Bestcode Next Series 8:: Technical Manual

BestCode Next Series 8:
Technical Manual
V1.13
Firmware 1.03.03
BESTCODE NEXT SERIES 8 1 Jan 2017

MANUAL – 40-0001-01
MANUAL – 40-0001-01
Introduction
Next Series 8 CIJ Technical Manual
Volume 1.13, January, 2017
For Replacement Guides:
CIJ Technical Manual: 41-0001-01
CIJ Operator’s Guide: 41-0002-01
Copyright BestCode 2011-2017

MANUAL – 40-0001-01
Introduction
Objective
This manual serves as a guide for operating the Next Series 8 Continuous Ink
Jet printer Series. All maintenance should be performed by a trained technician.
If lost, duplicate manuals are available online in hard and soft copy.
How to use this manual
In the electronic version, the table of contents can be used to navigate the
manual. By clicking on the Section or Subsection in the table of contents, the manual
will automatically jump to that page.
Distributors may contact info@bestcode.co for Technician Level Password.

MANUAL – 40-0001-01
Introduction

MANUAL – 40-0001-01
Introduction

MANUAL – 40-0001-01
Introduction

MANUAL – 40-0001-01
Introduction

MANUAL – 40-0001-01
Table of Contents
Two (2) Year Warranty
BestCode warrants the equipment conforms to BestCode’s published specifications and is

free from defects in workmanship and materials. This warranty is provided only to the Buyer.
Warranty on all products and spare parts are 24 months from the date of installation at the
customer location or 27 months from the date of invoice, whichever is earlier.
If a failure in defect or workmanship is discovered during the warranty period, the Buyer
must promptly notify BestCode in writing with the product serial number, stating the detail of the
failure and date of failure. The failed item must be returned to BestCode no later than thirty (30)
days after receiving a BestCode Return Material Authorization.
If the part failure is determined to have failed during the warranty period and has been
returned to BestCode’s factory, freight prepaid, BestCode will without charge repair or replace.
Repair or replacement of parts shall not extend original warranty period.
This equipment warranty specifically excludes: (i) any supply items or other consumable
parts, (ii) defects caused by Buyer failure to provide power or an operating environment that
conforms to BestCode’s published specifications, (iii) damage caused by flood, fire, lightning or any
other act of God, (iv) damage caused by misuse, abuse, neglect, modifications, use of parts or
consumables not manufactured or distributed by BestCode, failure to maintain equipment in
accordance to BestCode’s technical documentation, or damage caused repair or service by anyone
other than a BestCode authorized representative.
BestCode’s liability is limited to the repair or replacement of the defective part(s) and shall
not include any labor related to installation of the defective part(s). Parts determined to be covered
by this warranty will be shipped, freight prepaid via UPS, FEDEX or other economy service.
Alternative special delivery services shall be at Buyer’s expense.
BestCode warrants to the Buyer that consumables sold to the Buyer will be free from
defects in workmanship and material through the stated “expiration date” on the consumable
container.
THE FOREGOING WARRANTIES ARE IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR

IMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY,
FITNESS FOR A PARTICULAR PURPOSE AND NON-INFRINGEMENT. NO AGENT OR EMPLOYEE OF
BESTCODE IS AUTHORIZED TO MAKE ANY WARRANTY IN ADDITION TO THE FOREGOING.
IN NO CASE SHALL BESTCODE BE LIABLE FOR ANY OF BUYER’S OR ANY OTHER ENTITY’S LOSS
OF PROFITS, LOSS OF BUSINSSS, LOSS OF USE, INTERUPTION OF BUSINESS, NOR FOR INDIRECT,
SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES BASED UPON BREACH OF WARRANTY,
BREACH OF CONTRACT, NEGLIGENCE, STRICT TORT, OR ANY OTHER LEGAL THEORY. IN ANY EVENT,
BESTCODE’S MAXIMUM LIABILITY HEREUNDER, REGARDLESS OF THE LEGAL THEORY, SHALL NOT
EXCEED THE CONTRACT PRICE OF THE GOODS PROVIDED BY BESTCODE.

MANUAL – 40-0001-01
Table of Contents
WARRANTY EXCLUSION:
- 88S OPAQUE INK PUMPS, WARRANTED FOR THREE HUNDRED SIXTY-FIVE (365) DAYS.
- Positive AIR PUMPS, WARRANTED FOR THREE HUNDRED SIXTY-FIXE (365) DAYS.
What is not covered by this warranty?
 Product purchased from anyone other than BestCode or a BestCode Authorized Distributor.
 Expendable parts such as ink containers, tubing, and filters.
 Routine cleaning or normal cosmetic and mechanical wear.
 Damage from misuse, abuse or neglect.
 Damage from use of fluids other than BestCode approved fluids.
 Damage from use outside the product’s usage or storage parameters.
 Damage from use of parts not manufactured or sold by BestCode.
 Damage from modification or incorporation into other products.
 Damage from repair or replacement of warranted parts by a service provider other than a
BestCode Authorized Distributor.
 Damage to or loss of any product or equipment printed on by a BestCode Printer.
 Damage from failure to perform preventative maintenance.

MANUAL – 40-0001-01
Table of Contents
Contents
Section 1 ................................................................................................................................................................................. 16
General Information ............................................................................................................................................................... 16
BestCode Next Series 8 System ...................................................................................................................................... 16
How to use this Manual ........................................................................................................................................ 19
Safety Information ......................................................................................................................................................... 19
Section 2 ................................................................................................................................................................................. 22
System Overview and Detailed Specifications ........................................................................................................................ 22
Controller ....................................................................................................................................................................... 23
Printhead ....................................................................................................................................................................... 24
Consumable and Delivery .............................................................................................................................................. 25
Tank Capacity ........................................................................................................................................................ 25
Bottle Size ............................................................................................................................................................. 25
Fluid Consumption ................................................................................................................................................ 26
Ink Types ........................................................................................................................................................................ 30
Speed Tables and Descriptions ...................................................................................................................................... 31
Product Dimensions ....................................................................................................................................................... 38
Controller .............................................................................................................................................................. 38
Printhead............................................................................................................................................................... 38
90° Printhead ........................................................................................................................................................ 39
Peripherals Shaft Encoder ..................................................................................................................................... 39
Fluidic Diagram...................................................................................................................................................... 40
Block Diagram & Valve Locations ................................................................................................................................... 41
Section 3 ................................................................................................................................................................................. 43
Detailed System Setup ............................................................................................................................................................ 43
Mounting Controller & Printhead .................................................................................................................................. 45
Height limitations .................................................................................................................................................. 45
Stands ............................................................................................................................................................................ 46
Controller Stand – 40-0019-01 .............................................................................................................................. 46
Controller Stand with Conveyor Side Mount – 40-0019-01 & 40-0004-01 ........................................................... 47
Printhead Floor Stand – 40-0003-01 ..................................................................................................................... 48
Conveyor Side Mount – 40-0004-01 .................................................................................................................... 49
Printhead Mount ............................................................................................................................................................ 50
Clamp 25-0033-02 & Spud 22-0069-01 ................................................................................................................. 50
How to Position the Printhead for Side Coding ..................................................................................................... 51
How to Position the Printhead for Top-Down Coding ........................................................................................... 52
How to Position the Printhead for Bottom-Up Coding ......................................................................................... 53
Positive Air Kits .............................................................................................................................................................. 54
Section 4 ................................................................................................................................................................................. 55
Commission System ................................................................................................................................................................ 55
Commission System ....................................................................................................................................................... 56
System Installation ......................................................................................................................................................... 56
Controller Mounting ............................................................................................................................................. 56
Printhead Mounting .............................................................................................................................................. 58
Fluid System Commissioning ................................................................................................................................. 59

MANUAL – 40-0001-01
Table of Contents
Ink Troubleshooting During Commissioning ..........................................................................................................63
Pump Troubleshooting during Commissioning ......................................................................................................67
How to Install PhotoEye Sensor .............................................................................................................................72
Encoder Installation ...............................................................................................................................................74
Install/use BestCode Peripherals ....................................................................................................................................75
Installing bulkhead connectors ..............................................................................................................................75
How to Configure Ethernet Connection ..........................................................................................................................82
Connecting to another Device (PC, CIJ, Number Generator, etc) ..........................................................................82
Connecting to a Network (Router, Hub) ................................................................................................................84
Section 5 ................................................................................................................................................................................. 86
System Operation ................................................................................................................................................................... 86
Basic Navigation ..............................................................................................................................................................87
Turning Power On/Off............................................................................................................................................87
Starting/Stopping Jet. ............................................................................................................................................88
Selecting message for printing ...............................................................................................................................89
Section 6 ................................................................................................................................................................................. 90
User Interface Operation ........................................................................................................................................................ 90
Operation Basics .............................................................................................................................................................91
Home Screen ...................................................................................................................................................................92
Main screen Menus and Indicators .................................................................................................................................92
Sign In.....................................................................................................................................................................93
Help ........................................................................................................................................................................94
Print Enable ............................................................................................................................................................95
Solvent Tank Status ................................................................................................................................................96
Ink Tank Status .......................................................................................................................................................96
Printing Message....................................................................................................................................................97
Count......................................................................................................................................................................97
Message Select ......................................................................................................................................................99
Adjust ...................................................................................................................................................................100
Clean ....................................................................................................................................................................102
Setup ....................................................................................................................................................................103
Service Screen ......................................................................................................................................................107
Notifications .........................................................................................................................................................113
Creating Messages ........................................................................................................................................................114
Creating a Text Field.............................................................................................................................................115
Adding a User Defined Field .................................................................................................................................139
Adding and Creating Barcodes .............................................................................................................................142
Moving Fields inside Editor ..................................................................................................................................149
Font Features .......................................................................................................................................................151
Settings ................................................................................................................................................................155
Advanced Editor Features ....................................................................................................................................164
Section 7 ............................................................................................................................................................................... 172
Firmware and PC Tools ......................................................................................................................................................... 172
Download Firmware and PC Tools ................................................................................................................................173
Formatting USB for Firmware and PC Tools ..................................................................................................................173

MANUAL – 40-0001-01
Table of Contents
USB Folders ......................................................................................................................................................... 174
How to update Firmware via J-Link / Board Recovery ................................................................................................. 174
How to update Firmware via USB Load........................................................................................................................ 176
BestTools ...................................................................................................................................................................... 178
Fonts ................................................................................................................................................................... 178
Keyboard ............................................................................................................................................................. 185
Translations ......................................................................................................................................................... 190
Graphics .............................................................................................................................................................. 196
Remote Communication Protocol ................................................................................................................................ 199
Communication Description Overview ............................................................................................................... 199
Resource Requirements ...................................................................................................................................... 199
Serial COM port access ....................................................................................................................................... 200
Ethernet port access ........................................................................................................................................... 201
Interface Commands ........................................................................................................................................... 203
Command Usage ................................................................................................................................................. 209
Software Screenshot .................................................................................................................................................... 209
Section 8 ............................................................................................................................................................................... 212
Maintenance ......................................................................................................................................................................... 212
Maintenance Intervals ................................................................................................................................................. 213
Ink Filters Replacement Instructions ............................................................................................................................ 214
Air Filter Replacement Instructions. ............................................................................................................................. 221
Printhead Maintenance ............................................................................................................................................... 224
Section 9 ............................................................................................................................................................................... 227
Technical Operation and Troubleshooting ............................................................................................................................ 227
Flow Paths .................................................................................................................................................................... 228
General Flow Paths ...................................................................................................................................................... 228
Standard “Run” Operation .................................................................................................................................. 229
Flush Start / Stop and Printhead Clean Function Flow ........................................................................................ 232
External Peripheral Schematics .................................................................................................................................... 233
Troubleshooting ........................................................................................................................................................... 239
Software .............................................................................................................................................................. 241
J-link Error (IP/TCP Error) .................................................................................................................................... 241
Message not supported ...................................................................................................................................... 241
Controller ............................................................................................................................................................ 250
Fluidic .................................................................................................................................................................. 260
Printhead............................................................................................................................................................. 272
Misc ..................................................................................................................................................................... 283
Section 10 ............................................................................................................................................................................. 284
Service Routines and Parts.................................................................................................................................................... 284
Warranty Information .................................................................................................................................................. 285
Print head items .................................................................................................................................................. 285
Fluidic Items ........................................................................................................................................................ 285
Electronics and Cables......................................................................................................................................... 286
Fluidic Service Routines ............................................................................................................................................... 288
Cleaning the Venturi ........................................................................................................................................... 288

MANUAL – 40-0001-01
Table of Contents
Cleaning the Viscometer ......................................................................................................................................292
Main Pump Replacement .....................................................................................................................................296
Solenoid valve replacement .................................................................................................................................303
Ink Swap or Longterm Storage Flush ....................................................................................................................308
Electronic Components .................................................................................................................................................309
Main Board ..........................................................................................................................................................309
Fan .......................................................................................................................................................................311
Front Door............................................................................................................................................................312
Display Assembly .................................................................................................................................................312
Power Supply .......................................................................................................................................................312
Electronic Service Routines ...........................................................................................................................................314
Replacing the Power Supply .................................................................................................................................314
Touchscreen Replacement ...................................................................................................................................319
Touch Screen Calibration .....................................................................................................................................321
Touch Screen Flickering .......................................................................................................................................322
Positive Air Pump Installation ..............................................................................................................................323
Printhead Components .................................................................................................................................................325
Printhead .............................................................................................................................................................325
Printhead Service Routines ...........................................................................................................................................328
Printhead Tray Replacement................................................................................................................................328
Drop Generator Replacement ..............................................................................................................................340
Changing or Cleaning Nozzle ................................................................................................................................344
Jet Alignment .......................................................................................................................................................353
Modulation Calibration ........................................................................................................................................362
Fluidic Compartment ....................................................................................................................................................378
Ink Tank ................................................................................................................................................................378
Venturi Next Series 8 Assembly, Gen 2 – 20-0032-01 ..........................................................................................379
Viscometer ...........................................................................................................................................................381
Fluid Pumps ..........................................................................................................................................................382
Main Manifold Gen 2– 20-0040-01 ......................................................................................................................383
Main Filter ............................................................................................................................................................384
Dampener ............................................................................................................................................................384
Ink Fill Cup ............................................................................................................................................................385
Solvent Fill Cup .....................................................................................................................................................385
Fluidic Fittings ......................................................................................................................................................386
Tubing ..................................................................................................................................................................386
Section 11 ............................................................................................................................................................................. 388
Specific Application Setup..................................................................................................................................................... 388
Common Questions .............................................................................................................................................................. 396
Ink Data Sheets ..................................................................................................................................................................... 399
Appendix and BestCode Forms ............................................................................................................................................. 426
Print Samples Request Form .........................................................................................................................................427
BestCode CIJ Maintenance Check-List ..........................................................................................................................428

MANUAL – 40-0001-01
Table of Contents

MANUAL – 40-0001-01
General Information
Section 1
General Information

MANUAL – 40-0001-01
General Information
BestCode Next Series 8 System

The BestCode Next Series 8 CIJ printers are technologically innovative systems for
providing state-of-the art tracking and coding information. The Next Series 8 consists of a
family of 8 CIJs, each with a range of special features. The charts below illustrate the
primary differences between each machine, and highlights features such as speed, filter life,
and templates.
Model 82 86,87 88 88HS & 88S 88SOP

88HS1 Food
Screen 10.4” LCD with Touch Screen
Power 100-240Vac @ 120V, 60hz – 45V Amps (.45 watts

50-60Hz @240V, 50hz – 22.5V Amps (.225 watts).
3A MAX
Storage 4GByte Solid State Drive, 16 Mbyte Flash, 128 Mbyte RAM, USB
Interface (thumb drive)
Machine Interface RS232, Ethernet
Enclosure Stainless Steel Enclosure
Enclosure Rating IP 55 IP 65
Air Filter MERV 8 MERV 13
Inks MEK, Ethanol, Acetone, Blend, Food MEK White, Acetone

Plastic, Glass Bottle, Security, Grade White
Canning, Flexible
Message Printing
Maximum Number of Fields 30
Maximum Characters per field 100
Maximum Print Rasters 16000
Maximum Print Length 320in (8.1m)

MANUAL – 40-0001-01
General Information
Speed Ink Filter Air Filter

Filter Life(Hours) Life
Model Drop Frequency Speed 2000 5000 10000 1 Year
81 75 65kHz Faster ✓
82 65,75 65kHZ Faster ✓ *
86 65,75 65kHZ Fastest ✓ *
87 65,75 65kHZ Fastest ✓
88 65,75 65kHZ Ultra-Fast ✓ *
88HS 50 73kHZ Ultra-Fast ✓ *
88HS1 50 90kHZ Ultra-Fast ✓ *
88SM 40 90kHZ UltraFast ✓ *
88SF 65,75 65kHZ Ultra-Fast ✓ *
88SOP 65 65kHZ Ultra-Fast ✓ *
Print Formatting / Model Numbers

Two Line Three Line Five Line All Line Sixteen High
81, 82 86 87 88, 88SP, 88SF, 88HS, 88u1 88HS1
1 Line of 5 ✓ ✓ ✓ ✓ ✓
1 Line of 7 ✓ ✓ ✓ ✓ ✓
1 Line of 9 ✓ ✓ ✓ ✓ ✓
1 Line of 12 ✓ ✓ ✓ ✓ ✓
1 Line of 16 ✓ ✓ ✓ ✓ ✓
1 Line of 19 ✓ ✓ ✓
1 Line of 25 ✓* ✓ ✓ ✓
1 Line of 32 ✓ ✓
Templates
2 Line of 7 ✓ ✓ ✓ ✓ ✓
2 Line of 9 ✓ ✓ ✓ ✓
2 Line of 12 ✓ ✓ ✓ ✓
3 Line of 7 ✓ ✓ ✓
3 Line of 9 ✓ ✓ ✓
4 Line of 7 ✓ ✓
5 Line of 5 ✓ ✓
1 Line of 3 ✓ ✓
Max Speed Faster Fastest Ultra Ultra Ultra

MANUAL – 40-0001-01
General Information
How to use this Manual
This manual is used as a reference guide for training, setup, commissioning,
machine and software maintenance, and troubleshooting of Next Series 8 CIJ printers. This
manual provides specific machine specifications for each of the Next Series 8 family
members, as well as peripheral items used with the machine. This manuals details software
functions and features, navigation of the user interface, suggested maintenance routines,
and breakdowns of indicators and warnings encountered in the entirety of the user interface.
This manual provides instruction for operating the machine, and performing routine machine
functions, including; safely adding ink and solvent, Operating the Print Jet, Selecting and
editing messages, Cleaning, Replacing Electronic, Fluidic, and print head components.
Follow all Safety instructions and exercise common sense while performing any
service, maintenance, commissioning, part replacement, or troubleshooting.
Safety Information
PERSONAL INJURY: ALWAYS WEAR RUBBER GLOVES AND SAFETY

GLASSES WHEN HANDLING INKS AND SOLVENTS.

GLASSES DURING FLUIDIC MAINTENANCE.
PERSONAL INJURY: INKS AND SOLVENTS ARE POISONOUS, DO NOT

INGEST.
PERSONAL INJURY: DO NOT USE SOLVENT TO WASH INK FROM SKIN.

IF EXPOSED, GENTLY RINSE AREA WITH SOAPY WATER. IF
IRRITATION PERSISTS, SEEK MEDICAL ATTENTION.

MANUAL – 40-0001-01
General Information
EQUIPMENT DAMAGE: DO NOT ADD FLUIDS UNLESS INSTRUCTED BY
INDICATORS.
EQUIPMENT DAMAGE: THE PRINTHEAD MUST BE DRY BEFORE

STARTING PRINTER.
EQUIPMENT DAMAGE: THE PRINTHEAD SHOULD NEVER BE
COMPLETELY SUBMERGED IN SOLVENT.
EQUIPMENT DAMAGE: DO NOT ATTEMPT TO USE MULTIMETER TO
TAKE MEASUREMENTS ON ANY COMPONENT WHILE THE MACHINE IS

POWERED ON.
EQUIPMENT DAMAGE: DO USE MULTIMETER TO ATTEMPT TO

MEASURE THE CHARGE VOLTAGE AT THE PRINTHEAD. THIS WILL
PERMANENTLY DAMAGE THE MAIN BOARD.
FIRE HAZARD: INKS AND SOLVENTS ARE HIGHLY FLAMMABLE. NO

SMOKING OR OPEN FLAMES NEAR PRINTER OR FLUID STORAGE.
ELECTRICAL SHOCK: DISCONNECT MAIN POWER CABLE PRIOR TO
SERVICING MACHINE.
ELECTRICAL SHOCK: NEVER RUN MACHINE WHILE ELECTRONICS
COMPARTMENT DOOR IS OPEN.

MANUAL – 40-0001-01
General Information

MANUAL – 40-0001-01
System Overview and Detailed Specifications
Section 2
System Overview and Detailed

Specifications

MANUAL – 40-0001-01
Controller
Item Number Description Part Number

10.4” Touch Interface 20-0014-01
1
BestCode Next Series 8 Cabinet 20-0001-10
2
Fluidic Service Entry Door 25-0004-07
3
Air Filter Service Entry Door *
4
Printhead & Umbilical Assembly 20-0016-02
5

MANUAL – 40-0001-01
Printhead
Item Number Description Part Number

Front Cover 22-0039-02
1
Positive Deflection Plate *
2
Phase Detector *
3
Charge Electrode 22-0012-03
4
Drop Generator Kit 20-0008-01
5
Front Cover Fastener 22-0015-05
6
Ground Plate *
7
Drop Return System 20-0010-01
8
SPECIAL
* Parts integral to tray Printhead Tray Assembly 20-0009-01

MANUAL – 40-0001-01
Consumable and Delivery
Tank Capacity
Ink: 1.7 Liters
Solvent: 2.7 Liters
Bottle Size
Ink Bottle
Capacity: 32 oz (946ml)
Delivery: Foil Puncture
Solvent Bottle

MANUAL – 40-0001-01
Fluid Consumption
Number of Drops Consumed per Font

Avg Drops Characters per Liter of Ink
Font
8 142,469,879
5
11 103,614,457
7
19 59,987,317
9
30 37,991,967
12
53 21,504,887
16
85 13,408,929
19
130 8,767,377
25
190 5,998,731
32
Notes:
 Changing Speed, Width, or Gap has no effect on number of characters per liter.
 Increasing Bold reduces the number of characters per liter..
o Bold 2 will have half the characters of Bold 1 per liter of ink
o Bold 3 will have a third the characters of Bold 1 per liter of ink.
o Etc…
Solvent Consumption per hour based on

temperature
Temperature MEK Acetone Ethanol Acetone / Ethanol Blend
3 9 2 3 ml/hour
32F (0C)
3 9 2 3 ml/hour
50F (10C)
3 9 2 3 ml/hour
59F (15C)
3 9 2 3 ml/hour
68F (20C)
4 12 2 4 ml/hour
77F (25C)
6 18 3 6 ml/hour
86F (30C)
9 30 5 9 ml/hour
104F (40C)
15 50 8 15 ml/hour
122F (50C)

MANUAL – 40-0001-01
Fluid Consumption Testing
Fluid consumption testing is determined after commissioning volumes have been added to the
machine. Commissioning a machine requires 1 bottle of ink and 2 bottles of solvent.
Stage 1:Empty Tank, Ready to Be Stage 2, 1 Bottle Added Into the Tank
Commissioned
Stage 3, Ink in Tank after 1st Priming Stage 4, 1st Low Warning

MANUAL – 40-0001-01
Stage 5, 1 bottle added after Low Warning
To commission the Ink System, We begin with an Empty Ink Tank (Stage 1 Image). 1x 946ml bottle of
Ink is added to the Tank (Stage 2 Image). The machine will use 400ml of Ink to prime the system,
leaving 546ml in the tank (Stage 3 Image).
The Ink Low warning occurs at 400ml of ink in the Tank (Stage 4 Image).
The difference then between commissioning the system and needing to add a bottle of ink is only
146ml. This effect will give the appearance that the machine is quickly consuming ink, which is a
misconstrued fact.
When the Ink Low warning goes active, add 1 bottle of ink and begin consumption testing. (Stage 5
Image) It will be at a total volume of 1346ml. It can be found that the time from 1 bottle added from
a low condition to the next add will be in line with the listed consumption charts.

MANUAL – 40-0001-01
Stage 1:Empty Tank, Ready to Be Commissioned Stage 2, 2 Bottles Added Into the Tank
Stage 3, Solvent Low Warning Stage 4, 2 bottles added after Low Warning
To commission the Solvent Tank, We begin with an Empty Solvent Tank (Stage 1 Image). 2 x 946ml
bottles of Solvent is added to the Tank (Stage 2 Image). The machine will use a minimal amount of
Solvent to Prime the System, less than 50ml.
The Add 1 Bottle warning occurs at 1700ml.

The Solvent Low warning occurs at 600ml (Stage 3 image).
The difference then between commissioning the system and the Add 1 Bottle warning is 242ml. This
effect will give the appearance that the machine is quickly comsuming solvent, which is a
misconstrued fact.
When the Solvent Low warning goes active, add 2 bottles of Solvent consumption testing (Stage 4
Image). It will be a tank total volume of 2492ml. It can be found that the time from 2 bottles added
to the next Low Warning will be in line with the listed consumption charts.

