B; SAE AIR5468; SAE AS50881 (MIL-W-5088L); ASD-EN 4650; ASD-EN 3838; ASD-EN 3475-100; Boeing BAC 5152; Boeing DR-36911; Boeing HP8-28; Airbus AIPS07-06-001; Airbus AIPI07-06-001; Sikorsky SS7333; Eurofighter J56.714 Edition D
Regulatory compliance
CE; Machinery Directive 2006/42/EC; EMC Directive 2014/30/EC; FDA
CE; Machinery Directive 2006/42/EC; EMC Directive 2014/30/EC; FDA
Safety standards
Class 1 Laser System; EN ISO 11553-1; EN 60825-1; EN 60825-4; EN 60204-1
Class 1 Laser System; EN ISO 11553-1; EN 60825-1; EN 60825-4; EN 60204-1

Options and Accessories

Nova 840i
Nova 860i
Nova 880i
Wire Loading System

Manual or Automatic (wire ASL unit)

Manual or Automatic (wire ASL unit)

Manual or Automatic (wire ASL unit)
Tension Monitor

Optional

Optional

Optional
Knot & Splice Detector (KSD)

Standard

Standard

Standard
Powered Coiling Pan (7 inch / 18 cm diameter)

Optional

Optional

Optional
Powered Coil Pan (9 inch / 23 cm diameter)

Optional

Optional

Optional
Powered Coiling Pan (12 inch / 30 cm diameter)

Standard

Standard

Standard
Powered Coiling Pan (15 inch / 38 cm diameter)

Optional

Optional

Optional
Coiling Pan Sensor

Optional

Standard

Standard
8 kVA Transformer (208/480V to 230V)

Optional

Optional

Optional
Fume Extraction Unit

Optional

Optional

Optional
Signal Tower

Optional

Optional

Optional
Barcode Reader

Optional

Optional

Optional
Zebra Label Printer

Optional

Optional

Optional
Display (24")

Standard

Optional

Optional
Touchscreen Display (17")

Optional

Standard

Standard

Downloads

Nova 800i Series Brochure [EN]
14.64 MB | English