MANUAL – 40-0001-01
Ink Types
Ink # Ink Name Color Application Nozzle Size Used In
51-0001-01 MEK Black Black General 40, 65, 75 82,86,87,88,88S
51-0002-01 MEK Red Red General 65, 75 82,86,87,88,88S
51-0003-01 MEK Blue Blue General 65, 75 82,86,87,88,88S
51-0004-01 MEK Green Green General 65, 75 82,86,87,88,88S
51-0005-01 MEK Yellow Yellow General 65, 75 82,86,87,88,88S
51-0006-01 Acetone WHITE WHITE Dark Substrate 65, 75 88SP ONLY
51-0007-01 MEK Flex Plus Black Black Plastic Bag, Overwraps 40, 65, 75 82,86,87,88,88S
51-0010-01 MEK Invisible UV Invisible High Security 65,75 82,86,87,88,88S
51-0011-01 Acetone Black Black General, non-MEK 65,75 82,86,87,88,88S
51-0012-01 Ethanol Black Black General, non-MEK 40, 65, 75 82,86,87,88,88S
51-0013-01 Acetone Ethanol Black Black General, non-MEK 40, 65, 75 82,86,87,88,88S
51-0014-01 MEK Glass Bottle Black Black Glass and Glass Bottles 40, 65, 75 82,86,87,88,88S
51-0015-01 Red Food Grade Red Food Products 65,75 88SF ONLY
51-0020-01 MEK Black Pigment Black Darker Black 65,75 82,86,87,88,88S
51-0021-01 MEK UV Red Red Double Security 65,75 82,86,87,88,88S
Black to Blue Color 82,86,87,88,88S

51-0022-01 Blue Steam Activated 65,75
Change
51-0024-01 MEK White White Dark Substrate 65, 75 88SP ONLY
51-0025-01 MEK Light Blue Blue Dark and Light Substrates 65, 75 88SP ONLY
51-0026-01 Acetone Super Flex Black Thin Flexible Plastics 40,65,75 82,86,87,88,88S
51-0027-01 MEK Flex Black Black Plastic 40,65,75 82,86,87,88,88S
51-0028-01 MEK Orange Orange General 65,75 82,86,87,88,88S
Black to Red Color 82,86,87,88,88S

51-0029-01 Red Steam Activated 65,75
Change
51-0081-01 FastDry Black Black General Purpose 75 81 ONLY

MANUAL – 40-0001-01
Speed Tables and Descriptions

Speed Description
Fast (82,86,88,88S) Best Print Quality through use of Guard drops.
Lowest Print Speed for All Templates
Faster (82,86,88,88S) Middle Print Quality using less Guard drops. Drops will rarely print
out of place. Medium Print Speed for All Templates
Fastest (86,88,88S) Lowered Print Quality for Higher Speeds. Drops spacing will often be
uneven. High Print Speed for All Templates.
Ultra-Fast (88,88S) Identical Print Quality to Fastest.
Highest Print Speed for All Templates.
Single-Line Printing Speed Chart 82,86,88, 88SOP, 88SF

Font Template Speed Setting Raster/Sec ft/min in/sec m/min m/sec
Ultra-Fast 13000 1300 260 397 6.6
5 Fastest 13000 1300 260 397 6.6
Faster 7222 722 144 220 3.7
Fast 5000 500 100 153 2.5
Ultra-Fast 9286 929 186 283 4.7
7 Fastest 9286 929 186 283 4.7
Faster 5000 500 100 153 2.5
Fast 3421 342 68 104 1.7
Ultra-Fast 6619 662 132 201 3.4
9 Fastest 5909 591 118 180 3.0
Faster 3824 382 76 117 1.9
Fast 2600 260 52 79 1.3
Ultra-Fast 4854 485 97 147 2.5
12 Fastest 4333 433 87 132 2.2
Faster 2826 283 57 86 1.4
Fast 1912 191 38 58 1.0
Ultra-Fast 3166 317 63 96 1.6
16 Fastest 2826 283 57 86 1.4
Faster 2097 210 42 64 1.1
Fast 1757 176 35 54 0.9
Ultra-Fast 2080 208 42 64 1.1
19 Fastest 1857 186 37 57 0.9
Faster 1512 151 30 46 0.8
Fast 1066 107 21 33 0.5
Ultra-Fast 1277 128 26 39 0.65
25 Fastest 1140 114 23 35 0.6
Faster 1016 102 20 31 0.5
Fast 929 93 19 28 0.5
Ultra-Fast 1156 115 23 35 0.6
32 Fastest 1031 103 21 31 0.5
Faster 730 73 15 22 0.4
Fast 699 70 14 21 0.4

MANUAL – 40-0001-01
Multi-Line
Multi-Line
Printing Speed
PrintingChart
Speed82,86,88,
Chart 65kHZ
88SOP, 88SF
Ultra-Fast 1138 114 23 35 0.6
5L5 Fastest 1015 102 20 31 0.5
Faster 878 88 18 27 0.4
Fast 774 77 15 24 0.4
Ultra-Fast 3467 345 69 108 1.8
2L7 Fastest 3095 310 62 94 1.6
Faster 2407 241 48 73 1.2
Fast 1970 197 39 60 1.0
Ultra-Fast 1734 173 35 54 0.9
3L7 Fastest 1548 155 31 47 0.8
Faster 1182 118 24 36 0.6
Fast 1083 108 22 33 0.6
Ultra-Fast 1194 119 24 36 0.6
4L7 Fastest 1066 107 21 33 0.5
Faster 942 94 19 29 0.5
Fast 739 74 15 23 0.4
Ultra-Fast 2697 270 54 84 1.4
2L9 Fastest 2407 241 48 73 1.2
Faster 1806 181 36 55 0.9
Fast 1226 123 25 37 0.6
Ultra-Fast 1174 117 24 36 0.6
3L9 Fastest 1048 105 21 32 0.5
Faster 916 92 18 28 0.5
Fast 730 73 15 22 0.4
Ultra-Fast 1549 155 31 47 0.8
2L12 Fastest 1383 138 28 42 0.7
Faster 1102 110 22 34 0.6
Fast 929 93 19 28 0.5

MANUAL – 40-0001-01
Single-Line Printing Speed Chart 88HS

Ultra-Fast 15800 1580 316 482 8.03
Fastest 15800 1580 316 482 8.03

5 Faster 8778 878 176 268 4.46
Fast 6077 608 122 185 3.09
Ultra-Fast 11286 1129 226 344 5.73
Fastest 11286 1129 226 344 5.73

7 Faster 6077 608 122 185 3.09
Fast 4158 416 83 127 2.11
Ultra-Fast 7900 790 158 241 4.01
Fastest 7182 718 144 219 3.65

9 Faster 4647 465 93 142 2.36
Fast 3160 316 63 96 1.61
Ultra-Fast 6077 608 122 185 3.09
Fastest 5267 527 105 161 2.68

12 Faster 3435 343 69 105 1.74
Fast 2324 232 46 71 1.18
Ultra-Fast 3762 376 75 115 1.91
Fastest 3435 343 69 105 1.74

16 Faster 2548 255 51 78 1.29
Fast 2135 214 43 65 1.08
Ultra-Fast 2633 263 53 80 1.34
Fastest 2257 226 45 69 1.15

19 Faster 1837 184 37 56 0.93
Fast 1295 130 26 39 0.66
Ultra-Fast 1881 188 38 57 0.96
Fastest 1386 139 28 42 0.70

25 Faster 1234 123 25 38 0.63
Fast 1129 113 23 34 0.57
Ultra-Fast 1254 125 25 38 0.64
Fastest 1254 125 25 38 0.64

32 Faster 888 89 18 27 0.45
Fast 849 85 17 26 0.43

MANUAL – 40-0001-01
Multi-Line Printing Speed Chart 88HS

Font Speed Setting Raster/Sec ft/min in/sec m/min m/sec
Template
Ultra-Fast 1362 136 27 42 0.69
5L5 Fastest 1234 123 25 38 0.63
Faster 1068 107 21 33 0.54
Fast 940 94 19 29 0.48
Ultra-Fast 4158 416 83 127 2.11

2L7 Fastest 3762 376 75 115 1.91
Faster 2926 293 59 89 1.49
Fast 2394 239 48 73 1.22
Ultra-Fast 2079 208 42 63 1.06

3L7 Fastest 1881 188 38 57 0.96
Faster 1436 144 29 44 0.73
Fast 1317 132 26 40 0.67
Ultra-Fast 1436 144 29 44 0.73

4L7 Fastest 1295 130 26 39 0.66
Faster 1145 114 23 35 0.58
Fast 898 90 18 27 0.46
Ultra-Fast 3292 329 66 100 1.67

2L9 Fastest 2926 293 59 89 1.49
Faster 2324 232 46 71 1.18
Fast 1491 149 30 45 0.76
Ultra-Fast 1411 141 28 43 0.72

3L9 Fastest 1274 127 25 39 0.65
Faster 1113 111 22 34 0.57
Fast 888 89 18 27 0.45
Ultra-Fast 1837 184 37 56 0.93

2L12 Fastest 1681 168 34 51 0.85
Faster 1339 134 27 41 0.68
Fast 1129 113 23 34 0.57

MANUAL – 40-0001-01
Single-Line Printing Speed Chart 88HS1. V 01.03.03

Ultra-Fast 18040 1804 361 550 9.16
5
Fastest 18040 1804 361 550 9.16
Faster 10022 1002 200 305 5.09
Fast 6938 694 139 211 3.52
Ultra-Fast 12886 1289 258 393 6.55

7
Fastest 12886 1289 258 393 6.55
Faster 6938 694 139 211 3.52
Fast 4747 475 95 145 2.41
Ultra-Fast 9020 902 180 275 4.58

9
Fastest 8200 820 164 250 4.17
Faster 5306 531 106 162 2.70
Fast 3608 361 72 110 1.83
Ultra-Fast 6938 694 139 211 3.52

12
Fastest 6013 601 120 183 3.05
Faster 3922 392 78 120 1.99
Fast 2653 265 53 81 1.35

MANUAL – 40-0001-01
Single-Line Printing Speed Chart 88SM 40 Micron.

Ultra-Fast 18040 1804 361 550 9.16
5
Fastest 18040 1804 361 550 9.16
Faster 10022 1002 200 305 5.09
Fast 6938 694 139 211 3.52
Ultra-Fast 12886 1289 258 393 6.55

7
Fastest 12886 1289 258 393 6.55
Faster 6938 694 139 211 3.52
Fast 4747 475 95 145 2.41
Ultra-Fast 9020 902 180 275 4.58

9
Fastest 8200 820 164 250 4.17
Faster 5306 531 106 162 2.70
Fast 3608 361 72 110 1.83
Ultra-Fast 6938 694 139 211 3.52

12
Fastest 6013 601 120 183 3.05
Faster 3922 392 78 120 1.99
Fast 2653 265 53 81 1.35
Ultra-Fast 4295 430 86 131 2.18

16
Fastest 3922 392 78 120 1.99
Faster 2910 291 58 89 1.48
Fast 2438 244 49 74 1.24
Ultra-Fast 3007 301 60 92 1.53

19
Fastest 2577 258 52 79 1.31
Faster 2098 210 42 64 1.07
Fast 1479 148 30 45 0.75
Ultra-Fast 2148 215 43 65 1.09

25
Fastest 1582 158 32 48 0.80
Faster 1409 141 28 43 0.72
Fast 1289 129 26 39 0.65
Ultra-Fast 1432 143 29 44 0.73

32
Fastest 1432 143 29 44 0.73
Faster 1013 101 20 31 0.51
Fast 970 97 19 30 0.49

MANUAL – 40-0001-01
Multi-Line Printing Speed Chart 88SM 40 Micron.

Ultra-Fast 1555 156 31 47 0.79
5L5 Fastest 1409 141 28 43 0.72
Faster 1219 122 24 37 0.62
Fast 1074 107 21 33 0.55
Ultra-Fast 4747 475 95 145 2.41

2L7 Fastest 4295 430 86 131 2.18
Faster 3341 334 67 102 1.70
Fast 2733 273 55 83 1.39
Ultra-Fast 2374 237 47 72 1.21

3L7 Fastest 2148 215 43 65 1.09
Faster 1640 164 33 50 0.83
Fast 1503 150 30 46 0.76
Ultra-Fast 1640 164 33 50 0.83

4L7 Fastest 1479 148 30 45 0.75
Faster 1307 131 26 40 0.66
Fast 1025 103 21 31 0.52
Ultra-Fast 3758 376 75 115 1.91

2L9 Fastest 3341 334 67 102 1.70
Faster 2653 265 53 81 1.35
Fast 1702 170 34 52 0.86
Ultra-Fast 1611 161 32 49 0.82

3L9 Fastest 1455 145 29 44 0.74
Faster 1270 127 25 39 0.65
Fast 1013 101 20 31 0.51
Ultra-Fast 2098 210 42 64 1.07

2L12 Fastest 1919 192 38 58 0.97
Faster 1529 153 31 47 0.78
Fast 1289 129 26 39 0.65

MANUAL – 40-0001-01
Product Dimensions
Controller
Height: 19.4” (493mm)

Width: 15.4” (392mm)
Depth: 12.5” (318mm)
Dry Weight: 45 lbs (20.4 kg)
Printhead
Length: 9” (227.7mm)
Width: 1.5” (38.1mm)
Height: 1.5” (38.1mm)
Umbilical Length: 9’ 10” (3m)

MANUAL – 40-0001-01
90° Printhead
Length: 7.47” (189.7mm)

Width: 6.29” (159.7mm)
Height: 1.5” (38.1mm)
Umbilical Length: 9’ 10” (3m)
Peripherals
Shaft Encoder

MANUAL – 40-0001-01
Fluidic Diagram
Valve Name Harness Color

1 Printhead Valve Solder White/Orange/Red Stripe to Valve +
Solder White/Green/Yellow Stripe to Valve -
2 Flush Valve Brown from Valve harness, non-polarized
3 Bleed Valve Red from Valve harness, non-polarized
4 Makeup Add Valve Blue from Valve harness, non-polarized
5 Viscometer Valve Green from Viscometer harness, non-polarized
6 Tank Solvent Valve Yellow from Valve harness, non-polarized
7 Gutter Valve Orange from Valve harness, non-polarized

MANUAL – 40-0001-01
Block Diagram & Valve Locations
Valve Name Input / Output Tube Function

1 Printhead Input: Red, Blue Controls flow of fluid through Drop
Output: Nozzle, Yellow Generator. 3 Way NC
2 Flush Input: Green Used to jet solvent out of nozzle. 2

Output: Yellow Way NC
3 Bleed Input: Yellow Applies Vacuum to the drop generator.
Output: Black Used for Stops and Starts. 2 Way NC
4 Makeup Add Input: Orange Used to add Makeup to the Ink Tank.
Output: Black 2 Way NC
5 Viscometer Input: Violet, Brown Pushed viscometer ball up, flows into
Output: Gray ink tank via Gray. 2 Way NC
6 Solvent Tank Input: Orange Allows Makeup to be Vacuumed
Output: Blue through the drop generator. 2 Way NC
7 Gutter Input: White Printhead Drop Return on/off.
Output: Black/White Stripe 2 Way NC

MANUAL – 40-0001-01

MANUAL – 40-0001-01
Detailed System Setup
Section 3

MANUAL – 40-0001-01

MANUAL – 40-0001-01
Mounting Controller & Printhead
Height limitations

MANUAL – 40-0001-01
Stands
Controller Stand – 40-0019-01
Ships flat packaged
Assembly Time: 10 minutes

MANUAL – 40-0001-01
Controller Stand with Conveyor Side Mount – 40-0019-01 & 40-0004-01
Ships flat packaged
Assembly Time: 15 minutes

MANUAL – 40-0001-01
Printhead Floor Stand – 40-0003-01
Kit Parts:
A. 40-0005-01, CLAMP, 30MM
BASE
B. 40-0006-01, CLAMP, CROSS
30MM
C. 40-0007-01, CLAMP, SLEEVE
30MM
D. 40-0008-01, CLAMP, HINGE
30MM
E. 22-0072-02, STAND, LEG
F. 22-0073-01, ROD, 30MM 2FT
G. 22-0074-01, ROD, 30MM 3FT
H. 25-0033-03, BRACKET, PH
SHEET CLAMP
I. 22-0069-03, BRACKET, SPUD
J. 28-0137-01. LEVELING FOOT
K. 28-0135-01, M6X1X20mm
SCREW
Height: 73.5” (1869mm)
Armature Load: 14 lbs @ 5’
Width: 38” / 26” (965mm / 660mm) max/min
Weight: 32 lbs / 14.5kg
Depth: 38” / 26” (965mm / 660mm) max/min

MANUAL – 40-0001-01
Conveyor Side Mount – 40-0004-01
Kit Parts:
A. 40-0006-01, CLAMP, CROSS 30MM
B. 40-0008-01, CLAMP, HINGE 30MM
C. 40-0009-01, CLAMP, FLANGE 30MM PLASTIC
D. 28-0110-01, HANDLE, ADJUST
E. 22-0073-01, ROD, 30MM 2FT
F. 25-0033-03, BRACKET, PH SHEET CLAMP
G. 22-0069-03, BRACKET, SPUD
Height: 24” (610mm) Armature Load: 10 lbs
Width: 2” (51mm) Weight: 9lbs (4.1kg)
Depth: 24” (610mm)

MANUAL – 40-0001-01
Printhead Mount
Clamp 25-0033-02 & Spud 22-0069-01
SPUD
CLAMP
 Mount to Stand

MANUAL – 40-0001-01
How to Position the Printhead for Side Coding
Setup with Gutter closest to the floor.
Angled downward 5°
Issues with Incorrect Printhead Setup

When the Printhead is setup incorrectly, the following issues can occur.
 More high voltage trips during start-up (especially in high humidity applications)
 Solvent spray on the conveyor or product during start-up.
 Bearding or buildup of Ink on the Positive (Bent) deflector plate.
 If head is angled upwards, ink can run back into the umbilical or back onto cables and make
future service more difficult.

MANUAL – 40-0001-01
Commission System
How to Position the Printhead for Top-Down Coding
Setup with Gutter closest to the Product.
Angled back 5° away from the product.
Minimum 8mm (3/8” throw distance).
Why to Setup this way

 Top down printing has higher chance for small drop particles to splash back into the
printhead.
 Angling the head will prevent buildup of splash on the Deflector Plates and Gutter.
 If Printhead is too close to the product, splashed drops will build up faster.

MANUAL – 40-0001-01
Commission System
How to Position the Printhead for Bottom-Up Coding
Setup with Gutter closest to the Product.
Angled back 5° away from the product.
Minimum 8mm (3/8” throw distance).
Why to Setup this way

 Top down printing has the highest chance for small drop particles to fall back into the
printhead and quickly cause buildup on the Positive Deflector plate and gutter.
 Angling the head will prevent buildup of splash on the Deflector Plates and Gutter.
 If Printhead is too close to the product, splashed drops will build up faster.
 Positive Air Pressure is GREATLY recommended to assist in clearing splash away from the
printhead

MANUAL – 40-0001-01
Commission System
Positive Air Kits
Positive air kits are required for high dust, cold, wet, or humid applications. If the BestCode
Next Series 8 CIJ is installed into an application where any of these conditions exist, a variety of
issues will occur.
 High Voltage Trips from moisture on the plates.
 Bad starts from water entering nozzle.
 Frequent cleaning of the gutter from dust entering and clogging gutter hole.
The positive air kit provides a constant flow of air to the printhead that will reduce build up and
ingress of dust and water.
In particularly extreme environments (High Steam, etc), it is recommended to provide clean shop air
to the printhead. To ensure clean air is provided to the head, bestcode strongly recommends using
the following:
1. Shop air flows into a water separator to remove moisture.
a. Automatic drain recommended.
2. Dry air should now pass into an air filter to ensure there is no debris.
3. Air from the filter should then enter a pressure regulator to control flow of air to the
printhead.
4. Clean air should be brought into the cabinet via the “AUX” port on the side of the controller.
5. From there, route the Positive Air tube from the back of the cabinet into the front of the
cabinet and couple with the air feed.
If air pressure is too high, it will disrupt the print and cause poor quality. Be sure to test print
with air flow and without to ensure there is no impact on the print. A slow steady stream of air
should be felt passing out of the face of the printhead.
Recommendations for this configuration are available from BestCode.

MANUAL – 40-0001-01
Commission System
Section 4
Commission System

MANUAL – 40-0001-01
Commission System
Commission System
Commission System covers installation of the Next Series 8 CIJ. This will instruct the
user on how to install the machine, turn on and turn off the machine, perform first time start
up, how to add fluids, and prepare for the first print.
GLASSES WHEN HANDLING INKS AND SOLVENTS.
PERSONAL INJURY: SYSTEM COMMISSIONING SHOULD ONLY BE
PERFORMED BY A FACTOR TRAINED TECHNICIAN.
System Installation
System installation covers installation of the Series 8 CIJ. This will instruct the user
on how to install the machine and mount the
printhead.
Controller Mounting
 Place or bolt controller on to a sturdy

surface, or install on to the BestCode
Controller Stand.

MANUAL – 40-0001-01
Commission System
 Install power cable into the Next Series
8 machine.
 Be sure to fasten the locking clip
 Plug the provided power cable into a wall
socket providing 100-240Vac.
PRINTER MUST BE INSTALLED

NEAR AN EASILY ACCESSIBLE
POWER SOCKET/OUTLET.
DO NOT USE EXTENSION

CORDS. PRINTER MUST BE
CONNECTED TO SOCKET
DIRECTLY.
WALL SOCKET MUST BE WELL GROUNDED AND PROVIDE CONSISTANT

VOLTAGE BETWEEN 100-240Vac. IF VOLTAGE DROPS BELOW 90Vac
FOR MORE THAN 0.5sec, THE MACHINE WILL AUTOMATICALLY POWER
OFF.
IF WALL SOCKET IS NOT WELL GROUNDED, A DEDICATED GROUND
FOR THE CABINET MUST BE PROVIDED FOR PROPER FUNCTION OF

THE PRINTER.

MANUAL – 40-0001-01
Commission System
Printhead Mounting
 Install the printhead clamp
 Attach printhead to printhead

mounting bracket

MANUAL – 40-0001-01
Commission System
Fluid System Commissioning
SMOKING OR OPEN FLAMES NEAR PRINTER OR FLUID STORAGE.
 Touch and hold blank screen to turn on
 Device Maintenance Due screen will appear soon after 1st power up.
 Press OK to Temporarily Remove.
 Adding fluids with BestCode SmartFill™ Label will resolve.

MANUAL – 40-0001-01
Commission System
Commission the System Ink Type (V01.03.00)
1. Login using the Technical Level Password
2. Go to Service > Tools > Technician.
3. Press the “Commission Ink Type” Button.

MANUAL – 40-0001-01
Commission System
4. Select the Ink Type that the system will use.
5. Press Save Commissioning

button.
How to Add Fluids
1. Remove Ink Cap
2. Remove Ink Bottle Cap
DO NOT PUNCTURE OR
REMOVE THE FOIL SEAL!
Heavy pigment inks must be shaken for 60-120
seconds before installation into the Next Series 8

System.
3. Align SmartFill™ label and machine SmartFill™
Symbol before installing.

MANUAL – 40-0001-01
Commission System
4. Firmly push down 60

Seconds
P
5. Let bottle fully drain U
S
(Approximately 60 seconds) H
6. Re-install Cap
6. Pop-up will confirm correct fluid

is installed.
7. Repeat with 2 bottles of Makeup.
Correct SmartFill™ Label Alignment
SmartFill™ SmartFill™
Bottle Label Controller
Label

MANUAL – 40-0001-01
Commission System
Ink Troubleshooting During Commissioning
SmartFill™ Result= 3
This result means that the Label Symbols are not correctly aligned or that the system cannot read
the label. Press Retry and slowly turn the bottle 360 degrees until the Label is correctly read.
Ensure the Fill Cup coax cables are connected to the main circuit board.
SmartFill™ Result = 10
This result means that the Label has already been read and has been erased. Use an appropriate
label to continue with the fluid add.
SmartFill™ Label Required (Ink or Makeup)
This result will occur when the Start Button is pressed before a SmartFill™ label is read in for both
Ink and Solvent. This will occur during commissioning if the Labels are not read when fluid is added.

MANUAL – 40-0001-01
Commission System
SmartFill™ Prompt does not appear / Force SmartFill™ Label to be Read
 Touch the Fluid Status button to force the SmartFill™ Label Reader read SmartFill™ Label.
o This can be used if fluid is added when unit is powered off, and the Label is not
scanned at the time the
fluid is added.
 This will ensure that the SmartFill™ Label is read in and does not cause “SmartFill Label
Required” error.

MANUAL – 40-0001-01
Commission System
Test the Valves
The first step to commissioning a machine is testing the valve function. Before running the
pump, test each valve individually and listen or feel for valve function. Navigate to the Fluidic
Test Screen and cycle each valve 5-10 times. The valves will audibly click. If the
environment is too loud to hear clicking, open the back of the cabinet and touch each valve
while simultaneously turning on and off multiple times.
Valve Troubleshooting During Commissioning

If a valve does not click on, locate in fluidic system (see Page 37), remove the valve (leave
cables connected), and rinse solvent into valve while
simultaneously cycling the valve on and off. When the
valve begins to click, re-install and process with valve

testing.
 Remove the Valve
 Leave the Wires Connected
 Rinse Top and Bottom ports with Solvent.
 Rinse with more solvent until the valve begins

to operate.
For extremely troublesome valves, submerge the
valve in Solvent for 5-10 minutes, then repeat the

valve cycle.

MANUAL – 40-0001-01
Commission System
Test the Pump
 Press the service button
 Press the Fluidic button
 Slowly run the pump up to 15 RPS
 Allow pump to run for 1 minute

MANUAL – 40-0001-01
Commission System
Pump Troubleshooting during Commissioning
If the pump does not turn during commissioning, it has dried ink remaining in the pump that
is preventing the gears from turning. Follow to procedure below to alleviate.
 Remove the pump inlet tube
 Rinse the Pump Inlet with Solvent

MANUAL – 40-0001-01
Commission System
 Re-install Pump Inlet Tube
o Fully install the tube into
the fitting.
o See Technical Manual for
Details.
IF HIGH RPS FAULT OCCURS, IT IS LIKELY THAT TUBE IS NOT FULLY INSTALLED
 Run the Pump in the Fluidic Screen
 Repeat solvent Rinse and Pump cycling until Ink is dissolved.
For extremely troublesome pumps, add solvent the following way.

MANUAL – 40-0001-01
Commission System
 Remove Ink Feed from the Ink
Tank.
 Invert the Feed

 Fill the Entire line with Solvent
 Cycle pump as Shown on Previous

Page

MANUAL – 40-0001-01
Commission System
Clean the Nozzle
Go to the Service screen and press the

backflush icon. Perform 2 back flushes
before proceeding to prime the other
lines.
Prime the Ink Lines
 Activate the Printhead Valve.
 Activate the Gutter Valve.
 Run in this configuration for 1 minute.
Prime the Flush Line
Go to the Service screen and press the
Printhead Clean icon.

MANUAL – 40-0001-01
Commission System
Run the Jet until Ready to Calibrate
 Run the Jet
Final Checks before Completion
 Check for any leaks in fluidic compartment.

 Run until “Actual Viscosity” reaches 4.5cP.
o Viscosity is not temperature compensated. External viscosity checks should
be done at operating temperature.
 Gutter faults may occur during this initial start-up.
o This is due to air ingested during the first start-up. Restart the jet and
continue until target viscosity is reached.
Do no remove the nozzle during commissioning. Perform backflush to clean
nozzle.
 Check drop break-up.

 Test print using “BestCode” default message.
 Perform modulation calibration in the Target Environment.
o See Section 10 for Modulation Calibration

MANUAL – 40-0001-01
Commission System
How to Install PhotoEye Sensor
Mounting sensor to the Printhead
1) Spud 22-0069-01
2) Clamp 25-0033-02
3) M3 x 20 Flathead Screws (included with PhotoEye)
4) M3 Flat Nuts (included with PhotoEye)
5) PhotoEye
Multiple Styles available will mount this may, including;
44-1001-01, Laser Kit

44-1002-01, Proximity Kit
44-1004-01, Retro Reflective Kit
6) M6 x 10 Panhead Screws (Included with Printhead Floor Stand – 40-0003-01 and Conveyor Side
Mount 40-0004-01)

MANUAL – 40-0001-01
Commission System
Mounting Fiber Optic Sensor to the Printhead
1) Spud 22-0069-01
2) Clamp 25-0033-02
3) M3 x 20 Flathead Screws
(included with PhotoEye)
4) M3 Flat Nuts (included

with Fiber Optic)
5) Fiber Optic Sensor
7) M6 x 10 Panhead Screws (Included with Printhead Floor Stand – 40-0003-01 and Conveyor Side
Mount 40-0004-01)
8) Fiber Optic Detector
(included with PhotoEye)

MANUAL – 40-0001-01
Commission System
Encoder Installation
 Remove the rubber cap and verify that

the set screw in the spring adjustment
collar is loose. The pivot shaft should
rotate easily.
 Install the threaded end of the pivot

shaft through the mounting bracket.
 Install the washer and nut provided

finger tight
 Hold one end of the pivot shaft with a

5/32” or 4 mm hex “L” key while the
nut is securely tightened.
 At this point the housing assembly

should rotate easily around the pivot
shaft.
 Rotate the housing so the measuring

wheel is contacting the surface to be
measured. Insert the 3/32” hex “L”
key into the set screw on the spring
adjustment collar.
 Using the hex key arm for leverage,

rotate the collar around the pivot
shaft in the direction necessary to
increase the spring force that holds
the measuring wheel against the
surface to be measured.
 Tighten the set screw very securely to

avoid loss of spring pressure.

MANUAL – 40-0001-01
Commission System
Install/use BestCode Peripherals

This section covers installation of BestCode Photocell, Shaft Encoder, Alarm
Beacon, Auxiliary, USB, Ethernet, and Parallel Port.
Installing bulkhead connectors

Remove Power Cable
Open the front door

MANUAL – 40-0001-01
Commission System
Remove Blank Plug
Slide connector into hole and fasten nut

MANUAL – 40-0001-01
Commission System
Plug connector into Board

Encoder
Parallel
Auxiliary
Photo Eye 1
Alarm Beacon
Ethernet
USB Mini
USB
Serial RS 232
Close the front door

MANUAL – 40-0001-01
Commission System
Plug in the Power Cable
Configuring Peripheral Devices
 Press the setup button
 Press the Peripherals button

MANUAL – 40-0001-01
Commission System
Configure the Photocell
 Press the Photocell button
Set desired features for the Photocell.
o Debounce is used to filter mechanical bounce.

 Most common with relay triggering.
o Trigger
 Fall: triggers print when signal to eye is lost.
 Rise: triggers print when signal to eye is found.

MANUAL – 40-0001-01
Commission System
Configure the Shaft Encoder
 Press the Encoder button
 Select an Encoder Mode
Shaft Encoder Operation
Mode Function Resolution
Off No Encoder -
1 Mechanical Pulse is 1 Printed Raster. Use for Higher control of Resolution or in 1800
1x
applications where encoder is connected via gear rather than wheel.
1 mechanical pulse is 2 printed rasters. 3600

2x
1 mechanical pulse is 4 printed rasters 7200
4x
1 mechanical pulse is 8 printed rasters 14400
8x
1 mechanical pulse is 16 printed rasters. Use for Encoders with lower mechanical 28800
16x
resolution.
While encoder is normally turning clockwise, counter clockwise rotation will not cause 1800
Direction Forward
print. Print will resume at correct position when clockwise rotation resumes.
While encoder is normally turning counter clockwise, clockwise rotation will not cause 1800
Direction Reverse
print. Print will resume at correct position when counter clockwise rotation resumes.
 Shaft Encoder Mechanical Resolution - 1800 Pulses Per Revolution.

 Maximum Mechanical Pulses allowed: 100000 per channel per second.
(MECHANICAL PPR * LINE SPEED / WHEEL DIA < 200000) for 2 Channel
(MECHANICAL PPR * LINE SPEED / WHEEL DIA < 100000) for 1 Channel

MANUAL – 40-0001-01
Commission System
Shaft Encoder Emulation, Pulse Generators
 Circuit for Encoder is Open collector, 12V.
 For HTL or TTL signals, signal voltage must be 2V or greater to illuminate LED to create the
digital signal.
For Emulation and pulse generators, a maximum of 100000 Pulses per second should be
sent to the device. Signal generators enter on only 1 channel, and as such are limited to the
maximum mechanical pulse requirements of a single channel.
Alarm Beacon Behavior

The alarm beacon is non configurable. The alarm beacon reads out information solely on operating
conditions.
Machine is powered on. Machine is powered on Machine is powered Machine is on and

and Jet is Running. on and a Warning is an Error has
present. occurred.
Combinations of these can occur.
For instance, Jet can run while a warning is present.

Blue, Green, and Yellow may all be lit simultaneously.
There can be a warning while an Error is present.

Blue, Yellow, and Red would be lit simultaneously.
The Jet will never run during an Error condition.

Green and Red should never be lit simultaneously.

MANUAL – 40-0001-01
Commission System
How to Configure Ethernet Connection

The Series 8 CIJ has Network capability on all models.
Connecting to another Device (PC, CIJ, Number Generator, etc)

Connecting to another device required the use of a Category 5e Crossover Cable. These are widely
available.
 With the Series 8 CIJ powered down, connect the Crossover Cable to the Ethernet Plug on
the main Board, or use the Ethernet Peripheral plug.
 Connect the opposite end of the Cross Over cable to the PC device.
 Power on the Device
 Navigate to the Setup > Network

screen.
 Press the Configure button and go to “Static”

MANUAL – 40-0001-01
Commission System
 Set a Unique IP Address on the Same Gateway as the paired device.
 Match the Network Mask to the paired device.
Test the connectivity by pinging the IP Address entered on the Device from the paired
device.

MANUAL – 40-0001-01
Commission System
Connecting to a Network (Router, Hub)
Connecting to another device required the use of a Category 5e Patch Cable. These are widely
available.
 With the Series 8 CIJ powered down, connect the Patch Cable to the Ethernet Plug on the
main Board, or use the Ethernet Peripheral plug.
 Connect the opposite end of the Patch cable to the PC device.
 Power on the Device
 Navigate to the Setup > Network

screen.

MANUAL – 40-0001-01
Commission System
 Press the Configure button and go to “DHCP”
 Press the Save button and the Device will automatically obtain an IP Address and Network
Mask
Test the connectivity by pinging the IP Address entered on the Device from the Network

MANUAL – 40-0001-01
System Operation
Section 5
System Operation

MANUAL – 40-0001-01
System Operation
This section discusses basic system operations, such as powering on and off the
machine, when to add fluids, how to start and stop the jet, selecting new messages, and
editing messages.
Basic Navigation
Turning Power On/Off.
Power On
 Touch and hold blank screen
Power Off
 Press

MANUAL – 40-0001-01
System Operation
Starting/Stopping Jet.
Starting the Jet
1. Touch “Start” to Start Jet

2. Icon changes to “Starting” while the jet is starting
3. Icon Changes to “Ready” when the printer is ready to print
Stopping the Jet
1. Touch “Stop” to Stop Jet

2. Icon Changes to “Stopping” while the jet is stopping
3. Icon changes to “Stopped” when the jet is stopped

MANUAL – 40-0001-01
System Operation
Selecting message for printing
 Touch the Icon to select a message
• Touch the desired message, or use the and buttons.
• Touch the button to select message for printing

MANUAL – 40-0001-01
User Interface Operation
Section 6

MANUAL – 40-0001-01
Operation Basics
The BestCode 10.4” User Interface features touch technology. Icons (or buttons) are used to
navigate the interface. The touch screen can be operated using a stylus, finger, gloved
finger, and optionally a mouse.
The touch screen can be operated as shown below;
 Press “Message” Icon with
stylus, finger, gloved finger or

click with mouse.
 Button Darkens and mouse positions over the Icon
 The “Select” menu is opened

 Click the “Home” button

MANUAL – 40-0001-01
 Clicking the home button always
returns the user to the “Home

Screen”
Home Screen
Paus Solvent Tank Status
e or
Resu
Help / Machine Info
me Ink Tank Status
Print
ing
Oper
atio
User Login n
/ Logout Start Jet
Create New
Stop Jet
Message
Edit
Printing
Message
Displays
Default
Product/Print
Message
Count
Power Off Notifications
Edit or Select Message System Calibration, &

Diagnostic.
Print Setting Adjustments Backup and Restore
System Setup
Access Cleaning Options
(date, time, keyboard,
(Backflush)
Display, Users, Peripherals)

MANUAL – 40-0001-01
Main screen Menus and Indicators

This section discusses the menus and indicators accessible from the Home Screen.
Sign In
 Press the Sign In

button
 Enter the desired

name
 Sign ins can be
configured in the
Setup Screen when
signed in with the
Technician Level
password.

MANUAL – 40-0001-01
Help
 Press the help button
 The following information will be displayed.
(Ink system not commissioned) note will be replaced with the correct Ink type after it is
programmed.

MANUAL – 40-0001-01
Print Enable
Print enable is a quick home screen button used to stop and start printing. This feature stops print
without stopping the jet.
Print enable can also be used to trigger print. In applications where shaft encoders are used without
a photoeye, the Print Enable button can be disabled then enable to trigger print. From here the print
will begin with shaft encoder readings.
 Press the Enabled

button to pause
printing.
 Press the Disabled

Button to re-enable
print.

MANUAL – 40-0001-01
Solvent Tank Status
Displayed Status Cause Action

Solvent Tank is at the Add 1 or 2 bottles of Solvent to fill the
lowest operating volume. tank.
Solvent Tank is half full. Add 1 bottle of Solvent.

Machine will operate fine
at this volume.
Solvent Tank is full and No Action
requires no attention.
Solvent Tank is in a failure See Section 9: Troubleshooting

state.
Ink Tank Status
Displayed Status Cause Action

Ink Tank is at the lowest Add 1 bottle of Ink.
operating volume.
Ink Tank is full and No Action

requires no attention.
Ink Tank is in a failure See Section 9: Troubleshooting

state.

MANUAL – 40-0001-01
Printing Message
Printing message shows the name of the current message being printed. Printing message also
features the ability to quickly edit a message or create a new message without going through the
Select Screen.
Count
The count screen counts the number of physical prints. Product count is a continuous counter, and
will count every print trigger until it is reset for any message printed. An incremented print trigger
does not always mean an increment in Print Count will occur. Print count is also a continuous
counter; however this count is exclusive to the message being printed. The count is stored with the
message. Changing messages does not erase the count for the message.
Reset the Counters
 Press the counter button

MANUAL – 40-0001-01
 Press the reset button to return

the count to zero.
Adjust the print counter
Print counters can be adjusted to change

messages containing counters.
 Press the count button.
 Press the keyboard button on

counter 1 and set to 500.
 Press the keyboard button on
counter 2 and set to 1000.
 Press Save

MANUAL – 40-0001-01
 The counts on the screen are

updated and will increment after
each print from these points.
Message Select
The message select screen is used to
select, create, edit, or delete messages
that are currently available for use on the
system.
Search
Default Message
Scroll
up
Scroll down
Select Message Delete a Message
Create a New Message

Edit a Message

MANUAL – 40-0001-01
Message Search
Message search is used to quickly
navigate and select messages from the
Select Screen.
 Press the search button
 Enter the 1st letter of the message

desired.
 The 1st message beginning with
that letter will be highlighted.
Adjust
 Press the Adjust button

MANUAL – 40-0001-01
 These features are duplicates of
adjust settings in Message Editor.
 Adjust settings are message

dependent.
 Adjustments can be made while

the jet is running.
 Adjustments are automatically

updated to quickly allow message
setup.
Speed Screen
The speed screen is a tool assisted
configuration for setting the width and
speeds for currently selected messages.
 From the adjust screen, press the

Speed button
 First, enter the product length.

 This value represents the length
of distance that that photo eye
will be active as the product
passes.
 After entering the product length,

press the Line Speed Calculate
button.
o The jet must be off.
o Run the line at maximum
speed with the photo eye
configured at desired
position.
 A minimum of 2 products must pass the photo eye for a correct line speed to be entered.

MANUAL – 40-0001-01
 Optionally, line speed may be
entered manually using the
Keyboard button by the
calculator.
Notice that a pitch value has been

provided from the calculation.
 Next, Use the width button to

adjust the Print Resolution Value.
 Resolution value should be
between 30-100 drops/inch for legible print.
 If the Desired Resolution cannot
be met, increase the speed to the
next highest speed and repeat
width adjustments to find desired
Print Resolution.
 When finished editing, press the

save button.
 Start jet and confirm setup with
test print on the line.
SEE “SETTINGS” IN CREATING MESSAGES SECTION FOR MORE

DETAILS
Clean
The clean page contains two cleaning
functions. Printhead clean and Back Flush
Nozzle.
 Press the Clean button

MANUAL – 40-0001-01
Printhead Clean
This performs a flush stop routine. The
flush stop cleans ink out of the drop
generator, printhead valve manifold and
gutter. Printhead clean should be
performed as necessary.
Back Flush Nozzle

Cleans the inside the drop generator and
nozzle. Manual assistance is required.
This process is covered in Section 8:
Maintenance, Printhead Maintenance.
Setup
The setup page features setup options for Languages, keyboards, Date and Time, toggling peripheral
devices, and Network communication.
 Press the setup button

MANUAL – 40-0001-01
The Setup Screen
Printer Name: Set Keyboard 1

Can be changed
Screen Set Keyboard 2

Brightness
Set Keyboard 3
Charge
measurement
units in Speed
Screen Set Keyboard 4
Set Language
Create
Passwords
Date and date Configure Network Settings

formats
Toggle Encoder, Relay and
Photo eye
Creating Passwords
 Login to the Device Using the Technician

Level password.
 Go to the Setup Screen
 Press the “Password” button

MANUAL – 40-0001-01
 Enable Passwords
 Press the Arrow button to begin creating

passwords.
 Enter the Desired Password by pressing

the Keyboard button
 Press the Forward arrow on the New

Password to begin selecting features to
allow.

MANUAL – 40-0001-01
 Select the Desired Features to allow while

logged in under this password.
 When you have finished selecting the

Features, press the Back Arrow or Home
Button to complete.
 Press the Logout Button on the Home

screen to complete.
 The machine will now lock all features unless the operator is logged in.

MANUAL – 40-0001-01
Service Screen
The service screen is designed to be used by service technicians to calibrate the
drop production, perform diagnostic fluidic routines, update firmware, perform backups and
restore old data.
Calibrate
Modulation: Controls high
Creates drops from voltage status
the nozzle
Pressure: Disables errors for

Determines drop diagnostics
flight speed
Charge:
Enable or Disable
Determines voltage
Phasing
applied to drops.
Displays actual Displays

pump output and temperatures and
phase quality. ink status
Calibrate Default Settings

Feature Default Setting
Modulation 20-250 (typical 100)
Pressure 37-43 (typical 40)
Charge 65-75 (typical 70)
PSI / RPS 22 RPS @ 40PSI Typical
Phase Point 0-15 (all good values)
Phase Width 7-9
Phase Quality 100% (If Under 50%, HV is off)
Phase Threshold 32-10*
Error On during printing
HV Deflect On during printing
Phasing Enabled while running
Viscosity Status Reports viscosity trend (falling, rising, steady)
Target Viscosity 4.5 cP (Varies by Model)
Actual Viscosity Reports last viscosity reading and fall time
Printhead Temp Reports ink temperature in Printhead
Ink Temperature Reports ink tank temperature
Electric Temperature Reports electronics compartment temperature

MANUAL – 40-0001-01
* The lower the value the greater distance the ink stream is from the phase. Jet alignment can affect this value as the stream
moves distance from detector. If this is moving rapidly – indication of poor modulation or unstable jet, clogged nozzle, etc…
Tools
Backup Files Restore Files

to USB from USB
Update
Load Logged
Firmware
files to USB
Version from
USB
Access
Technician
Features
Backup
The backup feature is used to save machine data to USB. This feature can be used
to copy data from one BestCode CIJ to another.
Follow all on screen instructions during backup.
NOTE: USB MUST BE INSTALLED

MANUAL – 40-0001-01
 Press any of the arrows to perform a backup of that section.
 Press okay to perform the backup.

MANUAL – 40-0001-01
EQUIPMENT DAMAGE: DO NOT REMOVE USB STICK DURING FILE
TRANSFER. FAILURE TO OBSERVE THIS WARNING MAY LEAD TO

PERMENANT DAMAGE OF THE CONTROLLER BOARD.
Restore
The restore feature is used to load saved machine data from USB. This feature can
be used to upload copied data from another BestCode CIJ.
Follow all on screen instructions during Restore.
NOTE: USB MUST BE INSTALLED
 Press any of the arrows to perform a restore of that section.

MANUAL – 40-0001-01
 Press okay to perform the restore.
EQUIPMENT DAMAGE: DO NOT REMOVE USB STICK DURING FILE

TRANSFER. FAILURE TO OBSERVE THIS WARNING MAY LEAD TO
PERMENANT DAMAGE OF THE CONTROLLER BOARD.

MANUAL – 40-0001-01
Technician Screen
The technician screen contains a few features used mostly for calibration of the machine.
Adjust advanced
Print settings
Quickly delete
messages and
Reset Prints and
graphics.
Filter Life
Correct screen
flicker
Recalibrate the
touch screen
Return machine
to Factory state,
deletes Flush scripts for
messages, removing Ink
keyboards, from the system.
translations, and
settings
Re-format
memory drive to
Select System Ink fix memory
Type for corruption
SmartFill™ errors.
identification.
Print
Print screen has features to adjust modulation frequency, Stir Mode for Cold Environment and
heavy pigment inks, as well as gutter offset to eliminate gutter clipping in low height print modes.
Messages
Messages screen allows user to delete all messages or update messages from old version to new
version. This update feature should not be used unless instructed in Firmware release notes. As
firmware is updated, features will be added to the message files. Old message files may become
incompatible, and then must be updated.
Screen Calibrate
See Section 10 > Electronic Service Routines > Touch screen Calibration.
Restore Factory Defaults
Returns machine to factory settings. Only for machines needing to have all settings and files deleted.
Must perform Restore All from a default BestCode USB of matching Firmware version after the
process completes

MANUAL – 40-0001-01
Tools
The tools page contains a series of Tools to be used only by the Distributor or Technician. It proves a
means for resetting run time, pump time, and total prints (Docs) for cases where the machine is
rented. SmartFilter™ Labels reader can be tested on this screen. It allows the screen flickering issue
to be resolved, and allows SmartFilter™ Labels to be read to reset filter life counter.
Test Ink Fill

SmartFill™
Used to replace
Reader
main ink filter.
Test Makeup Fill Reset when

SmartFill™ replacing pumps
Reader to gauge life.
Adjust up or
down to reduce
Test
screen flicker.
SmartFilter™
Reader
Clear total prints.
Popularly used
Reset time the
for pay per print.
system has been
powered on.
Used for renting.
Notifications
Notifications are Icons that display active effects on the printer.
High Voltage is
Phasing is ON
Enabled
Encoder is
Enabled
USB Stick is
Installed
Additionally, a Mouse icon will appear if a mouse is being used to control the system instead of the
touch screen.

MANUAL – 40-0001-01
Creating Messages
 Press the New button to

create a new field.
 Enter a name for the

new message
 Press the “save” button

MANUAL – 40-0001-01
Creating a Text Field
Text fields are basic messages composed on non-variable text.
 Create a new message

 Press the “Text Field” button
 Type a message using the keyboard.
 Save the message

MANUAL – 40-0001-01
Adding an AutoCode Field
Auto code fields are fields that are automatically updating. This includes time, day, month, and year
coding for current or future dates. Also features build in print counter for tracking total message
print volume.
Time Codes
Time codes are codes used to track time. Intervals included are hour, minute, and second.
 Press the time button
 Select the desired time code.

MANUAL – 40-0001-01
 The time code is added into the editor.

 The time matches the time set inside
the software.
Counter Codes
Counter Codes are codes that track counter values in software. Counter values are displayed and
accessed on the Home screen.
 Press the counter button
 Select a counter to use.
*PROMPT START COUNT IS CURRENTLY UNAVAILABLE

MANUAL – 40-0001-01
 The counter begins at zero and

will increment with each print.
 Press Save
 Select the message for printing.

 Press Start
 The message will match the

print count value.

MANUAL – 40-0001-01
Date Codes
Date codes are messages that display dates. This includes print time, expiration dates, and
 Press the Date button
Normal Date Codes

Normal date codes are codes used to track details of the day the product was printed.
 Press the Normal Date button
The Normal Date Screen

The normal date screen contains all the
features to creating current time date codes.
Format

MANUAL – 40-0001-01
Format codes are all inclusive date codes. This code provides a quick method of adding date codes
to a message.
 Press the cycle button

in the format field to
view the different pre-
set formats.
The following are available

formats;
 MMDDYY
 DDMMYY
 YYMMDD
 MMDDYYYY
 DDMMYYYY
 YYYYMMDD
Month Codes
The month code feature allows users to add the month into the editor. The month code feature also
contains the Alpha Month feature, and day of month feature.
 Press the Month Codes

button

MANUAL – 40-0001-01
 Select the Month Code desired.
 The month code selected

appears in the editor.
 Press the New button to add

more fields

MANUAL – 40-0001-01
Year Codes
The year code feature allows users to define year dates to be entered into the editor. This includes
 Press the Year Codes button
 Select the Year Code Style desired
 The selected year code will appear

in the editor.
 Press the new button to add more
date codes

MANUAL – 40-0001-01
Week Codes
The week code feature allows using to define the week date to be entered into the editor.
 Press the Week Codes button
 Select the Week Code style desired
 The week code selected will appear

in the editor.

MANUAL – 40-0001-01
Roll Over Date Codes
Roll Over Dates Codes are used to extend normal date code allowances. This is used to add time in
case batches run over into the next day while batches are tracked by day produced.
 Press the Rollover Date button
The Rollover Date Screen

The Rollover Date screen is nearly identical to the Normal Date screen. The Rollover date screen
contains a “rollover” feature. This feature is used to provide roll over hours into the next day
without changing the date to that subsequent day.
Rollover Example
A batch of produced goods needs to be tracked to the day they were produce, not to the day they
were coded. 12 hours after the product is produced, it is coded. To ensure that the entire batch has
the same production date, a roll over code may be used.

MANUAL – 40-0001-01
 Set the roll over to 12 hours using the

“Rollover” arrows.
 Select the desired code to be used.
 Until 08/19/14 at 12:00pm, the

08/18/14 Code will be used.
 This will repeat and stay and active
feature in the message.

MANUAL – 40-0001-01
Expiration Date Codes
Expiration date codes are created in the message editor using the AutoCode functions. This
document serves to demonstrate how expiration date codes are created.
 Press the Expiry Date button
The Expiration Date Screen

The expiration date screen contains all the
features to creating expiration dates.
Expire
The expire feature allows users to set the duration of time until product expires.
 Press the Expiry Key button

MANUAL – 40-0001-01
 Press the numeric button
 Enter a day value until expiration

(365).
 Press the return key
Year Code
The year code feature allows using to define a expire year date to be entered into the editor.
 Press the Year Code button

MANUAL – 40-0001-01
 Select the Year Code Style desired
 The number year code 15 is

displayed
 This is the year code for 365 days
from the day this manual was
written (8/13/2014).
 Press the new button to add

more Expiry fields.
 Navigate back to the expiry page
using previous instructions.

MANUAL – 40-0001-01
Week Codes
The week code feature allows using to define a expire week date to be entered into the editor.
 Set the expire date (365).
 Press the week code button
 Select the Week Code desired.

MANUAL – 40-0001-01
 The week code MON is displayed

 This is the week code for 365 days
from the day this manual was
written (8/13/2014).

Expiry fields.
Format
Format codes are all inclusive expiration codes. This code provides a quick method of adding
numeric only expiration codes to a message.

MANUAL – 40-0001-01
 Press the cycle button in the format

field to view the different pre-set
formats.
The following are available formats;
 MMDDYY
 DDMMYY
 YYMMDD
 MMDDYYYY
 DDMMYYYY
 YYYYMMDD
 After selecting a format code, press

the green plus button to accept.
 The format code appears in the

editor as a complete expiry code.

MANUAL – 40-0001-01

Expiry fields.
Month Codes
The month code feature allows using to define an expiration month date to be entered into the
editor. The month code feature also contains the Alpha Month feature, and day of month feature.
 Press the Month Codes button

MANUAL – 40-0001-01
 Select the Month Code desired.
 The alpha code selected is then

added to the message.
Expiration Rollover Date

The Expiration Rollover Date screen is nearly identical to the Expiration Date screen. The Expiration
Rollover date screen contains a “rollover” feature. This feature is used to provide roll over hours into
the next day without changing the date to that subsequent day.

MANUAL – 40-0001-01
How to Setup Program Codes

Program codes allow manipulation of the presentation of Date Codes. Program codes can be used to
disguise sensitive product information, or to better conform to internal Date Code marking systems.
 Navigate to the Setup > Date / Time

screen
 Select Program Codes
 Select any of the Icons to create a

customized output for the Program Code.
 The “Code” field can be used to add the

custom data.
 The “Day of Year” area corresponds to the

action that will be modified.

MANUAL – 40-0001-01
Program Code Example
1. Create a new message
2. Go to AutoCode Fields > Date Codes > Normal Date > Year Codes
3. Add a “Day of Year” code to the message
4. Repeat, but now add a “Program Day of

Year” code to the message.
5. Save the message

MANUAL – 40-0001-01
6. Select the message for Printing
7. Go to Setup > Date / Time > Program Codes > Program Day of the Year
8. Change the “Day of Year” value to Todays

day of the year. (230 in this example)
9. Enter the desired Custom code for the

230th day of the year.

MANUAL – 40-0001-01
10. The code is changed to CDA instead of

230.
11. Press the Home Button
12. The message will now display the coded

value for the 230th day of the year as the
code defined.
13. This process would be then repeated for

all 365 days and to the desired code.

MANUAL – 40-0001-01
Shift Codes
Shift codes are codes used to define daily work shifts. These codes are useful for tracking crew
specific conditions of printed product.
 Press the Shift button
 The shift code will automatically appear in

the editor window.
 Shift codes can be customized in the

advanced editor.
 See Advanced Editor Features in Section
6.

MANUAL – 40-0001-01
Adding a User Defined Field
User define fields are “blank” fields that are programmed with manually entered data at the time
the message is selected.
 Press the User Define button
 Define the Length of the User

Define field.
 Name the User Define ID

MANUAL – 40-0001-01
 Press the Add button to add the

User Define field to the message.
 The Xs will represent the User

Define code Length.
 Save the message.
 Select the User Define message.

 Press Start

MANUAL – 40-0001-01
 The User Define input screen will

appear.
 Type in the User Define data.
 Any Keys on the Keyboard can be

used in the User Define.
 Spaces can be used by adding the
Unicode Space value as a key to
the keyboard (See Section 7,
Keyboard Editor)
 When done, press the Enter key.
 The User Define field is now ready

to print using the manually
entered data.
 Use the User button to rapidly

change the User Defined data.

MANUAL – 40-0001-01
Adding and Creating Barcodes
Current barcode features include the ability to add text to barcodes but not auto codes or variable
data. Creating barcodes is simple. More complex barcode formats, such as Code 128 are discussed in
detail.
 Create a New Message
 Select the “Barcode Field Button”
 Select the Desired Barcode to add to the

message.
 Choose whether to enable Human

Readable text.
 Press Next
 The following Screen will open up.
 Enter the desired Text and press the

“Add” button to add to the Message
Editor.

MANUAL – 40-0001-01
 Add Text to the BarCode Field.
 Use the “Symbol” Key on the keyboard to

access “Special Functions”
 Add AutoCodes
 Add Counters
 Etc…
 Press “Confirm” to add the Barcode to the

Editor.

MANUAL – 40-0001-01
 Press Save
 Barcode can be scanned from the display

to ensure accuracy.
Special Barcode Types

Depending on the Type of Barcode, the functionality may be straight forward or complex. This
section will discuss the more complex types of barcodes.
Code 128
Code 128 Barcodes are complex because they have multiple protocols for data entry into
the editor.
Type Application Code Sequence
Code 128 Normal Data Information start code

data
checksum
stop code
A UCC/EAN-128 start code
Conforms to the UCC/EAN-128 FNC1
standard. application identifier
data

MANUAL – 40-0001-01
Application Identifier allows checksum

understanding and sorting or data stop code
after scanning.
UCC/EAN-128 Start code
Serialized Shipping FNC1
Container Symbol This type of barcode uniquely Application Identifier (00)
identifies every package currently Package Type (0 = carton)
in transit and makes global UCC/EAN number system/numbering authority
tracking systems possible Manufacturer's ID code
Package serial number
Check character for readable text
Check character for entire barcode
Stop code
Multi-Information start code
Allows custom barcode creation FNC1
for integration into existing Application Identifier
scanning systems. Application Identifier Data
FNC1
Application Identifier
Application Identifier Data
Checksum
Stop Code
Accessing Code 128 Functions

Functions are available on the Keyboard while creating the barcode.
Press the Symbol key to access the 1st page of

Functions.
 Select a Function or Press the Shift Key to

access additional Functions.
 Select the Desired Function.
For more information on the Functions and how

they work, visit
https://en.wikipedia.org/wiki/Code_128

MANUAL – 40-0001-01
List of Application Identifiers for Code 128 Barcodes
Code Identifier
00 Serial Shipping Container Code

01 Shipping Container Code
10 Batch or Lot Number
11 Production Date (YYMMDD)
13 Packaging Date (YYMMDD)
15 Best Before/Sell By Date (YYMMDD)
17 Sell By/Expiration Date (YYMMDD)
20 Product Variant
21 Serial Number
22 HIBCC; quantity, date, batch, and link
23 Lot number
240 Secondary product attributes
250 Secondary Serial number
30 Quantity each
310 Net Weight, kilograms
311 Length or first dimension, meters
312 Width, diameter, or 2nd dimension, meters
313 Depth, thickness, height, or 3rd dimension, meters
314 Area, square meters
315 Volume, liters
316 Volume, cubic meters
320 Net weight, pounds
330 Gross weight, kilograms
331 Length or first dimension, meters logistics
332 Width, diameter, or 2nd dimension, meters logistics
333 Depth, thickness, height, or 3rd dimension, meters logistics
334 Area, square meters logistics
335 Gross volume, liters logistics
336 Gross volume, cubic meters logistics
340 Gross weight, pounds
400 Customer purchase order number
410 Ship to location code (EAN-13 or DUNS)
411 Bill to location code (EAN-13 or DUNS)
412 Purchase from location code (EAN-13 or DUNS)
420 Ship to postal code
421 Ship to postal code with 3-digit ISO country code
8001 Roll products: width, length, core diameter, direction, splices
8002 Electronic serial number for cellular telephones
90 FACT identifiers (internal applications)
91 Internal use (raw materials, packaging, components

MANUAL – 40-0001-01
Data Matrix
Data matrix is a 2D-Barcode format used to ensure high read accuracy even when part of
the data is lost during transmission or if the data matrix image is damaged.
Human Readable
Human readable is unavailable for Data
Matrix codes.
Size
Below is a table of maximum character
capacity for Data Matrix sizes. Data Matrix is more efficient when compressing numbers, so codes
composed of strictly numbers will always be able to hold a greater number of characters than one
compose with Alphanumerics.
Matrix Numeric capacity Alphanumeric capacity

Size
10x10 6 3
12x12 10 6
18x8 10 6
14x14 16 10
32x8 20 13
16x16 24 16
26x12 32 22
18x18 36 25
20x20 44 31
36x12 44 31
22x22 60 43
36x16 64 46
24x24 72 52
26x26 88 64
48x16 98 72
32x32 124 91

MANUAL – 40-0001-01
How to use a Data Matrix in a message

When creating a message with a Data Matrix, the most important feature is ensuring that
adequate spacing is provided between the Data Matrix and any other text or graphics in the
message. If the Data Matrix is too close to another field, it will be difficult for the barcode scanner to
determine the Data Matrix alignment and will then make it near impossible to read.
Not enough spacing Adequate Spacing

MANUAL – 40-0001-01
Moving Fields inside Editor
 Press the Page Left button to bring

full message onto the screen.
 Press the keyboard button to return

the key board to the screen.
 Drag and drop message to

Desired position

MANUAL – 40-0001-01
 Minimize the keyboard

 Select a field to be moved by
touching it.
 Tap the Move Field arrows to

move the code.
 Tap the Move Field arrows to

move the code.

MANUAL – 40-0001-01
 Save the message when editing

is complete.
 Message can now be selected
for printing.
Font Features
The font button in the Message editor allows users to modify the visual aspects of the message. This
includes changing the template, boldness, gap, and font size. These changes are represented in both
the editor screen and in the physical print.
 Type a message
 Touch the
button

MANUAL – 40-0001-01
Font Size
Font is the number of drops in a vertical line
of print. A 7 high font will have 7 vertical
drops.
 Increase the font size by pressing

the Font Up Arrow.
Bold
Bold is the thickness of the character in a
message. Increasing the bold will add
additional matching rows of drops to each
character.
 Increase the Bold Size by pressing

the Bold Up Arrow
Rotation
 Click on Rotation

MANUAL – 40-0001-01
Rotation can be adjusted multiple ways and is

greatly dependent on head orientation and
line direction.
Template
Templates are a controlling factor for font printed height. Increasing template size allows for
taller fonts to be printed. Templates also allow users to configure multiline messages.
 Increase the Template Size
Gap
Gap is the spacing between characters, increase the gap to stretch a single field.
Gap is similar to the Width feature, only the width feature causes the entire message width to
increase.
 Increase the gap

MANUAL – 40-0001-01
Auto-Numerals
Auto numerals change the number style used in the currently selected Auto-Code.
 Select a field and modify the

Auto-Numbers
 Choose the desired character
set to use for the selected

Auto-Code.
Note: Changing the Auto-Numeral will only affect the selected field. Fonts must be present
in the Font Files. This may require editing the font file with the Font Editor tool to ensure that
the desired font is present and drawn correctly.

MANUAL – 40-0001-01
Settings
The settings button in the Message editor

allows users to modify the non-visual aspects of
the message. This includes the message width,
height, and rotation. This also allows you to set
the print speed and delay.
Width
The width feature increases spacing between
rasters in a character by a fixed spacing of 5
drops.
Width should be configured using the Speed Screen after the message has been created.
Setting up Width Values with a Shaft Encoder

The following flow diagram is a logic loop to determine the correct width value to use in shaft
encoder setup.

MANUAL – 40-0001-01
The following points are very important when setting up the encoder
1) Begin on “Fast” speed setting.

2) Run the line at maximum speed when selecting width value.
3) Configure using the exact message to be printed
Look Here for

 Missed Encoder Missed Print Results
o Means width is too low.
o Increase width to alleviate.
 Missed Prints
o Photo eye triggers before print complete

MANUAL – 40-0001-01
For the BestCode Encoder, typical width values are between 40 and 120.
This will provide print between 80 DPI (Solid Characters, to 40 DPI (1 drop space between printed
drops).
Resolution Width Maximum Speed* Print

50 DPI 100 Speed Chart * 0.95
60 DPI 70 Speed Chart * 0.95 *

50DPI / 60DPI
90 DPI 44 Speed Chart * 0.95 *
50DPI / 90DPI
*Valid only on 7H Font (As Printed)
Delay
Delay is the distance between print trigger and beginning of print.
The delay feature is applicable under two circumstances; internal or external clock.
The internal delay clock is 65000 divisions per second, or 65000hz. As an example;
Use delay 1000. This will equate to a 1000 delay * 5 drops per delay / 65000 hz = 0.0770 Time delay
from Trigger to Print.
If the line speed is 10in/second, then 0.0770 x 10in/sec = 0.770” delay distance
With a shaft encoder, the delay is equal to shaft encoder pulses prior to Width divisions but after se
multiplication by 8.
Delay * Wheel Diameter / Digital Resolution = 1000 * 6” / 28800* = .213” delay distance
*Using 16x multiplication

MANUAL – 40-0001-01
Speed
The speed button controls the toggle of the four print modes; fast, faster, fastest, and ultra-fast.
These different speeds are tailored to suit different applications where print quality can be reduced
to increase maximum print speed.
 Fast has the most guard drops and provides best print quality.
 Faster has fewer guard drops, and provides good print quality.
 Faster has minimal guard drops, and provides readable print quality. Some distortion is
possible.
 Ultra-Fast has minimal guard drops, plus added speed features. Some distortion and
character width difference are possible.
Width Speed Line Speed Print
100 Fast 24 in/s
100 Faster 24 in/s
100 Fastest 24 in/s
100 Ultra- 24 in/s
Fast
Speed charts are found in section 1
Height
The height feature is used to increase or decrease the overall height of a printed message. Height is
the strength of the High Voltage Field used to deflect drops. By increasing the strength of the field,
the maximum deflection distance is increased.
Position of the face of the head from the print substrate has a large impact on print height; this can
be used to adjust to correct height in application where distance alone cannot meet height
requirements.
If the height setting is too low, gutter clipping may occur. This is when the lowest deflected drop is
not completely deflected from the gutter. The drop will hit the edge of the gutter and cause small
drops to be present in the print, and the bottom drop will be missing from the print. Use the Gutter
Offset value, or increase the height to eliminate gutter clipping.

MANUAL – 40-0001-01
Rotation
In settings, rotation is used to match desired font display with head position. This section discusses
and details all the potential settings for a message in Normal font rotation based on head position
and print substrate flow direction.
Left to Right Flow

Left to right flow is considered the standard flow direction for substrates passing the Series 8
printhead.
We will look at the effect of each rotation on physical change to print.
Below is a front view of the Series 8 printhead in what is considered standard setup direction.
Right Side
Drop Slot
SUBSTRATE FLOW DIRECTION

Bottom Side
Top Side
Left Side
Normal Rotation
TEST

MANUAL – 40-0001-01
Mirror Rotation
TEST
Flip Rotation
TEST

MANUAL – 40-0001-01
Mirror Flip Rotation
TEST
Right to Left Flow

Right to Left Flow is considered the nonstandard flow direction for substrates passing the Series 8
printhead.
We will look at the effect of each rotation on physical change to print.
Below is a front view of the Series 8 printhead in what is considered the non-standard setup
direction. Right Side
Drop Slot
SUBSTRATE FLOW DIRECTION
Bottom Side
Top Side
Left Side

MANUAL – 40-0001-01
Normal Rotation
TEST
Mirror Rotation
TEST

MANUAL – 40-0001-01
Flip Rotation
TEST
Mirror Flip Rotation
TEST

MANUAL – 40-0001-01
Advanced Editor Features
This section discusses the advance features for the font editor. This includes modifying formatted
date and time codes, customizing counters, programming shift codes, and setting print mode.
 Minimize the Keyboard

 Press the Advanced Button
General
The general tab is used to toggle on and off the Default settings andto select the character set to use
for AutoCodes.
Default settings are;
Save the Width, Speed, Height,

and rotation for automatic use in
future message creation.
Auto-Numerals allow the user to

select between 3 number sets
Latin (0,1,2,3,4,5,…)
Arabic (٠,١,٢,٣,٤,٥,…)
Eastern Arabic (٠,١,٢,٣,۴,۵,…)

MANUAL – 40-0001-01
Date and Time
The Date/Time tab is used to modify Date and Time delimiters, as well as Shift Codes. Delimiters are
the name of the separator used in Date and Time codes.
 Click the Time Delimiter key

button and change the
Delimiter.
 Repeat for the Date Delimiter.
o Use the Backspace key to
create a blank delimiter.
 These changes automatically

save.
 Press the Back arrow to
return to the message editor
and see the changes.
 The date and time delimiters

have been changed.

MANUAL – 40-0001-01
Shift Codes
This menu allows users to set shift times and number of shifts per day. Shifts are currently
 Return to the Date/Time advanced

page.
 Press the Shift Codes button.
The shift features are as follows
 Shift: Defines the currently selected

shift.
 Start: Defines the starting time of the
selected shift. (0:00 – 24:00)
 Shifts: Defines the number of shifts to
use per day.
o Max 24 Shifts
o Min 2 Shifts
 Code: Defines the code to be displayed
during the currently selected shift.
o Codes can be numeric,
alphabetic, or coded as
desired.
This is an example shift code setup.
 Three 8 hour shifts.

 Shift 1, 8am, Code A
 Shift 2, 4pm, Code B
 Shift 3, 12am, Code C
 Press the Back arrow to return to the message editor.

MANUAL – 40-0001-01
 Time is after 4pm, so defined shift

code B is displayed.
Counters
The counters tab is used to define counter features such as increment value, starting and ending
count, zero places, and how many times to complete full counts before stopping print.
Counter: Select the counter to modify.
Start Count: Defines number to begin count

from.
Leading Zeros: Toggles leading zeros.

I.E 1 vs 00000001
Incrementation: Defines increment value.

May be any negative or
positive integer.
End Count: Defines number to stop count

upon.
 Modify the Count settings

 Press the Back arrow to return to the
message editor.

MANUAL – 40-0001-01
 The counter field does not update

until the message is save.
 Save the message.
 Open the message again in the
editor.
 The counter field will begin

decrementing from 500 in steps of
-5, down to 0.
Print Mode
Print mode allows selection printer
behavior after a print trigger.
 Select Print Mode by

using the arrows.
 Pitch is the delay
between messages.
 Repeat is number of
times to repeat a
message after a single
trigger.

MANUAL – 40-0001-01
Normal
Normal printing is rather straight forward. For every print trigger, the selected message will print
once. Print can be triggered by sensor or simulated sensor (frequency pulse).
If line speed is greater than maximum print speed, prints will be missed and a warning will appear
on screen.
Auto-Print
Auto-Print is a print mode where as

long as print is triggered, print will
automatically occur. Print can be
triggered in the software using the
“print” button in the service screen,
by sensor, or simulated sensor.
Auto-print can use shaft encoder to
control print resolution, or can print
automatically based on arbitrary
delay units.
Without a shaft encoder, 1 pitch is

equal to 5 drops between the end
of a message to the beginning of subsequent message.
With a shaft encoder, pitch is the number of shaft encoder pulses between end of a message to the
beginning of subsequent message.
After successful print trigger, print will continue until interrupted. If line speed is greater than
maximum print speed, prints will be missed and a warning will appear on screen.
Delay Enable
The Delay Enable is a mode for Auto-Printing that forces a reset of the Delay between print triggers.
This means that if products of differing length are being printed, the distance of the initial delay
onto each product will be the same, but allows the auto print mode to be used to ensure the entire
product has codes along it.
Repeat Print
Repeat print is a print style used to print repeats of the message from a single print trigger. The
number of time to repeat the message can be specified, along the distance between the repeated
prints (pitch).

MANUAL – 40-0001-01
Reverse Print
Reverse print is intended for use in traversing applications. The reverse print mode reads triggers
from photo eye 2 and mirrors the message so that it will print reversed of the normal direction. The
intended use is the receive signals via traversing system as directional pulses for normal direction
pulse signals trigger to Photo Eye 1, and reverse direction pulse signals trigger to Photo Eye 2.
Auto-Select Print
This mode is for using a binary coded decimal value to select a message. The binary value is input
using the Parallel Cable kit based on the status of 8 pins on main board (J19 Aux Port).
The number associated on the Auto-Select Print page is linked to the state of J19.
Pin Position Function Pin Position Function

1 24V 10 MESSAGE SELECT 0
2 MESSAGE SELECT 1 11 MESSAGE SELECT 2
5 MESSAGE SELECT 7 14 GROUND
For example, if a message is named 1->1 on the Auto-Select Page, to select it for printing, Pin 10
should be shorted to Pin 14. To then switch to a different message with ID 2->2, Pin 2 should be
shorted to Pin 14.

MANUAL – 40-0001-01
Below is a table of 0-25 in this format. X means shorted to Pin 14, O means open to Pin 14.
Pin 5 13 4 12 3 11 2 10 Pin 5 13 4 12 3 11 2 10
ID Number ID 13 o o o o x x o x
Number
0 o o o o o o o o 14 o o o o x x x o
1 o o o o o o o x 15 o o o o x x x x
2 o o o o o o x o 16 o o o x o o o o
3 o o o o o o x x 17 o o o x o o o x
4 o o o o o x o o 18 o o o x o o x o
5 o o o o o x o x 19 o o o x o o x x
6 o o o o o x x o 20 o o o x o x o o
7 o o o o o x x x 21 o o o x o x o x
8 o o o o x o o o 22 o o o x o x x o
9 o o o o x o o x 23 o o o x o x x x
10 o o o o x o x o 24 o o o x x o o o
11 o o o o x o x x 25 o o o x x o o x
12 o o o o x x o o
For continued counting, follow a simple Binary to Decimal Chart. The Decimal value corresponds to the ID Number.

MANUAL – 40-0001-01
Firmware and PC Tools
Section 7

MANUAL – 40-0001-01
Firmware is the current version of the Series 8 CIJ software. Firmware updates are provided
from time to time and provide new features. The BestCode PC Tools are a collection of tools used to
modify features of the Series 8 CIJ. The PC Tools allow modifications to be made to Keyboards,
Fonts, Translations, and allows graphics to be created. Using the provided remote communication
protocol, remote operation of the machine can be accomplished.
Download Firmware and PC Tools

PC Tools are saved with the latest firmware version. These are available through the BestCode
distributor login online.
http://bestcode.co/distributor-login
Email info@bestcode.co for username & password.
The file to download is named VersionXXXXXX (Xs represent current release number) and is located
under “BestCode Firmware Updates”
Formatting USB for Firmware and PC Tools

1GB, Fat 32 Format and “LED” indicator suggested.
1) Unzip the VersionXXXXXX zip file.
2) Copy unzipped files directly to the USB drive as shown below.
NOTES:
If the folders are not in this format, the printer will not recognize the files.
The text file name will change to match current firmware release.

MANUAL – 40-0001-01
USB Folders
- Best_Tools
- bestCode
- bestCodeSoftware
Best_Tools – This folder contains the current Graphic Editor, Font Editor, Keyboard Editor and
Translator (do not use tools provided prior). These are the current tools for this firmware version.
bestCode – This folder contains the current machine operation files. Ensure you use these
folders/files supplied with the version attempting to load (they are matched). - Please note you can
use your own fonts/graphics and keyboards created prior.
bestCodeSoftware - This folder contains the software to load new firmware via USB.
*A text file is included that indicates the firmware version (no content, just name).
How to update Firmware via J-Link / Board Recovery

Firmware is loaded using a tool called a “J-link Device”. This tool is available for purchase, and is not
included with Series 8 CIJ printer.
Tool required: 44-0300-01, Tool, Firmware Install “J-Link Device”
1) Plug J-Link device into computer – USB port.
2) Double click the Setup icon on the USB drive – files will automatically be installed on your
computer (do not change file location) and a C8 icon will be installed on your desktop to be
used for installing BestCode images.
3) Select the C8 icon on your desktop.

MANUAL – 40-0001-01
4) The following screen appears, follow the directions on the screen:
Warning: Do not interrupt the process. If you interrupt the process, the load will not
orrectly process and will have to be repeated.
5) Ensure all processes “PASSED”.

a) Formate Nand Flast - PASSED.
b) Kickstart Loader - PASSED.
c) Stage 1 Loader - PASSED.
d) Factory Image - PASSED.
NOTE: If any indicate Failed – Repeat process, starting at step 4.
6) After confirming all PASSED, Installed Complete. Follow directions on screen.

a) System will automatically power down.
b) Wait for unit to power down, and remove the J-Link Device from printer.
7) Power on Series 8 system.

MANUAL – 40-0001-01
8) Install the BestCode USB into the Series 8 BestCode System.
9) Navigate in the Software to Restore Screen
a. Perform a restore all.
10) Power on/off to verify

correct functionality.
WARNING: Ensure powering

on/off by using the screen
power switch. Using the mains
plug will abort all changes, and
revert to previous settings.
Settings are saved at power
down.
How to update Firmware via USB Load

Install Firmware into the Series 8 CIJ system using a USB drive. This is the typical update procedure.
1) Use the BestCode USB stick, or other USB stick that has an LED (must be formatted for
FAT32).
NOTE:
This USB firmware update method can only be made to systems that already
contain firmware version 1.02.18 or later version.
2) Unzip the VersionXXXXXX zip file. Unzipping the files will yield the following file format.
Ensure this is the file/folder format on the USB stick.
NOTES: If the folders are not in this format, the printer will not recognize the files.
The text file name will change to match current firmware release.

MANUAL – 40-0001-01
3) Install USB Stick into BestCode system – USB drive (left hand side of CPU board).
4) Jet must be stopped.
5) At Main Screen – Sign In with

Technician Level password
6) Go to Service\Tools\Firmware Update
– system will start updating firmware.
NOTE:
User must be logged in with the

Technician Level Password to enable the
Firmware Update Prompt. If not logged
in, the prompt will not be present.
7) Progress bar begins showing %

complete. The flashing LED on your
USB stick will indicate that files are in
fact being loaded. System will power
off when complete. Load takes 3-4
minutes.

MANUAL – 40-0001-01
8) Power on – leave USB stick in place.

9) Verify the firmware update did in fact complete – you will notice completion by the new
version reference in the lower left hand corner “XX.XX.XX”.
10) Go to Service/Tools/Restore/
Restore All/OK.
WARNING: If you fail to

restore the new version
machine operation files, your
system will not receive all
updates – specifically
improved print quality.
11) This will load the current print quality controls, fonts, translations, keyboards, etc.... This
takes a few minutes also. It is complete when main screen appears again.
12) Power on/off to verify correct functionality.
BestTools
The BestCode PC Tools are a collection of tools used to modify features of the Series 8 CIJ. The PC
Tools allow modifications to be made to Keyboards, Fonts, Translations, and allows graphics to be
created.
Fonts
Fonts can be modified using the BestCode Font Editor. Fonts are then transferred to the machine
using the USB drive and the “Restore Font” feature.
Font Editor
The font editor tool is used to create and edit printable fonts on the Series 8 CIJ. This can be used to
customize individual characters to customer requirements.
Fonts are saved by template, and characters must be modified 1 template at a time.
1) Navigate to the C8FontEditor Tool (USB DRIVE:\Best_Tools\Font_Editor)

MANUAL – 40-0001-01
2) Run the C8FontEditor Tool
3) Press “File”, then “Open”
4) Go to the Fonts folder on the USB

a. USB DRIVE:\bestCode\Fonts
b. Select a Font to edit.

MANUAL – 40-0001-01
5) Click open to open the Latin9High.bin file.
6) Select desired character to modify.

MANUAL – 40-0001-01
7) Left Click inside a box to add or remove drops.
Mouse Click
8) Modify as desired
9) When finished with editing, press “File”, then “Save”

MANUAL – 40-0001-01
DO NOT CHANGE THE FILE NAME!
10) Press “Save” to complete editing.
How to Install Fonts

After font files are modified, the “Restore Font” feature is used inside the Series 8 system to install
the fonts for use.
1. Power on the Series 8 CIJ.

2. Install the USB with BestCode folder into the Series 8 USB port.
3. From the home screen, press the Service button.
4. Press the Tools button
5. Press “Restore”

MANUAL – 40-0001-01
6. Press the Fonts button
7. Press OK to begin the

load.
8. Follow all on screen
instructions.
9. When complete, you will be returned to the Restore screen.

MANUAL – 40-0001-01
Using Edited fonts
To use an edited font, simply create a message and open the font to view it.
1. Create a new message and enter the message editor.

2. Enter the character and font size that was edited
3. Font was loaded

successfully and is
ready for printing.

MANUAL – 40-0001-01
Keyboard
The keyboard editor is used to change character position or presence on the keyboard. Each Series 8
system can have 10 keyboards loaded, and can optimize 4 at a time.
Keyboard Editor
The keyboard editor tool is used to create and edit keyboards on the Series 8 CIJ. This can be used to
create custom keys to customer requirements, or to use special characters.
1) Navigate to the Keyboard Tool (USB DRIVE:\Best_Tools\C8IntlKeyboard)
2) Run the Keyboard Tool
3) Left Click the desired key to change

a. The selected Key will highlight blue

MANUAL – 40-0001-01
4) Select a character to replace the Key.

a. Latin Characters are shown as Default in bottom window.
b. Extended characters are available from the drop down window.

MANUAL – 40-0001-01
5) When finished with editing, press “File”, then “Save As”

6) Navigate to the Keyboards folder
a. (USB DRIVE:\bestCode\Keyboards)
b. The Keyboard must not contain special characters, the following cannot be used.
i. Numbers (1,2,3,4,5,…etc)
ii. Symbols (!,@,#,$,?,/,…)
iii. Blank Spaces
7) Press Save to save the new Keyboard.
How to Install Keyboards

After Keyboard files are modified, the “Restore Keyboard” feature is used inside the Series 8 system
to install the Keyboard for use.
2. Install the USB with BestCode folder into the Series 8 USB port.
3. From the home screen,

press the Service button.

MANUAL – 40-0001-01
6. Press the Keyboards

button.
7. Press OK to begin the load.

8. Follow all on screen instructions.
9. When complete, you will be returned to the Restore screen.

MANUAL – 40-0001-01
Selecting Keyboards for Use
Keyboards must be selected for use in the Series 8 System. By Default, only the QWERTY Keyboard is
available.
1) From the Home screen, press the Setup button.
2) Use the Up Arrow to set

to the New Keyboard.
3) This setting
automatically saves.
Using multiple keyboards

Multiple Keyboards can be used at the same time. To do this, it is accessible in every keyboard by
using the Globe button.
1) Open a Keyboard.

MANUAL – 40-0001-01
2) Press the “Globe” button to change keyboards.
3) The keyboard will change to the modified Keyboard.

4) This can be used for up to 4 keyboards at a time.
Translations
All of the text displayed in the User Interface can be modified to use different words. This feature
also allows users to control translations to other languages and to uniquely define their own
translations.
Translation Editor
The Translations Editor is a tool used to “Replace” text and words in the Series 8 User interface.
1) Navigate to theTranslation Tool (USB DRIVE:\Best_Tools\Tranlator 1-2-16)

MANUAL – 40-0001-01
2) Run the BestCode Translation Tool
Translation
Name in
Software
Change
Sorting to
quickly find Translation
desired Rows
Translation
Advanced
Characters
and
Number Set
3) Press “File” then “Open”

4) Navigate to the “Translations” folder
a. (USB DRIVE:\bestCode\Translations)

MANUAL – 40-0001-01
5) Select a Language to modify and press “Open”

a. New Languages can be created by opening the “Default.bct” and entering a new
language name in the “<New Name>” field.
b.
6) Click on a Row to make a translation.
7) Create a name for the new translation

a. This is the name the language will appear as on the Series 8 system.
b. The Language name cannot have special characters.
c. Do not give two languages the same name.
8) Select a number set to use.

MANUAL – 40-0001-01
9) When finished with editing, press “File”, then “Save As”

10) Navigate to the Translations folder
a. (USB DRIVE:\bestCode\Translations)
b. The File name must not contain any of the following characters
i. Numbers (1,2,3,4,5,…etc)
ii. Symbols (!,@,#,$,?,/,…)
iii. Blank Spaces
11) Press “Save” to save the new Keyboard.
Translating Alpha Codes

Alpha code translations are included in the Translation file. Days of the week, months, DDMMYY
formats, etc are all included in the translation file. Update these files are install the Translation to
the BestCode Series 8. With desired language selected, all Alpha Codes will update to Translated
Language.

MANUAL – 40-0001-01
How to Install Translations
After Translation files are modified, the “Restore Translation” feature is used inside the Series 8
system to update the translation.
2. Install the USB with BestCode

folder into the Series 8 USB port.
3. From the home screen, press the

Service button.
6. Press the Translations button

9. When complete, you will be

returned to the Restore screen.

MANUAL – 40-0001-01
How to Select a Language
Translations must be selected for use in
the Series 8 System. From the Home
screen, press the Setup button.
1) Use the Arrows to set to the New

Keyboard.
a. This setting automatically
saves.
2) Check your modifications

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Graphics
Graphics are special icons users can develop and use for special print. This is used for logos and any
special shapes or characters.
Graphic Editor
The graphic editor is a tool used to integrate graphics and logos into printable messages. Using
paintbrush, graphics can easily be drawn and installed into the machine.
1) Open the Paint Brush tool in Windows. (Start/All Programs/Accessories/Paint)

2) Click on the “View” tab in Paintbrush.
3) Turn on Gridlines and Rulers.
4) Open the Properties window (Press CTRL + E as shortcut)
5) Use a maximum Width of 256

pixels and Max Height of 32 pixels.
a. These represent drops.
6) Proceed to drawing the graphic.
7) Draw graphic in only black color.
8) Press the file button, then “Save As”

9) Navigate to the BestCode USB Graphic USB DRIVE:\bestCode\Graphics)
10) Save As XXXXXXXXX.bmp ()

a. Must be monochrome Bitmap *.bmp
b. Name cannot contain the
following.
i. Numbers
(1,2,3,4,5,…etc)
ii. Symbols
(!,@,#,$,?,/,…)
iii. Blank Spaces

MANUAL – 40-0001-01
Installing Graphics
After Graphics files are created, the “Restore Restore” feature is used inside the Series 8 system to
allow use of the Graphic in messages.
2. Install the USB with BestCode

folder into the Series 8 USB port.
3. From the home screen, press the

Service button.
6. Press the Graphic button

9. When complete, you will be

returned to the Restore screen.

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Using Graphics in Messages
Adding graphics to a message is covered in Section 6, Adding a Graphic Field.

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Remote Communication Protocol

This section provides protocol information involving remote communications with Series 8 BestCode
devices. Communication is via serial port or Ethernet port.
Communication Description Overview
General Overview
Remote communication paths
 Via Telnet over Ethernet (Telnet 192.168.1.50 23)

 Via serial COM port (internal UART3)
Command Structure
 Defined using the caret “^” symbol at the beginning of any given string of characters.
 This is modeled around the ZPL command structure.
Command Notes
 Commands are not case sensitive.

 Message names are not case sensitive.
 Message data will be represented identical to the input data.
 Ethernet communication is functional, but does not return device results.
o Output is always targeted towards the serial COM port.
Resource Requirements
Cabling Requirements
1. For Ethernet;
a. CAT5 Patch
2. For COM port;

a. USB cable
b. USB to COM port adapter.

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Serial COM port access
Tera Term terminal emulator is used for serial communications methodology. Tera Term is an open
source software project.
See image below for details on Tera Term version used by BestCode for Remote Communications
development.
Baud Rate: 115K
Data Bits: 8
Stop Bit: None
Flow Control: None
Verify serial COM connection
Terminal settings may be setup according to user preference. Under normal circumstances, terminal
local echo is not necessary.
 Send the “echo on” command (ÊN) to the device Via Tera Term.
 If echo is not enabled
o Good confirmation would be the “greater than” sign (>).
o Bad confirmation would be the question mark (?)
 If echo is enabled, more text is provided.
o Bad confirmation would result in “Unknown command or bad parameter”
o Good confirmation would be “Command Successful!”

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Ethernet port access
For Ethernet remote access, a command window issuing Telnet commands with the appropriate
network access address was employed.
A static IP address must be used for Ethernet connection to the BestCode Series 8 device.
Enabling Telnet in Windows
1. Access Control Panel\ Programs\Programs and Features

2. Select Turn Windows features on or off.
3. Enable the Telnet Client box.

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4. Open command prompt window
5. Enter “Telnet 192.168.1.50 23(CR)” without quotes.
6. The following response should appear.
smxNS Telnet Server v2.70 built “MONTH” “DAY” “YEAR” “CURRENT TIME”
Command interpreter ready
>_
If commands are entered via an automated means (i.e. external PC application), each command
string (or line) only needs a carriage return (hex 0D) to indicate end of line. The line feed (hex 0A) is
not necessary.
Command responses are made to the input port (Ethernet or COM).

MANUAL – 40-0001-01
Interface Commands
^CN – Count Query

This command provides a means of receiving the product count and the print count.
Using the command ^CN will return the product count followed by a comma and the print count
XXXXX,YYYYY. A “carriage return” and “line feed” follow the print count.
^DA Delay Adjust

This command provides a means of adjusting delay for the Selected Message.
^DA value
Change the delay of the selected message to the value requested via this command. There should
be a space following the command and the actual delay value.
^PA – Pitch Adjust

This command provides a means of adjusting pitch for the Selected Message.
^PA value
Change the pitch of the selected message to the value requested via this command.
There should be a space following the command and the actual pitch value. The value range is 0 to
1000000.
^RA – Repeat Adjust

This command provides a means of adjusting repeat for the selected message.
^RA value
Change the number of repeats for the selected message to the value requested via this command.
There should be a space following the command and the actual delay value. The value range is 0 to
1000000.
^PW – Print Width

This command provides a means of adjusting the print (pad) width for the selected message.
^PW value
Change the width of the selected message to the value requested via this command. There should
be a space following the command and the actual width value. The value range is 0 to 255.
^PH – Print Height

This command provides a means of adjusting the print height for the selected message.
^PH value

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Change the height of the selected message to the value requested via this command. There should
be a space following the command and the actual height value. The value range is 0 to 10.
^GPx – Gap
This command provides a means of adjusting the gap (width between characters) for the provided
field of the selected message. Therefore a value must follow the sub-command field as follows -
^GPx where x signifies the field number within the message.
^GPx value
Change the gap between viewable characters of the selected message. There should be a space
following the field specifier and the actual gap value. The value range is 0 to
^SBx – Set Boldness

This command provides a means of adjusting the boldness of characters for the selected message.
Therefore a value must follow the sub-command field as follows -^SBx where x signifies the field
number within the message.
^SBx value
Change the boldness of the characters for the selected message. There should be a space following
the field specifier and the actual bold value. The value range is 0 to 9.
ÊF – Echo Off

The command ÊF provides a means of turning off any echo provided by the BestCode device. This is
the default state at which the remote communications commence. With echo off, less text is
provided; therefore, results are more cryptic.
ÊN – Echo On
The ÊN command provides a means of turning on the echo of commands and data results provided
by the BestCode device. With echo on, more text is provided to better express results.
^MB – Mode Begin

This command provides a means of entering a one to one printing mode. This printing mode can
only be entered remotely. This mode will not be entered if the CIJ is not running.
^MB
Jet is not running. Jet is running.

Results with echo off: Results with echo off:
JNR 1-1
Results with echo on: Results with echo on:
Jet not Running OnetoOne Print
Mode

MANUAL – 40-0001-01
^MD – Message Data
The ^MD command provides a means of altering message data fields within the selected message.
The ^MD command must be followed by another command string “^TDx” to indicate a particular
field to be changed. This sub command ^TD is used to indicate which Text Data field is to be
changed. Therefore a value must follow the sub-command field as follows ^TDx where x signifies the
field number.
^MD Example 1
^MD^TD1 OCT
This example would insert the text of “OCT” into field 1 of the selected message. There must be no
space between the command and the field selector sub–command. More examples are provided.
^MD Example 2
^MD^TD1 Nov^TD2 28^TD3 2015
This example would insert Nov into field 1, 28 into field 2, and 2015 into field 3 of the selected
message.
^BDx – Barcode Data

This sub command ^BD is used to indicate which Barcode Data field is to be changed. Therefore a
value must follow the sub-command field as follows ^BDx where x signifies the field number within
the message.
^MD^BD1 12345678
This example would insert the barcode value representing “12345678” into the barcode field 1 of
the selected message. There must be no space between the command and the field selector sub–
command, but there should be a space following the field number and the actual text that is to be
changed. More examples are provided.
^ME – Mode End

This command provides a means of exiting a one to one printing mode. This command allows the
printing mode to be put back to a normal print mode.
^ME
Results with echo off: Results with echo on:

NORM Normal Print Mode

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^MS – Print Mode Status
This command allows a user to get the current status of the one to one printing mode.
^MS

1-1=OFF or 1-1=ON OnetoOne Mode=OFF or OnetoOne mode=ON
^NM t;s;o;p;x – New Message

This command provides a means of creating a new message on a BestCode device. Once the
message has been created on the device, the message may be selected for printing. There is a limit
of 255 messages that can be stored onto a device. With each new message you can add text or
barcode fields, and those commands (listed below) should be concatenated onto this new message
command. There is a limit of 1K character buffer input size.
^NM t;s;o;p;x
Coded Values (0-7) Correspond to the Selected Value Shown Below them
Code Function 0 1 2 3 4 5 6 7
t Template 1L5 1L7 1L9 1L12 1L16 1L19 1L25 1L32
Ultra-
s Speed Fast Faster Fastest
Fast
Tower
Mirror Normal Flip Mirror
o Rotation Normal Flip Mirror Mirror
Flip Tower Tower Tower
Flip
Print
p Normal Auto Repeat Reverse
Mode
x Message Name

MANUAL – 40-0001-01
ÂTn;x;y;s;data – Add Text Field
This sub command ÂT is used to add a Text Data field. The values following the sub-command field
are defined below. The following information is specifically focusing on the ÂB command string and
disregards any necessary previous string data.
ÂTn;x;y;s;data
0 1 2 3 4 5 6 7
s Font Size 5 7 9 12 16 19 25 32
n Field Number* Any valve 1 - 30
x X Position Any Value 0-100
y Y Position Any Value 0-32
Data Text to be contained in the new field
ÂBn;t;x;y;f;data – Add Barcode Field

This sub command ÂB is used to add a Barcode Data field. The values following the sub-command
field are defined below. The following information is specifically focusing on the ÂB command
string and disregards any necessary previous string data. If checksums are necessary for the barcode
field being added, that ‘data’ sting input for the barcode must contain the checksum value at the
end of the data string.
ÂBn;t;x;y;f;data
Code Function 0 1 2 3 4 5 6 7
Interleaved Code Code

t Barcode Type UPC-A UPC-E EAN-13 EAN-8
2 of 5 39 128
s Font Size 5 7 9 12 16 19 25 32
x X Position Any Value 0-100
y Y Position Any Value 0-32
Data Data to be added to the Barcode

MANUAL – 40-0001-01
NOTE: if checksum is required by barcode and manual is selected, the checksum digit must be
provided within the data string.
^SM – Select Message

The ^SM command provides a means of selecting a message on a BestCode device. Therefore, the
message must exist on the device before selection can be made.
^SM messageName
This would select the provided “messageName” for printing.
^SU – Status Update

The ^SU command provides a means of receiving status information from a BestCode device. The
resulting status provides modulation, charge, pressure, RPS, phase quality, errors on, high voltage
deflection on, and viscosity.
^SU

Mod[150] Chg[65] Prs[40] RPS[23.13] hQ[100%] STATUS: Modulation[150] Charge[65]
Err[1] HvD[1] Vis[ 0 Pressure[40] RPS[23.13] PhaseQual[100%]
AllowErrors[1] HVDeflection[1] Viscosity[ 0]
^DM – Delete Message

This command provides a means of deleting a message on a BestCode device. Therefore, the
message must exist on the device before deletion can be made.
^DM messageName
Delete the provided “messageName” from the device.
^TP – Temperature
Thie ^TP command provides a means of receiving temperature information from a BestCode device.
This will provide the temperature for three sensors – print head, ink, and electronics.
^TP

P[25.79] I[25.30] E[32.86]^SM Printhead[25.79°C] Ink[25.30°C]
Electric[32.86°C]
^TM – Run Time

Results: X.X hours
Where X.X is actual run hours within a tenth of an hour.

MANUAL – 40-0001-01
Quit – quit remote communications
The Quit command will stop the remote communications task and the only way to recover the
remote access is by restarting the device.
Command Usage
One to One print mode

The following data shows the procedure to enter One to One printing mode, alter data fields within
a selected message, and exit the mode when completed. The user MUST perform an ‘MD’ command
to initiate the One to One process of filling the print buffer.
^MB 1. Enter into One to One print mode

OnetoOne Print Mode
Command Successful!
^SM X 2. Select appropriate message
Command Successful!
^MD^TD2 X 3. Enter updated data into field
Command Successful!
MD ACK 4. Acknowledgement of print buffer update
PE ACK 5. Acknowledgement of photo eye
CP ACK 6. Acknowledgement of print completion
To continue the One to One print mode, continue with step 3 entering in updated field data. The
BestCode device will respond with steps 4 – 6 as the printing process continues.
Software Screenshot
The Series 8 BestCode family has the ability to
capture and display screenshots of the
interface via Ethernet connection. This has
been tested on local networks.
Insert BestCode USB stick into system

Inside the BestCode folder, there is a new folder
called “htdocs”, this is where the screen is
temporarily stored.
Configure your computer with a fixed IP

address: 192.168.1.100:

MANUAL – 40-0001-01
Ping your computer and the Series 8 system to ensure correct communications:
-Series 8 system is setup with an IP Address: 192.168.1.50
Type in the following in the web browser: 192.168.1.50/screencap.html

Press refresh on internet explorer as required – allows real-time monitoring of equipment status.

MANUAL – 40-0001-01

MANUAL – 40-0001-01
Maintenance
Section 8
Maintenance

MANUAL – 40-0001-01
Maintenance
This section discusses maintenance intervals, ink filter replacement, air filter
replacement, and printhead maintenance. This section is used as a guideline for performing
routine maintenance on the machine. Follow all safety instructions outlined in this section as
well as those listed in Section 1.3, Safety Information.
Maintenance Intervals
Maintenance Intervals
Frequency Maintenance Routine
Printhead Controller Connector Fluid Filters Air
(manual) Case inspection Filters
As Necessary * * *
2000 Operational 81,82, 88SOP
Hours
5000 Operational 86
Hours
8000 Operational 88,88S
Hours
Annual *
† Series 88 Base Model Only
Table 6.1.1: Maintenance Intervals
This chart only covers routine maintenance. All other maintenance required will be
instructed from the Series 8 10.4” Display. See Section 10, Service Routines, for manual
cleaning and maintenance instructions.

MANUAL – 40-0001-01
Maintenance
Ink Filters Replacement Instructions
When the Ink Filter has exceeded its life, (2000/5000/10000 hour depending on the filter
type) the above warning will appear. To resolve, replace the filter with a SmartFill™ Labeled
Ink Filter. This is a preventative maintenance measure to protect the pump from damage.
1. Unplug the power cord.

MANUAL – 40-0001-01
Maintenance
2. Loosen back door thumb screw

3. Remove back door
4. Remove the filter strap

MANUAL – 40-0001-01
Maintenance
5. Pull filter assembly out of the machine.
6. Firmly grasp filter.

7. Use 5/8” Open End Wrench
or Cresent Wrench to loosen
top nut.

MANUAL – 40-0001-01
Maintenance
8. Tip excess fluid into secondary container.
9. Firmly grasp filter.

10. Use 5/8” Open End Wrench or
Cresent Wrench to loosen
bottom nut.
11. Discard of filter and excess fluid in accordance with local procedure.

MANUAL – 40-0001-01
Maintenance
 Loosely thread nuts onto new filter.

 Ensure tubes are fully inserted
through the nuts.
 Tighten fitting finger tight.
 Use 5/8” Wrench or Crescent Wrench

and turn each nut 2 full turns (720°).
 Align the filter SmartFill™ Label with the SmartFill Symbol on the filter housing.
Align SmartFill™
Symbols
**Make sure flow directions also match**

MANUAL – 40-0001-01
Maintenance
 Fasten filter strap to secure

filter into filter housing.
 Plug in the Power cable and power on the system.

MANUAL – 40-0001-01
Maintenance
 Sign in with the Technician
Level Password
 Navigate to Service > Tools >

Technician
 Press the Tools button
 Press the Read Filter Tag

button
 Press the Status Button to

check that filter time is Reset.

MANUAL – 40-0001-01
Maintenance
 If the Filter time is not Reset, check the Alignment of the SmartFill™ label and retry.
Air Filter Replacement Instructions.

 Remove the power cable.

MANUAL – 40-0001-01
Maintenance
 Open Filter door.
 Pull and open filter clip.
 Pull forward on filter.

MANUAL – 40-0001-01
Maintenance
 Pull filter up and out.
 Dispose of used filter according to local

instructions.
 Push new filter down into filter housing.
 Push filter into housing.

MANUAL – 40-0001-01
Maintenance
 Rotate filter clip into place.
 Locate filter spring into locking hole.

 Close filter door to complete.
Printhead Maintenance
The printhead features two unique cleaning features for basic maintenance. These
two cleaning features are “Back Flush Nozzle” and “Clean Stop”. If either of these cleanings
are required, the user will be alerted through software to perform the cleaning action.
Back Flush Nozzle

Back flush cleaning is used to clean nozzle of dried ink. It is also used to remove debris from the
nozzle.
 Remove printhead cover

MANUAL – 40-0001-01
Maintenance
 Press the Clean Button
 Press the Back Flush
Nozzle button
 Rinse nozzle with solvent for 15

seconds.
 This cleaning should always be

performed before making the
decision to remove the nozzle.

MANUAL – 40-0001-01
Maintenance
Printhead Clean
The printhead clean is a function that jets solvent through the drop generator. This cleans the
nozzle, gutter, and valve manifold. This cleaning should only be used for extended shutdown, or to
assist in starting the jet after several day shutdowns.
 Press the Clean button
 Press the Printhead Clean button.
 The cleaning process does not require external assistance. The cleaning is
performed automatically once the button is pressed.

 This function is automatically programmed into the Flush Stop and Flush start
routines. It is not required to perform this daily.

MANUAL – 40-0001-01
Technical Operation and Troubleshooting
Section 9
Technical Operation and
Troubleshooting

MANUAL – 40-0001-01
Flow Paths
General Flow Paths

This diagram shows all the possible flow paths for the fluidic system.

MANUAL – 40-0001-01
Standard “Run” Operation

This basic drawing shows how ink is jetted and returned via vacuum. The basic viscometer
loop is included
Basic Flow Logic Loop: Active Valves: Printhead and Gutter.
1) Ink is pulled from the Ink Tank directly into the Pump
2) The Output of the Pump feeds into the Main Filter.

3) The Main filter output flows to the top of the Venturi.
4) The Green Line Feeds ink to through the Manifold and Out to the Printhead Valve.
5) The Printhead Valve Activates and Allows Flow of Ink into the Gutter
6) The White Line has Vacuum Applied to it while the Gutter Valve is Active.
7) The Black/White Striped line returns Ink to the Venturi, where Vacuum is generated.
8) The Purple Line is Split from the green line to Feed the Viscometer
9) Brown line is on the side opposite the Viscometer Restrictor, and returns Ink to the
ink Tank.

MANUAL – 40-0001-01
Viscosity Check During Run
This diagram shows how the viscosity check occurs in the machine.
Viscosity Check Flow Logic: Active Valves: Printhead, Gutter, Viscometer.
1) The Standard “Run” Operation is occurring.

2) The Viscometer Valve Activates and pushed the Metal Ball to the top of the
Viscometer.
3) After 30 Seconds, the Viscometer Valve De-Activates and the Ball begins to fall.
4) A timer is started to measure how long until the Ball passes the Inductive Sensor.
5) The Time is captured and converted to a value in cP.
6) The Target Viscosity is ALWAYS 4.5 cP.

MANUAL – 40-0001-01
Run with Solvent Add

After the viscosity check, the system will decide whether to add solvent.
Solvent Add Flow Logic: Active Valves: Printhead, Gutter, Solvent Add.
1) The Basic Flow Logic Loop is Occurring.
2) A Viscosity Check was just finished and determined that the Ink is thickening.
3) Solvent Add Valve activates for 1 second, then de-activates.
4) This Solvent Add Valve on/off cycle occurs 5 to 6 times in succession depending on
Ink thickness.

MANUAL – 40-0001-01
Flush Start / Stop and Printhead Clean Function Flow

This flush diagram is used to show how the stop and start cleaning process is achieved.
Flush Flow Logic: Active Valves: Gutter, Flush, Solvent Tank
1) Printhead Valve turns off.
2) The Bleed Valve opens to applyVacuum to the drop generator.

3) Once the jet has stopped, the Solvent Tank Valve opens
4) Solvent is pulled through the drop generator.
5) The Solvent Tank Valve and Bleed Valve de-activate.
6) The Flush Valve activates, and pushes clean solvent out of the drop generator into
the gutter to clean the gutter and gutter sensor.
7) The Flush Valve and Gutter Valve de-activate.

MANUAL – 40-0001-01
External Peripheral Schematics
Alarm
Beacon
Shaft Encoder
Parallel

MANUAL – 40-0001-01
Ethernet
Photocell
Auxiliary

MANUAL – 40-0001-01
Serial
USB

MANUAL – 40-0001-01
Collector Information

MANUAL – 40-0001-01
Wiring information
The peripheral devices for the Series 8 BestCode system use an array of connectors. For the
Shaft Encoder, Parallel, Photocell, and Auxiliary, Molex Microfit 3.0 ™ connectors and crimps are
used.
Name Crimp Housing Tool Cable

Alarm Molex 43030-0008 Molex 43025-0600 Molex 63819-0000 22 AWG Suggested
Shaft Encoder Molex 43030-0008 Molex 43645-0400 Molex 63819-0000 22 AWG Suggested
Parallel* Molex 43030-0008 Molex 43025-1800 Molex 63819-0000 22 AWG Suggested
Ethernet XXX XXX XXX CAT5 Patch
Photocell Molex 43030-0008 Molex 43025-0400 Molex 63819-0000 22 AWG Suggested
Auxiliary Molex 43030-0008 Molex 43025-0400 Molex 63819-0000 22 AWG Suggested
Serial XXX XXX XXX DB9 Cable
USB XXX XXX XXX USB 2.0 or Higher
*Parallel cable kit is available. Kit interfaces with Series 8 Bulkhead wall to maintain IP Rating.
Notes:
1) Hand wiring and routing of foreign Peripherals may cause lapse in IP Rating.
a. To ensure IP Rating, use only BestCode supplied Peripherals.
Using the Molex Crimper

MANUAL – 40-0001-01
Wiring the Parallel Kit
Pin Position Function Pin Position Function

1 24V 10 MESSAGE SELECT 0
5 MESSAGE SELECT 7 14 GROUND
6 RELAY NO 15 RELAY COMMON
7 RELAY NC 16 GROUND
8 24V 17 PHOTOEYE NPN
9 PHOTOEYE PNP 18 GROUND

MANUAL – 40-0001-01
Instructions:
1) From back of bulkhead fitting, strip and solder 18 wires (22awg) of 300mm length (12”) into
the fitting.
a. Individually sleeve each solder joint for maximum protection
2) Strip and apply crimp to end of each wire.
3) Install crimps into the Molex Housing.
a. Mate crimps 1-1 from Bulkhead fitting to the Molex Housing.
4) Install the Cable assembly into the Series 8 System using the “Parallel” bulkhead knockout
on the side of the machine.
5) Repeat the process for the device side, matching device features to the corresponding pins.
a. Use the provided seal and grommet to ensure cable maintains IP 67 Rating.
To
Peripheral
De

MANUAL – 40-0001-01
Troubleshooting
Before attempting to troubleshoot any part of the Series 8 system, read and heed these warnings.
PERSONAL INJURY: ALWAYS WEAR RUBBER GLOVES AND SAFETY GLASSES WHEN HANDLING
INKS AND SOLVENTS.
PERSONAL INJURY: ALWAYS WEAR RUBBER GLOVES AND SAFETY GLASSES DURING FLUIDIC
MAINTENANCE.
PERSONAL INJURY: INKS AND SOLVENTS ARE POISONOUS, DO NOT INGEST.
PERSONAL INJURY: DO NOT USE SOLVENT TO WASH INK FROM SKIN. IF EXPOSED, GENTLY
RINSE AREA WITH SOAPY WATER. IF IRRITATION PERSISTS, SEEK MEDICAL ATTENTION.
EQUIPMENT DAMAGE: DO NOT ADD FLUIDS UNLESS INSTRUCTED BY INDICATORS.
EQUIPMENT DAMAGE: THE PRINTHEAD MUST BE DRY BEFORE STARTING PRINTER.
EQUIPMENT DAMAGE: THE PRINTHEAD SHOULD NEVER BE COMPLETELY SUBMERGED IN

SOLVENT.
EQUIPMENT DAMAGE: DO NOT ATTEMPT TO USE MULTIMETER TO TAKE MEASUREMENTS

ON ANY COMPONENT WHILE THE MACHINE IS POWERED ON.
EQUIPMENT DAMAGE: DO NOT USE MULTIMETER TO ATTEMPT TO MEASURE THE CHARGE

VOLTAGE AT THE PRINTHEAD. THIS WILL PERMANENTLY DAMAGE THE MAIN CPU BOARD
CHARGE CIRCUIT.
FIRE HAZARD: INKS AND SOLVENTS ARE HIGHLY FLAMMABLE. NO SMOKING OR OPEN
FLAMES NEAR PRINTER OR FLUID STORAGE.
ELECTRICAL SHOCK: DISCONNECT MAIN POWER CABLE PRIOR TO SERVICING MACHINE.
ELECTRICAL SHOCK: NEVER RUN MACHINE WHILE ELECTRONICS COMPARTMENT DOOR IS

OPEN.
ELECTRICAL SHOCK: DO NOT REMOVE MAIN POWER CABLE WHILE THE MACHINE IS
RUNNING.

MANUAL – 40-0001-01
Software
Firmware
List of issues during Firmware Loading
J-link Error (IP/TCP Error)

Issue: J-link tool does not recognize a USB driver.
Symptoms: J-Link LED does not respond when plugged into USB on PC.
J-link pop-up requesting IP/TCP Load.
Solution: Reinstall C8 Setup File from BestCode USB
Solution: Manually download and install J-link driver:
http://www.segger.com/jlink-software.html?step=1&file=JLink_490e
Solution: J-link connection must be reset, unplug USB and plug back in.
Solution: J-link USB cable is damaged.
Solution: J-link tool is damaged.
Message not supported

Issue: After firmware
update, messages are
no longer supported.
Symptoms: Error on boot up.

Error when restoring
messages.
Solution: Firmware load

procedure was not
properly followed.
Install BestCode USB.
Sign In with the
Technician Level
Password, go to
Service > Tools > Technician > Messages > Messages > Press “OK”. Only messages
present on the machine before the firmware update may be converted to new
format.
Solution: Message prior to V01.02.31 must follow new firmware update procedure outlined in
the Best_Tools folder on the bestcode USB.

MANUAL – 40-0001-01
Solution: Messages prior to V01.02.16 cannot be used on a machine after V01.02.31. They
must be recreated.
Messages deleted after Firmware Update

Issue: After firmware update, messages are no longer present.
Symptoms: Messages may appear to be erased from the system.
Solution: Firmware load procedure was not properly followed. Install BestCode USB. Sign In
with the Technician Level Password”, go to Service > Tools > Technician > Messages
> Messages > Press “OK”. Messages present on the machine before the Firmware
update will be restored.
Solution: Message prior to V01.02.16 must follow new firmware update procedure outlined in
the Best_Tools folder on the bestcode USB.
Notes: If the battery was removed during the Firmware load, the messages have been
permanently lost.
Bad Script or Charge Tables

Issue: After firmware update, printer has wrong Script or Charge Tables
Symptoms: Warning on Boot Up
Printer will not run
Warnings Present:
 Charge memory file is corrupt.

 Charge memory file version unsupported.
 Script file is corrupt.
 Script file version unsupported.
Solutions: Firmware load procedure was not properly followed. Wrong files are on USB used to
Load firmware update. Use correct Firmware files on USB and repeat firmware
install.
Solution: Install USB with correct firmware files into USB on BestCode machine.
Go to Service > Tools > Restore > Restore > System > Press “OK”.
Restart printer when complete.

MANUAL – 40-0001-01
Firmware Fault

update, the machine
will not fully boot
Symptoms: Firmware Fault

appears on screen.
Solution: Incorrect version of

Firmware was loaded
onto the device.
Download the most
recent firmware and
load it using the J-Link
tool.
FPGA Fault
Issue: Machine will not boot
or the jet will not run
Symptoms: Firmware Fault

appears on screen.

Firmware was loaded
onto the device.
Download the most
recent firmware and
tool.
Solution: Data has been

corrupted on the device. Re-install the latest firmware with the J-Link tool.

MANUAL – 40-0001-01
Software Version Fault
update, the machine
will not fully boot
Symptoms: Software Version

fault appears on
screen.

Firmware was loaded
onto the device.
Download the most
recent firmware and
tool.
Memory Fault
Causes: USB was plugged in

before the device has
booted.
USB stick is damaged,

data on the stick is
not correctly
configured.

MANUAL – 40-0001-01
Update Messages
Causes: A recent software

update has added
new features to
messages that has
made previous
messages obsolete.
You may have the
option to update the
messages
automatically,
depending on the
version.
Symptoms: Failure to follow this recommendation will lead to corruption of the board and may
cause performance issues and lockups.
Memory Fault: Internal Memory Error

MANUAL – 40-0001-01
Symptoms: Error Appears, Internal Memory Error
Solution: Open the BestCode USB and go into the HTdocs folder.
Copy the norFormat.bin file from this directory into the “BestCode” folder.
Install the USB to the machine. Perform J-Link using the J-Link tool
*Do Not Copy both NorFormat.bin and NorDelete.bin into the BestCode folder at
the same time.
Solution 2: If the NorFormat process does not work, perform the NorDelete process.
Open the BestCode USB and go into the HTdocs folder.

Copy the norDelete.bin file from this directory into the “BestCode” folder.

MANUAL – 40-0001-01
Install the USB to the machine. Perform J-Link using the J-Link tool
the same time.
This is a more extreme option and takes a bit longer to complete compared to
option 1.
*Both NorFormat.bin and NorDelete.bin will be

deleted from the “BestCode” folder after performing
their tasks to prevent accidental NOR clears.
Backup & Restore
Print memory could not be loaded

Issue: During Restore, files cannot be loaded to the Series 8 system.
Symptoms: Amber Fault Warning
Amber light on Alarm Beacon
Appears after trying to restore files from USB
Solution: USB is not properly formatted. See Section 7 for USB formatting and details.
Solution: Charge Memory files are corrupt. Download Firmware from distributor portal and
repeat firmware load process.
Print memory could not be saved

Issue: During Backup, files cannot be saved to the Series 8 system.
Appears after trying to backup files to USB
Solution: Charge Memory files are corrupt. Download Firmware from distributor portal and
repeat firmware load process.

MANUAL – 40-0001-01
Script file version unsupported
Issue: During Restore, Unsupported File Warning
Charge files will not load.
Solution: Charge Memory files are the incorrect version. Verify current Firmware version and
USB files match.
Solution: Update Firmware and USB stick to newest version available on Distributor Portal.
Unable to detect the memory device
Issue: During Backup or Restore, USB cannot be detected.
Solution: Ensure USB is installed into the device.
Solution: Check USB cable to Bulkhead Cable if present.
Solution: Unplug and Reinstall USB stick.
Solution: USB is damaged or full.
Boot Up Issues
The Device will not load past the “Loading – Please Wait” screen
Cause: NOR memory has become corrupted and must be reformatted.

MANUAL – 40-0001-01
Solution: Open the BestCode USB and go into the HTdocs folder.
Copy the norFormat.bin file from this directory into the “BestCode” folder.
Install the USB to the machine
Perform J-Link using the J-Link tool
the same time.
Solution 2: If the NorFormat process does not work, perform the NorDelete process.
Open the BestCode USB and go into the HTdocs folder.

Copy the norDelete.bin file from this directory into the “BestCode” folder.

MANUAL – 40-0001-01
Install the USB to the machine
Perform J-Link using the J-Link tool
the same time.
This is a more extreme option and takes a bit longer to complete compared to
option 1.
Both NorFormat.bin and NorDelete.bin will be deleted

from the “BestCode” folder after performing their
tasks to prevent accidental NOR clears.
Controller
Power issues
Low input voltage detected.

Issue: Low input voltage
warning is present.
Amber light on Alarm

Beacon
Solution: Power supplied to the

machine is less than
90V. Seek out better
power source or use power conditioning to provide more stable power to the unit.

MANUAL – 40-0001-01
Power Failure
Issue: Machine has
powered off without
being instructed so.
Solution: Ensure locking clip for

power cable is
installed into the side
of the machine.
Proper sealing of this
cable is critical to
providing accurate
power to the unit.
Solution: Check power cable

for damages or potential causes of power loss.
Solution: Power loss due to brown out, or loss of power to power source.
Solution: Swap power supply to determine if hardware is damaged or faulty.
The Machine will Not Power On

Issue: Pressing the Touch Screen will not power on the Machine.
Solution: Press and Hold finger on the touch screen for 5 seconds. If the board will power on
from holding for a longer time, replace main CPU board.
Solution: Try touching other areas of the Touch Screen to power it on. If some areas will
power on the Unit and Others will not, replace the touch screen assembly.
Solution: Use a flat metal tool to contact the Pins on JP6 together. This by-passes the touch
screen and touch circuitry on the main board to ensure the Power Supply is working.
If you are able to navigate the user interface with the touch screen, replace the
Main Board. If you are un-able to navigate the user interface, replace the touch
screen.
Solution: Use a flat metal tool to contact the Pins on JP6 together. If the main board does not
power on, the issue is located between the Main CPU board and the wall connection
for power. Inspect cables for loose connections or damage. If no damage is found to
cables, try a different socket. If this is not the issue, replace the Power Supply.
Solution: Ensure that JP3 jumper is present. If the jumper has been removed, the system will
not power on. If the jumper has been removed, only 2 pins will be seen.

MANUAL – 40-0001-01
The Machine Powers on with only a White Screen
WARNING: DO NOT J-LINK THE DEVICE IF YOU ARE SEEING THIS SCREEN. J-LINK LOADING WILL NOT
CORRECT THE BATTERY ISSUE AND WILL RESULT IN MESSAGES BEING LOST.
How to Remove and Test the Battery
 Power down and unplug the machine
ELECTRICAL SHOCK: NEVER RUN MACHINE WHILE ELECTRONICS COMPARTMENT DOOR IS

OPEN.
 Open Front Door

 Locate the battery

MANUAL – 40-0001-01
 Remove
the
battery
 Test
Battery Voltage
NOTE:
Batteries with voltage measuring under 2.8V will cause the
White Screen to Appear.
Test replacement battery to ensure it measures 3.0V - 3.3V

before replacement.
Purchasing a Replacement Battery

 The correct battery is CR2032.
 There are many suppliers for the CR2032 battery.

o The BestCode Unit is supplied with a Panasonic, but any other supplier is adequate.
o CR2032 batteries can be purchased at most convenience stores, drug stores, electronic stores, etc. It
is a very common electronics battery.
o BestCode offers the CR2032 battery for sale with part number : 13-9004-01

MANUAL – 40-0001-01
Installing the New Battery
 Test replacement battery to ensure it measures 3.0V - 3.3V before replacement.

 Power down and unplug the machine
ELECTRICAL SHOCK: NEVER RUN

MACHINE WHILE
ELECTRONICS COMPARTMENT
DOOR IS OPEN.
 Install battery with Positive side

making contact with the positive
contacts
WARNING: DO NOT ATTEMPT TO SHORT THE

BATTERY TO GROUND. THIS WILL RAPIDLY
DISCHARGE THE BATTERY AND RENDER IT
USELESS.

MANUAL – 40-0001-01
Setting the Date and Time
 Use the Date / Time screen to set the Date and Time.
Date and date

formatting
Electrical Components
System Temperature High

Issue: System Temperature High warning is displayed.
Symptoms: System Temperature High warning is displayed.
Machine will power down or not allow running of the Jet.
Solution: Ambient temperature exceeds maximum operating temperature. Move machine to

cooler location.
Solution: Air filter is expired and not allowing air flow through the machine. Replace air filter.
Solution: Main Board temperature sensor is faulty, replace board to confirm.

MANUAL – 40-0001-01
System Temperature Low
Issue: System Temperature Low warning is displayed.
Symptoms: System Temperature Low warning is displayed.
Machine will power down or not allow running of the Jet.
Solution: Ambient temperature is below minimum operating temperature. Move machine to

warmer location.
Solution: Main Board temperature sensor is faulty, replace board to confirm.
Power Supply Fault
Issue: Incomplete or no print.

Power Supply Fault
Solution: Replace the Power

Supply.
300V supply circuit is damaged. This

happens by shorting the charge
electrode to ground or to the phase.
Can be caused by improperly installing

the cover while printing or trying to
Ohm test the charge electrode.
Fan Fault
Issue: Machine Powers off

after entering the GUI.
Solution: Check Fan connector

and wires for damage.
Replace/repair crimp if
necessary.

MANUAL – 40-0001-01
SmartFill™ Problems
SmartFill Result = 3 when adding fluids
Issue: Unknown SmartFill ID

pop-up appears when
trying to add new
bottle of fluid.
Solution: Make sure the Fill

cup coax cables are
connected to the CPU
board.
Solution: Make sure a

SmartFill™ Label is
present on the bottle
of fluid.
Solution: The bottle is not oriented correctly to the SmartFill™ reader. Rotate the bottle and
try again.
SmartFill Result = 3 Randomly

pop-up appears
randomly.
Solution: The Tank level detect

has recently changed
condition to LOW and
the Solvent Low
button was Pressed
without Fluid being
added.
Solution: Fluids were added

that did not have a
SmartFill™ label or
the label was not read from the bottle. A SmartFill™ label must be read in to
permanently resolve.

MANUAL – 40-0001-01
SmartFill Result = 10 When Adding fluids or New Filter

pop-up appears when
adding fluid or when
replacing Main Ink
Filter.
Solution: The SmartFill™ label

was detected, but
there is no data on
the label. This means
the fluid has already
been used or read.
SmartFill Result = 11 When Adding fluids or New Filter

pop-up appears when
adding fluid or when
replacing Main Ink
Filter.
Solution: The SmartFill™ label

installed is the wrong
type (trying to add
Makeup to Ink Tank
or opposite).
Solution: SmartFill™ Labels for fluids cannot be used to reset the Filter life.

MANUAL – 40-0001-01
How to test the SmartFill™ Label readers
1. Login with the Technician Level Password
2. From the Home page, nagivate to Service>Tools>Technician>Tools
3. Insert a bottle of Ink into the Ink Fill cup. Do not remove the cap.
a. Optionally, an active SmartFill™ label may be used and inserted into the Ink Fill cup
by hand.
4. Press the “Test Read Ink Tag” button.
5. The system will confirm that the SmartFill™ Label was read.
**This does not consume the Label**
6. Repeat test for Makeup, and Filter using correct Makeup and Filter SmartFill labels.

MANUAL – 40-0001-01
Fluidic
Pump and Transducer
RPS Fault
Issue: Printer stops start
routine immediately
after pump turns on.
Symptoms: RPS Fault Occurs.
Jet will not start.
Ink may flows out of

Gutter. (Diagnosed
using Service >
Fluidic)
Poor or little vacuum

(Diagnosed using
Service > Fluidic)
Solution: Clogged bottom Venturi restrictor. Must be cleaned.
Solution: Clogged top Venturi restrictor. Must be cleaned.
High RPS Fault

Issue: Printer stops soon
after Starting.
Symptoms: Fault Occurs.
Jet may start.
Pump RPS > 30.
Solution: Missing viscometer

restrictor.
Solution: If no vacuum, missing

Top Venturi restrictor
Solution: If venturi is operating and viscometer restrictor is present, pump has reached it’s
end of life and must be replaced.

MANUAL – 40-0001-01
No Pressure Detected from the Pump.
Issue: Printer stops soon after Starting.
Solution: Delete old

messages.
Solution: Ensure pressure

transducer is
connected.
Solution: Ensure pump cable

is connected.

MANUAL – 40-0001-01
Viscosity
No Viscosity Reading
Issue: Viscosity is not

reported/correctly
reported to Software.
Symptoms: 0.0 Viscosity readings

after 30 minutes of
operation.
Ink sample measure
at operating
temperature is much
thicker than Bestcode
viscometer reading.
Viscosity status shows “failed”
Solution: Clogged bottom viscometer restrictor.
Solution: Debris in viscometer capillary. Rinse with solvent.
Solution: Damaged viscometer valve wires. Bad crimps.
Solution: Leaking viscometer valve. If Ink flows out of the Gray tube into the ink tank while
the viscometer is no performing a check, then ink is leaking through the valve.
Solution: Check main Board LED 13. The LED should illuminate when the ball passes the
sensor on viscometer. If sensor light illuminates, but LED on board does not, check
viscometer housing crimps. Re-crimp wires and install into new housing.

MANUAL – 40-0001-01
The ink's viscosity is too high.
Issue: Viscosity is reported

as above 6 cP.
Symptoms: Machine is printing.
Difficult to achieve
proper drop breakup.
Poor Vacuum.
Solution: Test Makeup Add

valve. Ensure that
solvent is able to be travel from the Solvent Tank to the Ink tank. Use Fluidic test,
run pump to 20 PSI, open Printhead Valve and Gutter Valve. Lift the Orange tube
from the solvent tank. Open the Makeup Add valve. If the solvent add lines are
properly working, air will begin to fill the orange line (since we are no longer
drawing solvent). Return the Orange line to the solvent tank. Run machine for a few
hours to allow ink to return to Target Viscosity.
Solution: Environment is much colder than previous environment. Run machine to allow ink
to return to Target Viscosity.
Solution: Machine has been turned off for a period of time longer than 1 week (@ 77F avg).
Run machine to allow ink to return to Target Viscosity.
The ink's viscosity is too low.
Issue: Viscosity is reported

as below 3 cP.
Difficult to achieve
proper drop breakup.
Poor Vacuum.
Amber Warning Light

MANUAL – 40-0001-01
Solution: Environment is much warmer than previous environment. Run machine to allow ink
to return to Target Viscosity. Remove some ink and replace with equal volume of ink
at correct viscosity.
Solution: Too many cleanings have been performed on the machine.
 Excessive head rinsing

 Excessive Back Flushing
 Excessive Flush Start / Stop or Printhead Clean
Solution: Makeup Add valve has been manually opened or is stuck open.
Erratic Viscosity Readings (Below 3.0cP sometimes reads 4-8cP)

Issue: Viscosity reading is not accurate, and reads numbers that can be very different from
the previous reading.
Amber Warning Light
Viscosity reading on Service page is erratic
Air may be visibly present in the viscometer.
Foaming is present in the ink tank.
Solution: Too many cleanings have been performed on the machine.
 Excessive head rinsing

 Excessive Back Flushing
 Excessive Flush Start / Stop or Printhead Clean
Solution: The Ink or Solvent is not a BestCode approved fluid or the wrong fluid has been
added to the system. Incorrect fluids can cause Excessive foaming which will lead to
air in the Viscometer. This causes the ball to fall slower, which gives higher Viscosity
readings. The system will add solvent to correct the ink thickness and make problem
worse and worse until the system is cleaned and correct fluids are added.
Solution: Leaking viscometer valve. If Ink flows out of the Gray tube into the ink tank while
the viscometer is not performing a check, then ink is leaking through the valve.

MANUAL – 40-0001-01

MANUAL – 40-0001-01
Ink and Solvent Levels and Temperature
Ink Low
Issue: Ink Low Warning is
Present
Symptoms: Ink Tank is visibly low.
Solution: Check software for

proper ink add
symbol on Home
page. Add 1 bottle of
Ink.
Ink High
Issue: Ink High Warning is Present
Symptoms: Machine will not print or power’s down after powering up.
Ink High Warning is Present
Ink Tank is OVER filled
Ink Tank is Empty
Ink Tank is visibly at an OK level
Solution: Remove Back Cover and Examine Ink Tank.
 If Ink Tank is OVER filled, remove Ink from the tank until the Status returns to
Full.
 If Ink Tank is Empty, Add 1 bottle of Ink. Re-prime the Ink Pump in the fluidic
test screen.
 If the Ink Tank is visibly at an OK level, check the Ink Level Switch for damaged
wires, and ensure the Switch is plugged into the Control Board.

MANUAL – 40-0001-01
Solvent Low
Issue: Solvent Low Warning
is Present
Symptoms: Solvent Tank is visibly

low.
Solution: Check software for

proper Solvent add
symbol on Home
page. Add 1 to 2
bottles of Solvent.
Solvent High
Issue: Solvent High Warning is Present
Symptoms: Machine will not print or power’s down after powering up.
Solvent High Warning is Present
Solvent Tank is OVER filled
Solvent Tank is Empty
Solvent Tank is visibly at an OK level
Solution: Remove Back Cover and Examine Solvent Tank.
 If Sovent Tank is OVER filled, remove Solvent from the tank until the Status
returns to Full.
 If Solvent Tank is Empty, Add 1-2 bottles of Solvent. Re-prime the Solvent Line in
the fluidic test screen.
 If the Solvent Tank is visibly at an OK level, check the Solvent Level Switch for
damaged wires, and ensure the Switch is plugged into the Control Board.

MANUAL – 40-0001-01
Solvent Out
Cause: Solvent tank has

dried out due to not
adding and running
the machine.
Solvent Level detect

is damaged and
needs to be replaced.
Solution: Visually inspect level

to determine if issue
is sensor related.
If tank is empty, add 2
bottles of appropriate Makeup. Follow commissioning steps to re-prime the solvent
line to ensure Flush Start/Stop is operating correctly.
Unable to Determine Fluid Levels

Issue: Unable to Determine Fluid Levels warning appears
Symptoms: Machine will not run.
Solution: Remove Back Cover and Examine Fluid Tanks.
 If the Solvent Tank is visibly at an OK level, check the Solvent Level Switch for
damaged wires, and ensure the Switch is plugged into the Control Board.
 If the Ink Tank is visibly at an OK level, check the Ink Level Switch for damaged
wires, and ensure the Switch is plugged into the Control Board.
Solution: Replace Ink and Solvent level detects to determine cause of failed readings.
Ink Temperature High

Issue: Jet stops or machine powers down due to warning.
Symptoms: Red error that Ink Temperature is high.
Solution: Ambient temperature exceeds maximum operating temperature. Move machine to

cooler location.
Solution: Damaged Ink level detect cable. Measure ink temperature and compare to
temperature reported in software. Large variations indicate a faulty level detect or
connector.

MANUAL – 40-0001-01
Ink Temperature Low
Issue: Jet stops or machine powers down due to warning.
Symptoms: Red error that Ink Temperature is Low.
Solution: Ambient temperature is below minimum operating temperature. Move machine to

warmer location.
Solution: Damaged Ink level detect cable. Measure ink temperature and compare to
temperature reported in software. Large variations indicate a faulty level detect or
connector.
Solution: Run pump in Fluidic Test screen with Errors Disabled for 30 minutes. This will warm
the ink. Login with the Technician Level Password and enable Ink Tank Stir in the
Technician Screen (Service>Tools>Technician). Do not power down machine. Ink Stir
will keep Ink warm and prevent errors.
Tanks and Fills
Solvent Tank has Ink inside

Issue: Solvent in the Solvent Tank is Dark or same color as Ink Tank.
Symptoms: Ink may have high viscosity

Problems with BackFlush
Problems with Clean Starts and Stops
No Solvent Jet from Printhead Clean
Solution: The solvent in the tank should be clear. It will turn black if the solvent line does not
prime correctly. Remove the solvent tank and pull out the solvent tube from the
tank. Submerge the end of the solvent pipe in a bottle/beaker of clean solvent.
Using “FLUIDIC TEST” turn the pump on to approximately 20psi. Turn on Solvent
Tank Valve and Bleed Valve. You should see the clean solvent being pulled into the
tube and solvent filter. IMPORTANT – THERE SHOULD BE NO AIR. If air is visible
check for bad tube connections. If solvent does not prime check that Solvent Tank
Valve and Bleed Valve are operating correctly, remove and clean if necessary.
Bottles will not empty into the Tanks

Issue: Solvent bottle does not empty while adding to Tank and causes solvent to flow over
the top of the machine.
Ink bottle does not empty while adding to Tank and causes ink to flow over the top
of the machine.
Solution: Foil is stuck in the puncture, remove the foil.
Solution: Holes in the Puncture are too small, and need to be modified.

MANUAL – 40-0001-01
 Remove the cap.
 Grasp puncture with pliers.

o Grab part on the metal.
 Twist puncture and lift

from the fill.

MANUAL – 40-0001-01
 Drill holes open to 5mm (3/16 inch).
 Repeat for all 7 holes.
 Apply solvent to puncture O-ring.

 Grasp puncture with pliers.
o Grab part on the metal.
 Press and twist back into fill

MANUAL – 40-0001-01
Printhead
Print Quality
Print quality goes from Good to Bad during the day

Issue: Print is sometimes bad, sometimes it is good.
Solution: Perform modulation calibration in the working environment. Perform the

Modulation calibration while the unit is running at the average temperature in the
environment.
Solution: Test Ink viscosity, ensure it matches reading in software. Do not cool the ink,
measure at operating temperature. If there is discrepancy between actual viscosity
and software reading, replace the entire viscometer with a spare. If the issue is still
present, there is a problem with the ink causing air to trap in the viscometer and
causing poor readings. It is likely that the incorrect solvent is being used, or that
counterfeit fluids are installed.
Print is missing bottom line of drops

Solution: Increase the height of the print using the “Height” feature in the adjust screen.
Solution: Add Gutter Shift to position the print further out of the gutter.
Solution: Perform backflush, then align the nozzle to the required 80/20% horizontal position.
Solution: Increase the Charge %, then perform modulation calibration.
Top line of Print is scattered through the message
Solution: Decrease the Charge %, and then perform modulation calibration
Modulation Issues
Cannot find a 100V Modulation Window

Issue: Print is good during part of the Day, and bad in others
Drop Breakup is poor
Can only produce drops at High Modulation values and modulation window is small.

MANUAL – 40-0001-01
Solution: Microscopic debris is in the drop generator causing disruption of the Jet. Perform a
backflush and restart the jet.
Solution: Replace nozzle and perform modulation calibration.
Solution: Check for clogs of pigment in the Printhead Valve, Printhead Valve manifold, Drop
Generator, and dampener. Best way to test for clogs causing flow problems is to
remove the drop generator nozzle and start the jet. Ink should easily pour out of the
open drop generator. If it does not, there is a flow problem obstructing the ink and
causing drop flight speed problems.
Solution: Check cabinet filter door for calibration pressure and charge %. Set to these values
in the service screen and perform modulation calibration.
Jet
Jet is moving/flickering inside the gutter

Issue: Print is distorted
Jet is moving and not constantly in the gutter
Solution: Microscopic debris is in the drop generator causing disruption of the Jet. Perform a
backflush and restart the jet.
Solution: Partial clog inside the nozzle and is moving as the jet flows past it. Perform backflush
or use Ultra-Sonic cleaner to remove debris. As a last resort, replace the nozzle.
Solution: If ink stream is jumping in and out of position or is erratically flickering, there is a
high chance that the nozzle is partially clogged. Perform a backflush of the nozzle.
Solution: Perform a printhead clean and examine the jet during the solvent jet function. If
solvent jets clean, issue is in ink (Viscosity is very thin or thick, or incorrect solvent /
ink has been added to the machine and is causing excess foaming in the ink tank.
Test ink to confirm.
Messy Starts/Stops even after Back-Flushing (Many Times)

Issue: Jet comes out of gutter and sprays out of the head
Symptoms: HV Trip Fault on Start-Up
Symptoms: Head is messy after stopping
Solution: Larger Debris has become lodged in the Drop Generator. Remove the nozzle and
purge ink out using Fluidic Screen functions.
Solution: Nozzle clog cannot be cleared with a Back-Flush. Replace the nozzle or wash with
Super Nozzle Cleaner in the Ultra-Sonic Bath.

MANUAL – 40-0001-01
Jet Continues after pump stops
Issue: Jet comes out of
gutter and sprays out
of the head
Issue: Jet continues to jet

after pump has
stopped and makes
mess in the head.
Symptoms: Jet has bad stops and

flush stops
Symptoms: Gutter Fault on Start
Symptoms: Head is messy after

stopping
Solution: Test the solenoid valve in the printhead. If the valve is stuck open, starts and stops
will be messy.
Solution: Test the Bleed Valve in the Fluidic Compartment. If this valve is stuck closed, stops
and starts will be messy. This is caused since pressure cannot be relieved from the
drop generator during stops.
Solution: Login using the Technician Level Password and navigate to the Technician Screen.
Ensure Fluid Config setting is set to “2”, not “1”.
Gutter
Stream out of Gutter during Starts/Stops

Issue: Ink Stream is Out of the gutter During Clean Starts
Symptoms: Ink does not jet into the gutter.
Ink stream starts in gutter but sometimes exits the gutter.
Solution: Unplug High Voltage Cable from PSU. If Jet becomes stable, replace PSU.
Solution: Check the Solvent Lines, (Orange, Blue, Yellow). If there is air in the Blue or Orange
line, it is possible that the line is not correctly primed or that a leak is present at any
of the unions for the Solvent Pickup. See Commissioning Guide to correctly prime
the Solvent Line. If Ink is in the Solvent Tank, see Tank Troubleshooting.

MANUAL – 40-0001-01
Poor Gutter Suction
Issue: Gutter does not work
Symptoms: Poor or No suction on the gutter.
Other vacuum features function normally (Backflush, Solvent Add).
Solution: Run pump in fluidic test and turn on gutter valve. Remove bottom pipe from venturi
and spray solvent into port, if suction move on if not replace venturi.
Solution: Remove gutter valve, spray solvent into bottom port, if no suction check vacuum
connection on left side of manifold and/or make sure vacuum hole in manifold is
clear. (Normally it’s the tube not connected correctly). If suction at this point use a
wash bottle to check valve is opening and check tube/gutter for clogs. Spray solvent
thru length of tube until it comes out of gutter.
Solution: If suction is low make sure there is no air leak, missing valve seals or any poor tube
connection will cause this.
Buildup of Ink on the Gutter

Issue: Ink is building up after very few prints
Symptoms: Print is missing top or bottom line

Ink drips from the head.
Ink drips from the gutter onto the High Voltage Plates and causes Trip.
Solution: Increase the height of the message to move the drops further away from the gutter.
This will prevent gutter clipping.
Solution: Check Jet Alignment. If jet is too far into the gutter, gutter clipping will occur and
cause ink buildup. Correct alignment.
Solution: Use Gutter Shift in the Technician Screen to push the drops further out of the gutter
while maintaining a similar print height.
Jet hits gutter but pours out

Solution: Gutter Valve (Valve 4) is clogged, remove and clean valve.
Solution: Gutter is clogged, clean with solvent.

MANUAL – 40-0001-01
Stream out of Gutter during Solvent Add
Issue: Ink Stream is Out of the gutter During Clean Starts
Symptoms: Ink does not jet into the gutter.
Ink stream starts in gutter but sometimes exits the gutter when Valves 3 and 6 click.
Solution: Check the Solvent Lines, (Orange, Blue, Yellow). If there is air in the Blue or Orange
line, it is possible that the line is not correctly primed or that a leak is present at any
of the unions for the Solvent Pickup. See Commissioning Guide to correctly prime
the Solvent Line. If the Solvent in the Tank is black, see Tank Troubleshooting.
Buildup of Ink on the Gutter

Issue: Ink is building up after thousands of prints
Symptoms: Print is missing top or bottom line

Ink drips from the head.
Ink drips from the gutter onto the High Voltage Plates and causes Trip.
Solution: Increase the height of the message to move the drops further away from the gutter.
This will prevent gutter clipping.
Solution: Check Jet Alignment. If jet is too far into the gutter, gutter clipping will occur and
cause ink buildup. Correct alignment.
Solution: Use Gutter Shift in the Technician Screen to push the drops further out of the gutter
while maintaining a similar print height.
Solution: Examine drop breakup. Satellite drops can cause buildup on the gutter. As the ink
builds up on the gutter, it will block the bottom drop of print from exiting the head.
Solution: Static electricity on the product is forcing some ink drops back into the printhead.
Drops will be attracted to the Gutter and High Voltage Plates and will build up.

MANUAL – 40-0001-01
How to Troubleshoot Gutter Detect Problems
If ink is not entering gutter with jet on – there is no connection between gutter and gutter detect
unit. If the gutter detect does not fault when this occurs, then perform the following.
 Disconnect Gutter Detect from J31 “Gutter Black” on CPU board – this will cause fault.
o This will prove the CPU and electronics / software is working correctly.
o This will also prove that the Gutter Detect is shorted to ground (never able to offer a
fault condition).
 If the gutter tube is connected to ground (the base assembly of the printhead is ground) –
this will exhibit the fault. This can be caused by damaged heat shrink.
Additionally, the coax cable connecting the gutter tube to the CPU board has both signal and
ground line. Notice pictures below – if the coax shield is connected to the tube this will
exhibit the fault. This can be caused by damaged heat shrink on coax shield or no heat
shrink on coax shield:
CUT AWAY THIS SLEEVE TO LOCATE GUTTER SENSOR
 Correct – heat shrink on gutter tube

coax.

MANUAL – 40-0001-01
Incorrect – heat shrink not

present on gutter tube coax.
Potential to short signal/gutter
tube to ground.
Use Ohm Meter to Test Cable.

MANUAL – 40-0001-01
0 Ohms
>0 Ohms
IF THE GROUND SHIELDING IS TOUCHING THE TUBE, THE SENSOR WILL NOT WORK.

MANUAL – 40-0001-01
Phase
Phase Value Maximum / Minimum

Issue: Red Error every few
minutes with Phase Error.
Symptoms: Poor Print Quality
Phase Quality is at 0%
and never increases.
Phase Quality may

increase but only to 50-
70%
Solution: Clean the Phase Detector.

Ink present will cause poor phase quality and cause Phase Value to increase and
decrease without end.
Solution: Ensure the Charge Electrode is present, clean, and that the mounting screw is tightly
fastened.
Solution: Check ground connection of the tray to controller using digital multimeter Ohm
function. Check Yellow coax center conductor for shorts to ground.
Resistant over 3ohms or OL reading suggests bad grounding of the tray.
Check ground lug is tightly
connected on the back of the
printhead tray, also check ground
cable in the controller at primary
junction by power entry.
Solution: Check 14 pin Printhead Connector

on Controller Board for poor or
damaged crimps.
Test each crimp for shorts to
ground.
Solution: Use eye loupe to examine drop

breakup. If drop breakup is
extremely poor or if no breakup is
occurring, phase will always be 0%.
Check modulation connect in the
print head and connection to the
control board. If connection is good
and there are no shorts in the wire to ground, perform modulation calibration.

MANUAL – 40-0001-01
Solution: If modulation calibration does not correct the phase quality, replace nozzle. If nozzle
does not fix issue, replace entire drop generator.
High Voltage & Trip
High voltage trip is not connected

Issue: Jet will not complete
Startup or allow
printing.
Symptoms: Red error that High

Voltage Trip is not
connected.
Jet powers down
soon after starting.
Solution: Check Red Coax

connection in
printhead and on Control Board.
Check Red coax center conductor for shorts to ground.
Solution: Replace Red Coax cable in Umbilical and test startup for errors.
Solution: Center conductor on printhead tray should OL to ground and both HV plates.
If Red Coax center conductor is shorted to Ground or one of the high voltage plates,
replace printhead tray.
High Voltage Fault

Issue: Jet will not complete
startup or allow printing.
Symptoms: Red error that High

Voltage Trip during the
startup.
Jet powers down soon

after starting print.
Jet powers down after

extended run.
Solution: Clean the high voltage plates with cleaner and ensure high voltage plates, charge
electrode, and phase detector are dry and free of ink before starting the jet.

MANUAL – 40-0001-01
Solution: Check Red Coax connection in printhead and on Control Board.
Check Red coax center conductor for shorts to ground. Ensure cable is sealed in the
printhead and that no ink is present of the connectors.
Solution: Check ground connection of the tray to controller using digital multimeter Ohm
function. Resistant over 3ohms or OL reading suggests bad grounding of the tray.
Check ground lug is tightly connected on the back of the printhead tray, also check
ground cable in the controller at primary junction by power entry.
Solution: Check HV plates to ground. If either plate to ground measures 34Mohm, there is a
short to ground in the printhead umbilical. Inspect the HV wires in the back of the
printhead tray for damage and also check HV wires for damage at the controller
bulk head connection. Replace or repair damaged high voltage cable. If plate to
ground measures 0-2 ohms, there is a short in the printhead after the resistor and
the printhead must be replaced.
Solution: Center conductor on printhead tray should OL to ground and both HV plates.
If Red Coax center conductor is shorted to Ground or one of the high voltage plates,
replace printhead tray.
Printhead Temperature
Printhead Temperature High

Issue: Jet stops or machine
powers down due to
warning.
Solution: Ambient
temperature exceeds
maximum operating
temperature. Move
machine to cooler
location.
Solution: Printhead
Environment is too
hot, add positive
pressure air kit to
help remove heat from the printhead.

MANUAL – 40-0001-01
Printhead Temperature Low

Issue: Jet stops or machine
powers down due to
warning.
Solution: Ambient
temperature is below
minimum operating
temperature. Move
machine to warmer
location.
Solution: Printhead temperature sensor is damaged. Solder and repair. The sensor is located
on underside of printhead valve manifold. Wires should solder to Brown and Gray
leads from umbilical multicore cable.
Misc

MANUAL – 40-0001-01
Service Routines and Parts
Section 10

MANUAL – 40-0001-01
Warranty Information
The following table details replacement parts information with notes on typical service level. Also
details specific situations which void part warranty.
Parts suspected of being faulty should be mailed to BestCode for Warranty Evaluation.
Replacements will be provided after evaluation.
Print head items

Part Number Description Warranty Status
20-0016-01 Printhead, Assembly Series 10 year MTBF. Replacement instructions provided
8 Series 65 Nozzle with spare part shipment.
22-0029-01 Nozzle, Series 8 Series 65 10 year MTBF. Permanently clogged nozzles will be
replaced. No warranty for cleanable nozzles.
21-0002-01 Seal, Nozzle Plate Non-warranty. Replacement provided with New
Nozzle kit.
20-0008-01 Generator, Series 8 Series 10 year MTBF. Disassembling, Loosening,
Drop Assembly Tightening, or Removing resonator voids warranty.
20-0009-01 Printhead, Phase/Base 10 year MTBF. Replacement instructions provided
Assembly with spare part shipment.
22-0010-07 Gutter, Series 8 Series 10 year MTBF.
33-0002-01 Valve, 3 Way Printhead 10 year MTBF. 2 year Warranty.
22-0006-07 Manifold, 3 Way Printhead 10 year MTBF. 2 year Warranty.
22-0003-04 Cam, Series 8 PH 10 year MTBF. Broken pin not warranty. Bin breaks
easily if horizontal screws are not loosened at least
1/8 turn.
22-0007-03 Gutter, Detect 10 year MTBF.
22-0012-03 Charger, Series 8 PH 10 year MTBF.
22-0015-05 Thumbscrew, Series 8 PH 10 year MTBF.
22-0038-02 Cover, Series 8 Back 10 year MTBF. Standard wear and tear not covered.
22-0039-02 Cover, Series 8 Front 10 year MTBF. Standard wear and tear not covered.
Fluidic Items
32-0001-01 Pump, Series 8 Series 10 year MTBF Warranty. Opened pump case or
Assembly motor case voids warranty.
32-0002-01 Pump, Series 8 Series 10 year MTBF Warranty. Opened pump case or
Heavy Pigment Assembly motor case voids warranty
32-0005-01 Pump, Series 8 Air Pump 10 year MTBF Warranty. Opened pump case or
motor case voids warranty
33-0001-01 Valve, 2 Way Ink 10 year MTBF. 2 year warranty. Ink clogs not
covered.

MANUAL – 40-0001-01
Fluidic Items (Continued)

21-0008-01 0-ring, Valve 2 Way 2 year warranty.
34-0003-01 Sensor, Ink Pressure 10 year MTBF.
27-0005-04B Cap, Ink Fill Non-warranty
27-0005-04W Cap, Solvent Fill Non-warranty
21-0007-01 0-ring, Series 8 Fill Caps Standard wear and tear not covered.
20-0011-01 Venturi, Series 8 Series Assembly 10 year MTBF. 2 year warranty.
34-0001-01 Switch, Ink Level 10 year MTBF. 2 year warranty.
34-0002-01 Switch, Solvent Level 10 year MTBF. 2 year warranty.
21-0012-01 Gasket, Ink Tank 10 year MTBF. 2 year warranty.
21-0013-01 Gasket, Solvent Tank 10 year MTBF. 2 year warranty.
21-0017-01 O-ring, small tank plug 10 year MTBF. 2 year warranty.
21-0018-01 O-ring, large tank plug 10 year MTBF. 2 year warranty.
21-0022-01 O-ring, pressure sensor 10 year MTBF. 2 year warranty.
21-0023-01 O-ring, Puncture 10 year MTBF. 2 year warranty.
22-0026-03 Puncture, Solvent 10 year MTBF. 2 year warranty.
22-0027-03 Puncture, Ink 10 year MTBF. 2 year warranty.
20-0012-01 Tank, Ink 10 year MTBF. 2 year warranty.
20-0013-01 Tank, Solvent 10 year MTBF. 2 year warranty.
31-0021-01 Filter, Solvent 10 year MTBF. 2 year warranty.
10 year MTBF. 2 year warranty.
23-0039-03 Plug, Fill Tanks Overtightening damage not covered.
Electronics and Cables

19-0082-01 PCB, CPU 82 10 year MTBF. Backup Battery not covered. Attempted
servicing such as soldering, component replacement, or
user damaged connection housing not covered.
20-0014-01 LCD, 10.4" Touch 10 year MTBF. Removed touch screen not covered.
Assembly
18-0001-03 PSU, Series 8 Series 10 year MTBF. Void warranty if cage opened.
18-0002-01 Fan, Series 8 Series 10 year MTBF. Void warranty if fan motor disassembled.
28-0033-01 Latch, Quarter Turn 10 year MTBF. 2 year warranty. Standard wear and tear
not covered.

MANUAL – 40-0001-01
Electronics and Cables (Continued)

16-0027-01 Sensor, Inductive 10 year MTBF. 2 year warranty. Standard wear and
tear not covered.
21-0011-01 Gasket, EMI Series 8 10 year MTBF. 2 year warranty. Standard wear and
Door tear not covered.
16-0100-01 Cable, Mains US 10 year MTBF. 2 year warranty. Standard wear and
tear not covered.
16-0101-01 Cable, Mains Euro 10 year MTBF. 2 year warranty. Standard wear and
tear not covered.
16-0102-01 Cable, Mains UK 10 year MTBF. 2 year warranty. Standard wear and
tear not covered.
16-0001-05 Cable, Printhead 10 year MTBF. 2 year warranty. Standard wear and
Harness tear not covered.
16-0002-03 Cable, PH Ground 10 year MTBF. 2 year warranty. Standard wear and
tear not covered.
16-0004-05 Cable, HV +4KV 10 year MTBF. 2 year warranty. Standard wear and
tear not covered.
16-0005-04 Cable, HV -4KV 10 year MTBF. 2 year warranty. Standard wear and
tear not covered.
16-0017-08 Cable, PSU/Mains 10 year MTBF. 2 year warranty. Standard wear and
tear not covered.
16-0018-06 Cable, Valve Harness 10 year MTBF. 2 year warranty. Standard wear and
tear not covered.
16-0023-02 Cable, Coax Umbilical 10 year MTBF. 2 year warranty. Standard wear and
tear not covered.
16-0024-04 Cable, Coax PH 10 year MTBF. 2 year warranty. Standard wear and
tear not covered.
16-0026-04 Cable, Pressure Sensor 10 year MTBF. 2 year warranty. Standard wear and
tear not covered.
16-0027-02 Cable, Viscometer 10 year MTBF. 2 year warranty. Standard wear and
Sensor tear not covered.
16-0028-02 Cable, Viscometer 10 year MTBF. 2 year warranty. Standard wear and
Valve tear not covered.
16-0031-02 Cable, LCD Power 10 year MTBF. 2 year warranty. Standard wear and
tear not covered.
16-0032-01 Cable, LCD Ribbon 10 year MTBF. 2 year warranty. Standard wear and
tear not covered.
16-0033-03 Cable, Mains Ground 10 year MTBF. 2 year warranty. Standard wear and
tear not covered.
16-0034-03 Cable, Door Ground 10 year MTBF. 2 year warranty. Standard wear and
tear not covered.

MANUAL – 40-0001-01
Fluidic Service Routines


INJEST.
Cleaning the Venturi
 Remove all tubes from the Venturi manifold
 Rinse out the inside of

the venturi manifold with MEK.

MANUAL – 40-0001-01
 Check the restrictor for
debris.
How to clear a clog
 Remove the top restrictor

using a 1/16” Allen Driver or
Key.

MANUAL – 40-0001-01
 Examine the top restrictor for clogs,
rinse with MEK as necessary
 With top restrictor removed,
rinse out the inside of

the venturi manifold with
MEK.
 Check the remaining restrictor for
debris.

MANUAL – 40-0001-01
EQUIPMENT DAMAGE: DO NOT REMOVE THE BOTTOM RESTRICTOR!
FAILURE TO FOLLOW THIS INSTRUCTION MAY LEAD TO DAMAGES.
Tuning the Venturi
 Reinstall the top restrictor using a 1/16” Allen
Driver or Key.
 Run the top restrictor down until it touches
the bottom restrictor.
 Back the top restrictor off 1 ¾ to 2 complete

turns.

MANUAL – 40-0001-01
Cleaning the Viscometer
Cleaning out the viscometer glass
 Remove Power Cable
 Remove the solvent
tank.

MANUAL – 40-0001-01
 Remove the purple tube from
the viscometer.
 Using a 2mm hex drive, remove the two

screws from the back of the viscometer.
 Remove the viscometer valve
assembly.

MANUAL – 40-0001-01
 Lift the viscometer top return out

of the ink tank.
 Spray solvent through the
viscometer top return to clean the
viscometer glass.
Cleaning the Viscometer Restrictor
 Remove the viscometer valve
assembly.

MANUAL – 40-0001-01
 Rinse the bottom port with
MEK.
 Using a 1/16 Allen driver or key, remove the Viscometer Restrictor.
 Examine the top restrictor for clogs,

rinse with MEK as necessary

MANUAL – 40-0001-01
 Check viscometer bottom port for debris.

 Use a 2mm drill to clear any plastic debris from the
manifold.
 Reinstall the viscometer

restrictor.
 Screw the restrictor in
until it bottoms out.
Main Pump Replacement

SERVICING MACHINE.

MANUAL – 40-0001-01
 Unlock Front door
 Open Front door
 Remove pump cable

MANUAL – 40-0001-01
 Push grommet into fluid

compartment
 Loosen back door thumb screw

 Remove back door
PERSONAL INJURY: ALWAYS WEAR

RUBBER GLOVES AND SAFETY GLASSES
DURING FLUIDIC MAINTENANCE.
 Lift the return block above the ink fluid level
 Allow the fluid to drain up through the filter, pump, and back into
tank.

MANUAL – 40-0001-01
 Remove the two pump mounting

screws
 Remove the pump from the machine
 Remove tubes from pump
fittings.

MANUAL – 40-0001-01
EQUIPMENT DAMAGE: USE ONLY LINT FREE TOWELS WHEN
WORKING IN FLUIDIC SYSTEM. FAILURE TO OBSERVE MAY

COMPROMISE NOZZLE AND FILTERS
 Push down on collet
 Gently pull out tube

 Discard of old pump in
accordance with local
instructions.

INGEST.

 Rinse pump inlet with solvent

MANUAL – 40-0001-01
 Trace the feed tube back to
the tank and ensure it is

installed into the pump inlet.
 Push tubes into fittings.
 Tug on tubes to ensure they

are firmly seated in the
fittings.
 Apply a small amount of solvent to the O-rings on the return

 Press the return back into the tank
 Install the two pump mounting screws

MANUAL – 40-0001-01
 Push grommet into wall hole to seal.

 Plug the pump cable into the board.

MANUAL – 40-0001-01
 Close and lock front door

Solenoid valve replacement

SERVICING MACHINE.

MANUAL – 40-0001-01

PERSONAL INJURY:
ALWAYS WEAR RUBBER
GLOVES AND SAFETY GLASSES DURING FLUIDIC MAINTENANCE.
 Remove valve cables

MANUAL – 40-0001-01
 Remove the two screws
 Remove Valve
 Clean excess ink using solvent

and lint free towels

INGEST.


MANUAL – 40-0001-01
 Seat gasket in new valve
 Align valve on manifold
 Install the screws

MANUAL – 40-0001-01
 Replace terminals
 Close back door
 Fasten thumb screw

MANUAL – 40-0001-01
Ink Swap or Longterm Storage Flush
Flushing the machine is recommended if a new ink is to be installed, or if the machine is being
powered down for a period of time greater than 1 month.
The following items are required to perform a proper Flush.
 5-6 liters of cleaner matching the ink currently installed.

 #1 Phillips screw driver
 3/16” slotted screw driver
 Nitrile or solvent resistant gloves
 Eye protection
 Respirator or NOSHA rated breathing apparatus.
 Air Compressor with dryer and rubber tipped nozzle
 Solvent resistant pale for clean fluid pickup (5 gal bucket).
 Solvent resistant pale for waste fluid return (5 gal bucket).
 Solvent wash bottle with solvent matching ink currently installed.
 Lint free paper towel
Flush Procedure
1) Power off Machine
2) Move to a well-ventilated area that is free of ignition sources.
3) Remove Back Cover.
4) Remove ink and solvent fills.
5) Lift ink tank and solvent tanks out of the machine.
6) Lay lint free paper towels on the floor of the fluidic compartment in case of spills.
7) Use 3/16 slotted screw driver to pry ink pickups and returns from the ink tank.
a. Spray solvent around each to dissolve dried ink and briefly lubricate O-rings.
8) Power on the machine.
9) Place the Ink pickup tube into the Pickup Bucket with 5000mls of cleaner.
a. Ensure the tube is submerged in the fluid.
10) Place the Venturi return tube, and both viscometer return tubes into the Waste Bucket.
11) Remove the printhead front cover and position the head over the Waste Bucket.
12)

MANUAL – 40-0001-01
Electronic Components
This section discusses electrical components in the Series 8 CIJ printer. Also, an
overview of component layouts and instructions on replacing the components are provided.
Main Board
Boards are ordered by Model level.
Board only, does not include cables, screws, or mounting hardware.
Viscometer
Pump Valve
Harness Ink RF
Encoder Pressure
Sensor Filter RF
Parallel Solvent RF
Air Pump
Photo Eye 2
Photo Eye 1
SD Card
Alarm Beacon
Ethernet
USB Mini
USB
Solvent Level
Detect
Serial RS 232
Ink Level
Printhead Detect
Red, EHT Trip

Black, Gutter
Yellow, Charge Detect
Display
Electrode
Fan Display
Blue, Modulation Power
Board Power

MANUAL – 40-0001-01
Part Number Description
19-0082-01 PCB, CPU 82
19-0086-01 PCB, CPU 86
19-0088-01 PCB, CPU 88
LED Meanings
LED # Enabled Condition Color

1 +12 V to Ink Pump (Always on) Green
2 +24 V to Ink Pump (Always on) Green
3 +3.3V on PhotoEye 1 (When signal received) Green
4 +12 V supply to Valve Harness (Always on) Green
5 +24 V supply to Valve Harness (Always on) Green
6 +3.3V on PhotoEye 2 (When signal received) Green
7 +3.3V on Encoder using PhotoEye 1 (Illuminates with each pulse) Green
8 +3.3V on Encoder using PhotoEye 2 (Illuminates with each pulse) Green
9 NOT USED Green
10 NOT USED Green
11 NOT USED Green
12 NOT USED Green
13 Viscometer Sensor Detect (illuminates when ball passes sensor) Green
14 Phase Detect (Illuminiates when phase drop passes phaser) Green
15 Phase Complete (Flashing when Phase is good) Green
16 Pump Tach (Always on, Flashing) Green
19 Hardware Heartbeat (Board Hardware actively running) Green
20 Software Heartbeat (Board Software actively running) Green
21 +5 V supply to board from PSU Green
22 +24 V supply to board from PSU Green
23 Charge Voltage Enabled (+300V) Red
24 EHT Voltage Enabled Red
Fuses
Fuse Associated LED Meaning Color
1 LED 1 If OFF while running, Short in Pump Cable
2 LED 2 If OFF while running, Short in Pump Cable
3 LED 4 If OFF while running, short in Valve Harness
4 LED 5 If OFF while running, short in Valve Harness
5 LED 21 If OFF, 5V supply is compromised. Determine if problem is
interal (power supply issue) or external (peripheral)
6 LED 22 If OFF, 24V supply is compromised. Determine if problem is
interal (power supply issue) or external (peripheral).
If LED is DIM, there is likely a partial short to one of the
Peripheral Devices.

MANUAL – 40-0001-01
Fan
All models use same fan
18-0002-01 Fan, Series 8 Series

28-0040-01 Fan Mounting Screws (M5 x 1.63 x 10 Flathead Self tapping)
Molex 43030-0008 Fan Crimps
Molex 43645-0300 Fan Connector Housing

MANUAL – 40-0001-01
Front Door
All Models use the same Front Door
Front Door Assembly with LCD

20-0002-01 Front Door, Bare
Lanyard, Front Door, 8”
16-0034-03 Cable, Door Ground
Nut, Door Ground/Lanyard, M3 Integral Lock Washer
Screw, Lanyard Mount, M3 x 6
Door Hinge
28-0033-01 Latch, Quarter Turn
21-0011-01 Gasket, EMI Series 8 Door
29-0002-05 BestCode Front Overlay
Hinge Nuts, M5 Nut with Nylon Insert
Hinge Screws, M5 x 10
16-0031-02 Cable, LCD Power
16-0032-01 Cable, LCD Ribbon
Display Assembly
All models use same Display Assembly
20-0014-01 LCD, 10.4" Touch Assembly

LCD Mounting Screws, M3 x 10
LCD Mounting Spacer, ¼” Length, ¼” ID, ½” OD
Back Light Cable
Touch Screen
Cable
Display to Main
Board
Powe
Display Feed
r
from
Main
Boar
d

MANUAL – 40-0001-01
Power Supply
All models use the same Power Supply
20-0014-01 Power Supply

Power Supply Nuts, M4 Nut with Nylon Insert
16-0017-08 Cable, PSU/Mains
Main Board
Connector Pow
er
Entry
High Voltage High Voltage

Ground Plate Jack Deflection Plate Jack

SERVICING MACHINE.


MANUAL – 40-0001-01
Electronic Service Routines
Replacing the Power Supply
 Remove the power cable.
 Open Filter door.
 Pull and open filter clip.

MANUAL – 40-0001-01
 Pull forward on filter.
 Pull filter up and out.
 Unlock the front door

MANUAL – 40-0001-01
 Open the front door
 Carefully remove these 6 cables from the main board.

MANUAL – 40-0001-01
 Remove these 5 cables
from the main board.

o Fan
o Modulation
o EHT trip
o Gutter Detect
o Charger
 Remove Positive and negative

high voltage cables from the
power supply.

MANUAL – 40-0001-01
 Remove these four screws from the power supply mount.
 Pull power supply forward then up.
 Be careful to not damage the main

board.
 Lift the power supply out of the

machine.
 The power supply is non-

serviceable and the cage should
not be opened.

MANUAL – 40-0001-01
Touchscreen Replacement
ELECTRICAL SHOCK: DISCONNECT MAIN POWER CABLE PRIOR TO SERVICING
MACHINE.
ELECTRICAL SHOCK: NEVER RUN MACHINE WHILE ELECTRONICS COMPARTMENT

DOOR IS OPEN.
 Unlock front door

 Open front door

MANUAL – 40-0001-01
 Remove 4 mounting screws.
 Disconnect the Display to Main Board and Power From main board cables
 Lift the display out of the
door

MANUAL – 40-0001-01
Touch Screen Calibration
1) Plug in a mouse to the USB to navigate the User Interface.
2) Sign in using Technician Level Password

MANUAL – 40-0001-01
3) Enter the Technician Screen

through Service, then Tools.
4) Enter the Screen Calibrate

Page
5) Touch the targets that appear

to Calibrate.
Touch Screen Flickering

 Go to the tools page

MANUAL – 40-0001-01
 Adjust the Back Light

Frequency to between 0-20
Positive Air Pump Installation

SERVICING MACHINE.
Positive Air Pump Kits are recommended for use in environments with High Humidity, high
condensation, or high dust. The Air Kit will prevent water and dust from entering the printhead and
causing issues with High Voltage Trips, gutter faults, print quality, and Jet Starts/Stop.
 Locate the mounting PEM

for the Air Pump bracket.

MANUAL – 40-0001-01
 Locate Air Line behind the Ink Tank.
 Route the Input side of the Air

Pump through the Cable Gland used
by the Main Ink Pump.
 Connect the Air Tube to the Output

side of the Air Pump.
 Install to CPU board – J11 “Air

Pump”.
 Air pump will automatically enable

and disable with Jet On/Off.

MANUAL – 40-0001-01
Printhead Components
Printhead
Valve Manifold Assembly

32-0002-01 Valve, 3 Way Printhead
20-0038-01 Manifold, 3 Way Printhead
Screw, Valve Assembly Mount, M3 x 5 Flathead
Screw, Valve Manifold Coupling, M3 x 25 Panhead
Heat Shrink, Valve Solenoid
Red, Ink Feed
Blue, Makeup
Feed
Drop Generator Assembly

20-0008-02 Assembly, Drop Generator, 62 micron nozzle
22-0029-01 62 micron nozzle, 82/85 / 86/88/88HS/88SP/88SF
22-0030-01 75 micron nozzle, For Large Drop Printing (82, 85,86,88 only)
Screw, Nozzle, M2 x 5 Flatheat
Screw, Vertical Clamping, M2 x 6 panhead
Screw, Horizontal Clamping M2.5 x 6 with washer
Heat Shrink, Modulation Cable
Modulation
Cable
Nozzle Plate
Bleed Tube
Ink Input Tube
Drop Generator

MANUAL – 40-0001-01
Gutter
22-0010-07 Gutter Manifold
Screw, gutter mount, M2 x 5 Flathead
22-0083-01 Sensor, Gutter Detect Kit
Ink Return Barb Drop Entry Hole
Sensor, Gutter Detect Kit
The gutter detect kit has a metal tube with attached coax cable, and heat shrink for sealing.
Tube from the gutter and white marked tube from umbilical attach to the tube. The heat
shrink should overlap the Teflon tubes ¼” each side to provide adequate sealing.

MANUAL – 40-0001-01
Printhead, Assembly
20-0016-02 Printhead, Assembly Series 8 Series 65 micron nozzle

20-0009-01 Printhead, Phase Assembly
22-0012-03 Charge Electrode
Screw, Charge Electrode, M2 X 12 Pan head
25-0032-04 Face plate, gutter mount
Screw, face plate mount, M3 x 6 Flathead
22-0038-02 Cover, Series 8 Back
Screw, back cover mount, M2 x 5 Flathead
22-0015-05 Screw, Thumb, Cover
22-0039-02 Cover, Series 8 Front
Screw, Tray Mounting, M3 x 6 Flathead
20-0016-02 is an entire printhead and umbilical replacement. The assembly contains all necessary
parts, including the connectors on the controller end for easy exchange of the printhead. Includes
calibrated and aligned drop generator.
20-0009-01 is the phase replacement. This part replaces the high voltage plates, strobe LED, phase
signal, and connection for charge tunnel.
Printhead Umbilical
Umbilical, Series 8, 3m
16-0076-01 Coax, Umbilical 10ft
16-0001-05 Harness, Printhead Cable 10ft
28-0072-01 Fitting, Printhead
22-0014-06 Block, umbilical mount, Blue
28-0133-01 Fitting, Controller, Umbilical Mount
Screw, Controller Umbilical Mounting, M3 x 16
Nut, Umbilical Mounting, M3 Star Locking Style

MANUAL – 40-0001-01
Printhead Service Routines
Printhead Tray Replacement
PERSONAL INJURY: ALWAYS WEAR RUBBER GLOVES AND SAFETY GLASSES

WHEN HANDLING INKS AND SOLVENTS.

IF EXPOSED, GENTLY RINSE AREA WITH SOAPY WATER.
IF IRRITATION PERSISTS, SEEK MEDICAL ATTENTION.
EQUIPMENT DAMAGE: DO NOT ADD FLUIDS UNLESS INSTRUCTED BY

INDICATORS.
EQUIPMENT DAMAGE: THE PRINTHEAD MUST BE DRY BEFORE STARTING

PRINTER.
EQUIPMENT DAMAGE: THE PRINTHEAD SHOULD NEVER BE COMPLETELY

SUBMERGED IN SOLVENT.

SMOKING OR OPEN FLAMES NEAR PRINTER OR FLUID
STORAGE.
ELECTRICAL SHOCK: DISCONNECT MAIN POWER CABLE PRIOR TO SERVICING

MACHINE.

DOOR IS OPEN

MANUAL – 40-0001-01
DISCLAIMER
DO NOT CUT OR REMOVE ANY WIRES OR TUBES UNLESS INSTRUCTED. THIS REPLACEMENT
METHOD DOES NOT REQUIRE ANY TUBES TO BE REMOVED FROM THE VALVE MANIFOLD OR DROP
GENERATOR.
• DO NOT CUT THE COAX CABLES
• DO NOT CUT THE TUBES
Failure to follow these instructions may lead to further damages.
Kit Parts(20-0009-01)
2 x 27-0061-01
Printhead
Tray
9 x 27-0034-02
4 x 27-0051-01

MANUAL – 40-0001-01
Required Tools
1. No. 0 Phillips head screw driver
2. No. 1 Phillips head screw driver
3. 5.5mm Nut Driver or Wrench
4. Wire cutters or Wire strippers
5. 100% lead free solder
6. Soldering Iron
7. Heat Gun
How to Remove the Tray

• Remove all printhead covers
• Remove Face plate and gutter tube from gutter.
Use No. 0 Phillips
Use No. 1 Phillips
DO NOT CUT THE GUTTER TUBE

MANUAL – 40-0001-01
• Remove the tray screws from the umbilical
• Remove the valve manifold screws
Use No. 1 Phillips
Use No. 0 Phillips
• Lift away the umbilical from the printhead.
• Remove the ground nut.
Use 5.5mm Driver

• Remove drop generator adjuster screws

MANUAL – 40-0001-01
 Remove the drop generator screws
Use No. 1 Phillips
 Lift the drop generator and valve manifold away from the tray
• Lift the fluidic tools from the tray
DO NOT CUT THE VALVE MANIFOLD TUBES

MANUAL – 40-0001-01
 Disconnect the Red and Yellow Coax
DO NOT CUT THE COAX CABLES
Wire Cutters

MANUAL – 40-0001-01
• Cut the following cables. (All come from the epoxy)
• Red High Voltage
• Black High Voltage
• Blue phase wire
• Red phase wire
• Violet phase wire
• White phase wire
• Green phase wire
• Yellow phase wire
• Pink phase wire
• Black phase wire
• Orange Phase Wire
Use No. 0 Phillips
• Lift away the bad phase tray
• Remove the charger
• Discard of the tray in accordance with local procedures

MANUAL – 40-0001-01
• Strip the multicore wires on the umbilical end and on the new phase tray.
• Slide 1 piece of phase wire heat shrink over each wire.
• Solder the umbilical wires to the mating phase tray wire.
• Re-attach the ground wire.
Use heat gun to shrink the phase wire sleeving
Use 5.5mm Driver

MANUAL – 40-0001-01
• Strip the high voltage wires on the umbilical end and on the new phase tray.
• Slide 1 piece of adhesive high voltage wire heat shrink over each wire.
• Solder the umbilical high voltage wires to the mating tray high voltage wire.
• Use heat gun to shrink the high voltage wire

MANUAL – 40-0001-01
• Install the drop generator
• Use old cam Use No. 1 Phillips

• Install the valve manifold
Use No. 1 Phillips
Use No. 0 Phillips

MANUAL – 40-0001-01
• Insure the 4 coax cables are connected (Red, Yellow, Blue, Black).
 Insure the 4 coax cables are connected (Red, Yellow, Blue, Black).
 Move heatshrink into place and seal the connectors with heat gun

MANUAL – 40-0001-01
 Install Back Cover
 Install Face plate
Use No. 0 Phillips
• Install the back cover

Use No. 1 Phillips
• Install the face plate
• Push the gutter tube onto the gutter barb ¼“ (6.35mm)
Jet must be re-aligned to the gutter after replacing the printhead tray.

MANUAL – 40-0001-01
Drop Generator Replacement

INGEST.

SERVICING MACHINE.

MANUAL – 40-0001-01
 Remove front cover
 Remove Face Plate
Screws
 Remove Gutter tube from Gutter
 Remove Both Drop Generator Tubes
Remove Drop
Generator
Bleed Tube
Remove Drop
Remove
Generator
Gutter Tube
Feed Tube
Remove Face
Plate Screws.
 Remove Back Cover Screws

MANUAL – 40-0001-01
Remove Back
Cover Screws
 Remove Back Cover

 Cut Open Blue Heat Shrink on Drop Generator Cable.
Remove Center Piece of

Blue Shrink Sleeve  Disconnect the Modulation Coax connectors.

MANUAL – 40-0001-01
Remove Drop
Generator
from the
bracket.
Remove Drop Generator

Side Screws
 Attached new drop generator to the bracket.

 Connect and heat shrinks the Modulation Coax Cable.
 Connect the Drop Generator Feed and Bleed Tubes.
 Re-attach the printhead back cover.
 Mount the Faceplate and install the gutter tube onto the Gutter.
 Power on the Machine
 Perform a back flush to ensure Nozzle is clean and free of debris during install and shipping.
 Align nozzle and calibrate modulation for the new drop generator.

MANUAL – 40-0001-01
Changing or Cleaning Nozzle
 Remove the front

cover
 Remove the two nozzle

screws.
(Use No. 0 Phillips)
 Lift out the nozzle

MANUAL – 40-0001-01
 Rinse both sides of the
nozzle well with solvent.

 Replace nozzle if
necessary
 Go to fluidic screen and run pump and open printhead valve to ensure drop
generator has only clean ink inside.
 Measure out 50-100ml of ink before re-installing nozzle.

MANUAL – 40-0001-01
 Ensure nozzle seal
is present.
 Position nozzle
 Install the two

nozzle screws.
(Use No. 0
Phillips)

MANUAL – 40-0001-01
 Put on the front

cover
Replacing the nozzle seal

INGEST.


MANUAL – 40-0001-01
 Remove the front cover
 Remove the two nozzle

screws.
(Use No. 0 Phillips)
 Lift out the

nozzle

MANUAL – 40-0001-01
 Position the head vertically,
this aids in removal and

reinstallation of the seal.
 Remove the nozzle seal

from the drop generator seal
groove.
 Go to fluidic screen and run pump and open printhead valve to ensure drop
generator has only clean ink inside.
 Measure out 50-100ml of ink before re-installing nozzle.

MANUAL – 40-0001-01
 Install New Seal over boss feature in Drop Generator if necessary.
o Update to New Seal style shown below.
 Re-install nozzle to complete
 Position nozzle

MANUAL – 40-0001-01
 Install the two

nozzle screws.
(Use No. 0
Phillips)
 Put on the front

cover

MANUAL – 40-0001-01
Advanced Nozzle Cleaning
For nozzles that are particularly difficult to clean, a special nozzle cleaning solvent is available.
The Nozzle Clean Solvent, 47-0053-01, provides a consistent method to recovering/cleaning nozzles
that have not been able to be cleaned by other solvents. The Nozzle Clean Solvent is used to clean
the nozzle when removed from the system as a soak/clean agent. NOTE: The Nozzle Clean Solvent is
not compatible with inks or makeup solvents.
Nozzle Clean Solvent instructions
a) Remove nozzle from drop generator and place into a small jar.
b) Cover nozzle with cleaning solution, ensure the nozzle is completely submerged.
c) Soak nozzle for 10 minutes.
d) Place jar with cleaner and nozzle into a bath of warm water in the Ultra-Sonic cleaner.
a. Cleaner is non-flammable.
e) Run the ultra-sonic bath for 2 minutes maximum.
f) Remove the nozzle from the Nozzle Clean Solvent and clean with MEK before re-installing.
Do not leave in cleaner longer than 30 minutes.

MANUAL – 40-0001-01
Jet Alignment
To align the nozzle, there are two sets of adjustments made; horizontal and vertical.
The position of the vertical jet alignment lies on a plane called the “traverse” plane. The
traverse plane vertically bisects the gutter hole. The position of the horizontal jet alignment
lies parallel to a plane called the “median” plane. The median plane horizontally bisects the
gutter hole.
Traverse
plane
Gutter Hole
Median
Plane
Starting the Jet for Alignment
PERSONAL INJURY: DO NOT USE SOLVENT TO WASH INK FROM SKIN. IF
EXPOSED, GENTLY RINSE AREA WITH SOAPY WATER. IF IRRITATION
PERSISTS, SEEK MEDICAL ATTENTION.

MANUAL – 40-0001-01
PERSONAL INJURY: DO NOT LEAVE EQUIPMENT UNATTENDED WHILE
RUNNING WITH ERRORS DISABLED. FAILURE TO COMPLY CAN LEAD TO
EQUIPMENT DAMAGE, PERSONAL INJURY, OR DEATH.
EQUIPMENT DAMAGE: USE ONLY LINT FREE TOWELS WHEN WORKING IN
FLUIDIC SYSTEM. FAILURE TO OBSERVE MAY COMPROMISE NOZZLE AND
FILTERS.
EQUIPMENT DAMAGE: FAILURE TO FOLLOW INSTRUCTIONS MAY LEAD TO
EQUIPEMENT DAMAGE.
EQUIPMENT DAMAGE: DO NOT ATTEMPT TO ADJUST THE NOZZLE BEFORE
LOOSENING THE ADJUSTER SCREWS.
ELECTRICAL SHOCK: NEVER SERVICE MACHINE WHILE HIGH VOLTAGE IS
ACTIVE AND ERRORS ARE DISABLED. FAILURE TO OBSERVE MAY LEAD TO
ELECTRICAL SHOCK OR FIRE.
FIRE HAZARD: INKS AND SOLVENTS ARE HIGHLY FLAMMABLE. NO SMOKING
OR OPEN FLAMES NEAR PRINTER OR FLUID STORAGE.
 Remove the front cover

MANUAL – 40-0001-01
 Press the service button
 Disable Errors
 Disable HV Deflect
 Disable Phasing
 Start the Pump
Vertical Adjustment

MANUAL – 40-0001-01
 Loosen vertical adjustment screws by 1/4 turn.
 Use slotted screw driver in Drop Generator Slot move jet up and down.
Drop Generator Gutter

Slot
Po
in
t
 Tighten screws once jet isofaligned to the traverse plane centered on the gutter hole.
ro
Horizontal Adjustment ta
ti
on
Drop Generator
Adjuster Cam
 Loosen the horizontal adjustment screws by 1/4 turn.

 Use a slotted screw in the adjuster cam to aligned
the jet horizontally.

MANUAL – 40-0001-01
 Tighten screws once jet is in the gutter hole.
Ideal Jet Location
 Drops shoulder enter the
gutter coincident the traverse
plane.
 Drops should enter the gutter
30% positive the median
plane, or 80% across the
gutter hole in the direction
opposite the gutter barb.

MANUAL – 40-0001-01
Drop Entry
Position
 Enable Errors
 If Error occurs, check alignment again.

MANUAL – 40-0001-01
Adjusting the Charge Electrode
In circumstances where the charge electrode is blocking the jet, it is required to adjust its
position. The jet should be centered 50/50 through the charge electrode.
 Below image shows offset charge electrode

MANUAL – 40-0001-01
 Use a No.0 Phillips screw driver to loosen the charge electrode screw.
 S
lide the charge electrode into place, such that the jet likes 50/50 through the tunnel.
 Use screw driver to slide charge electrode.

MANUAL – 40-0001-01
 Tighten the charge electrode screw and confirm jet position.

MANUAL – 40-0001-01
Modulation Calibration
Modulation calibration is a critical field service repair. If a nozzle or drop generator must be
replaced, it is almost certain that the modulation will need to be calibrated.
Modulation refers to the oscillation of the piezo-electric device that drives drop formation.
Drop Generator Anatomy
Bleed
Ink Feed
line
Nozzle
Piezo
Assembly
Conic
Chamber
Throat
Ink is fed in through the Ink Feed line. In the conic chamber, a high frequency mechanical stress
(called modulation) is applied onto the ink. The ink travels through the throat and enters the nozzle.
The combination of the massive restriction from the nozzle and modulation causes droplets of ink to
form on the output of the nozzle.

MANUAL – 40-0001-01
Charger Anatomy
As drops are formed, a specially tuned LED is used to illuminate and show the quality of the drops
being produced. These can be seen using an eye-loupe.
Ink Jet Filament

LED
Ink Drops
Charge Tunnel
Drop Formations
Ideal Drop Formation
Drops of ink begin to form about 20% through the charge tunnel. Round drops begin to form
immediately.

MANUAL – 40-0001-01
Filament too Long
A long filament does not mean that the printer will not work. However, with a filament this long, it is
difficult to examine the drop breakup. Typical solutions are increasing modulation voltage or
recalibrating for best frequency band and voltage range. Other possible causes include high viscosity
or low pressure.
Filament too short
A short filament does not mean that the printer will not work. However, with a filament this short, it
is difficult to examine the drop breakup. This is a key sign of over modulation. Odd shaped drops can
also be formed if modulation is too high. Typical solutions are reducing modulation voltage or
recalibrating for best frequency band and voltage range.
Satellite Drops
Satellite drops will always cause print disturbances. Print will be sprayed with extra, miniature
drops. Satellites are almost always related to low modulation voltage. Modulation Calibration is
required to correct satellite drops.

MANUAL – 40-0001-01
How to Calibrate Modulation (Except 88HS and 88HS1)
Tips and Advice
Good modulation range is a critical for achieving long print times with low maintenance. Having an
80V to 100V modulation range is the goal of every calibration.
Modulation voltages range from 20V to 250V. The perfect scenario is having a set Modulation of
100V with a window of good print range from 50V to 150V.
The piezo-electric device is non-accessible, non-repairable, and non-serviceable. Attempting to Only

Calibrate with the “BestCode” Message. Only calibrate when viscosity is at target (4.5cP).
Procedure
1) Determine the type of modulation problem at hand.

2) Gather necessary tools
a. Eye-Loupe
b. Paper
c. Pen or Pencil
3) Sign in using the Technician Level Password
4) Enter the Technician Screen through Service, then Tools.

MANUAL – 40-0001-01
5) Select Modulation Frequency A
6) Enter the Calibrate screen

MANUAL – 40-0001-01
7) Disable phasing
Phasing MUST be disabled

when adjusting Modulation
to phase errors occurring.
This is critical with 75u nozzle.
8) Decrement or Increment the

Modulation voltage until
good breakup and print are
found.
9) The lowest Boundary print should look like this;
10) Take print samples at every 10V increment until print becomes broken, or until a 100V
window in established.

MANUAL – 40-0001-01

MANUAL – 40-0001-01
11) If print breaks before a 100V window is achieved, return to step 5 and use the next
modulation frequency.
12) Repeat until ideal print window is achieved.
Notes;
Keeps print window notes for each frequency (A-G), choose the band with the modulation
set point closest to 100Volts.
In the example shown, the modulation set point would be 120Volts
a. Lower Print Boundary is 70Volts
b. Upper Print Boundary is 170Volts +
c. Take the arithmetic mean (170 + 70)/2 = 120Volts
13) Test the lower pressure reliability of the modulation set point by setting pressure to 37psi.
14) Take a test print.
15) Test the upper pressure reliability of the modulation set point by setting pressure to 43psi.
17) Examine the two prints for flaws.
a. If the print is broken or exceptionally poor, this would be a poor Modulation set
point.
18) Test the lower charge reliability of the modulation set point by setting the Charge to 67%
20) Test the upper charge reliability of the modulation set point by setting the Charge to 73%
a. If the print is broken or exceptionally poor, this would be a poor Modulation set
point.
23) If the Modulation Range is 100V or more, and passes both the Pressure and Charge
reliability test, then the Modulation set point is good and calibration is complete.

MANUAL – 40-0001-01
How to Calibrate Modulation for 88HS and 88HS1
Recommended Settings
Before beginning modulation calibration, use the following settings and test the Print.
Modulation: 100 – C
Pressure: 40 PSI
Charge: 40%

MANUAL – 40-0001-01
Tips and Advice
The 88HS and 88HS1 run at exceptionally high frequency. The result of this is that modulation
calibration is smaller drops. To compensate for this, the calibration process is changed to give more
accurate placement of Pressure, Charge, and Modulation set points.
Modulation voltages range from 20V to 250V.
For 88HS machines, you must have the PrintHead Config set to 2. This allows the use of Height 10 in
the adjust screen. The additional height helps maintain full size message printing with lowered
charge.
The piezo-electric device is non-accessible, non-repairable, and non-serviceable. Attempting to

modify drop breakup by modifying or gaining access to the piezo-electric device will end poorly.
Only Calibrate with the “BestCode” Message. Only calibrate when viscosity is at target (4.5cP).
Procedure
1) Determine the type of modulation problem at hand.
2) Gather necessary tools
a. Eye-Loupe
b. Paper
c. Pen or Pencil
3) Sign in using the Technician Level Password
4) Enter the Technician Screen through Service, then Tools.

MANUAL – 40-0001-01
5) Select Modulation Frequency C

6) Set Gutter Shift to 100
7) Set Printhead Configuration to 2 (Must have BestCode USB installed)
a. Press Save button on Printhead Configuration 2 to save.
8) Enter the Calibrate screen

MANUAL – 40-0001-01
9) Disable the Phase
10) Decrement or Increment the

Modulation voltage until
good breakup and print are
found.
11) The lowest Boundary print should look like this;
12) Take print samples at every 10V increment until print becomes broken, or until a 100V
window in established.

MANUAL – 40-0001-01

MANUAL – 40-0001-01
13) If print breaks before a 100V window is achieved, return to step 5 and use the next
modulation frequency.
14) Repeat until ideal print window is achieved.
Notes;
Keeps print window notes for each frequency (A-G), choose the band with the modulation
set point closest to 100Volts.
In the example shown, the modulation set point would be 120Volts
a. Lower Print Boundary is 70Volts
b. Upper Print Boundary is 170Volts +
c. Take the arithmetic mean (170 + 70)/2 = 120Volts
15) Test the lower pressure reliability of the modulation set point by setting pressure to 37psi
17) Test the upper pressure reliability of the modulation set point by setting pressure to 43psi.
PROCEEDURE FOR 88HS and 88HS1 ONLY:

 If the Pressure fails at 37 PSI, test at 38PSI.
 If 38PSI has good print, use a pressure set point of 41psi.
 If 38PSI is not good, continue to increase by 1 PSI until Print at the lower pressure is good.
o If the lower pressure is above 42 PSI, select a different modulation band (A-G) and
look for a different modulation window.
 Once the lower pressure is determined, test the higher pressure.
o If the lower pressure is set at 40PSI, then test the higher pressure at 6 PSI higher, 46
PSI.
o If the test at 6PSI above your lower pressure is good, then continue to the charge
test.
o If the test at 6PSI above your lower pressure is bad, then select a different
modulation band (A-G) and look for a different modulation window.
20) Test the lower charge reliability of the modulation set point by setting the Charge to 37%
22) Test the upper charge reliability of the modulation set point by setting the Charge to 43%

MANUAL – 40-0001-01
PROCEEDURE FOR 88HS and 88HS1 ONLY:
25) If the Print fails at 37% Charge, test at 38% Charge.
26) If 38% Charge has good print, use a charge set point of 41% Charge.
27) If 38% Charge is not good, continue to increase by 1% until Print is good.
a. If the lower charge percent is above 42%, select a different modulation band (A-G)
and look for a different modulation window.
28) Once the lower Charge percent is determined, test the higher Charge percent.
a. If the lower Charge is set at 39%, then test the higher pressure at 6% higher, 45%.
b. If the test at 6% above your lower Charge is good, then set Charge to the middle
42%.
c. If the test at 6% above your lower Charge is bad, then select a different modulation
band (A-G) and look for a different modulation window.
29) Set the Charge percent and pressure to the point determined by testing and set modulation
to the determined point.
30) Test prints on the entire 100V window and ensure print it is good quality.
Troubleshooting 88HS and 88HS1 Modulation Calibration
If after performing the modulation calibration procedure, you have issues with the Print, use these
examples to help correct the Print issues.
Top Line of Print is Distorted
Top Drop furthest from Gutter
Bottom Drop Closest to Gutter
 This issue is caused by Over Charging of the Ink Drops.
 This problem may occur immediately OR only during parts of the day.
 The best solution is to reduce charge to 40% and check the Modulation Window. You may
have to select a new frequency range, but 40% charge will work.

MANUAL – 40-0001-01
Bottom line of Print is distorted or missing
 If the bottom line of Print is missing, it is likely caused by gutter clipping.
 Ensure the Jet is aligned correctly.
 Make sure that Gutter Shift Value is 100.
o If these are all set, increase Gutter Shift Value until the Print is good.
o Some 88HS and 88HS1 machines will require 200V of Gutter Shift to work correctly,
this is okay to do.
Top line of drops joins together or falls into the middle of the Print
Top Drop furthest from Gutter
Bottom Drop Closest to Gutter
 This problem is common when using the “Fastest” or “Ultra-Fast” setting.
 This problem may occur immediately OR only during parts of the day.
 The best solution is to reduce charge to 40% and check the Modulation Window. You may
have to select a new frequency range, but 40% charge will work.
For 88HS machines, you must have the PrintHead Config set to 2.
This allows the use of Height 10 in the adjust screen. Without the
additional height, messages will not print correctly.

MANUAL – 40-0001-01
Fluidic Compartment
Ink Tank
All models use the same Ink Tank. Ink Tank assembly includes viscometer returns, ink pickup, fill cup
plug and level detect.
Venturi Assy, Gen2
Fill Cup Plug
Ink Level Detect Viscometer Active

Return, Brown
Tube
Viscometer Top
and Bleed Return,
Gray Tube
Pickup to Pump
Inlet
Tank assembly includes fill plugs
Part Number Description Part Number Description

20-0012-01 Tank, Ink, Assembly 21-0017-01 O-ring, Small Tank Plug
21-0012-01 Gasket, Ink Tank 21-0018-01 O-ring, Large Tank Plug
Ink Tank Screws, M3 x 12 34-0001-04 Level Switch, Ink
Ink Tank Lock Washer 27-0024-01 Return, Viscometer
23-0039-03 Plug, fill 27-0022-03 Ink Pickup

MANUAL – 40-0001-01
Venturi Next Series 8 Assembly, Gen 2 – 20-0032-01
20-0032-01 Venturi, Series 8 Series Assembly Gen 2
Restrictor, Venturi Top
23-0034-01 Tube, Return
21-0018-01 O-ring, Tank Plug Large
The Venturi is a device that provides suction on return drops. In some cases, the Venturi may
become clogged or “detuned”. The Venturi controls the flow of ink to the Printhead.
The Venturi manifold consists of an inlet from the pump, an outlet into the tank, feed to the Valve
Manifold, and 2 Vacuum lines from the Valve Manifold. The Black Vacuum line handles the Bleed,
Makeup Add, and Nozzle Vacuum. The Black/White marked vacuum is used exclusively for the
Gutter Vacuum.
Ink Out
Vacuum
Black/White
Vacuum

MANUAL – 40-0001-01
Solvent Tank
All models use the same Solvent Tank. Ink Tank assembly includes solvent pickup, fill cup plug and
level detect.
Part Number Description

20-0013-01 Tank, Solvent, Assembly
21-0013-01 Gasket, Solvent Tank
Solvent Tank Screws, M3 x 12
Solvent Tank Lock Washer
23-0039-03 Plug, fill
27-0023-01 Solvent Pickup
34-0002-02 Level Switch, Solvent
21-0017-01 O-ring, Small Tank Plug
21-0018-01 O-ring, Large Tank Plug
Solvent Pickup,
Orange Tube
Level Detect
Viscometer Mounts
Fill Cup Plug

MANUAL – 40-0001-01
Viscometer
All models use the same Viscometer.
Viscometer assembly includes calibrated viscometer with sensor, valve, connector, and gland.
The viscometer is a device used to determine the thickness of the ink in the system. The Series 8
system uses a falling ball style viscometer. A valve on the back of the viscometer controls the flow of
ink through the viscometer capillary glass. Inside the glass is a metal ball. When the valve is opened,
the ball is forced to the top of the viscometer. After a set period of time, the valve closes and the
ball will begin to fall. A sensor is mounting close to the capillary glass to detect when the ball has
fallen the correct distance. Software then uses the time information to calculate the viscosity.
Key Features
 Falling Ball style

 Non-temperature compensated
(external viscosity checks must be
done at operating temperature)
 No-Stick ball design
Ball
NOTE: GLASS AND BALL NOT
SOLD. IF EITHER ARE LOST, MUST
REPLACE ENTIRE ASSEMBLY
Glass
20-0015-01 Viscometer Assembly Sensor Housing

16-0027-01 Viscometer Sensor
Cable
16-0075-01 Viscometer Valve
Cable
33-0001-02 Valve, 2 Way
21-0008-01 Gasket, Valve, 2 Way
28-0099-01 25mm Cable Gland
M3 x 30 Valve Mounting Screw
22-0060-01 Viscometer Restrictor
M6 x 8 Torx Viscometer Bracket
Screw
Molex Viscometer Crimp
43030-0008
Molex Viscometer Connector
43025-0600 Housing
Valve Flow Restrictor

MANUAL – 40-0001-01
Fluid Pumps
Pump assemblies do not include bracket.
Assemblies include fittings, housings, and gland.
32-0001-01 Pump, Series 8 Series Assembly
32-0002-01 Pump, Series 8 Series Heavy Pigment Assembly
Pump Bracket
Pump Bracket Screw
Pump Bracket Nut
Molex 43030-0008 Pump Crimp
Molex 43645-0800 Pump Connector Housing
Pump Straight Fitting, ¼”
Pump 90 fitting, ¼” Heavy Pigment
28-0100-01 32mm Cable Gland
Pump assemblies do not include mounting bracket.

MANUAL – 40-0001-01
Main Manifold Gen 2– 20-0040-01
34-0003-01 Sensor, Pressure Transducer
21-0022-01 Gasket, Pressure Transducer
Screw, Pressure Transducer (M4 x 16)
33-0001-02 Valve, 2 Way
21-0008-01 Gasket, Valve 2 Way
Screw, Valve 2 way (M3 x 30)
Screw, Manifold Mounting (M4 x 25)
16-0018-07 Harness, Cable, Valve Manifold
16-0026-04 Cable, Pressure Transducer
Vacuum
Printhead Black/White
Makeup
Gutter
Printhead
Ink
Makeup
Tank
Ink In
Viscometer
Bleed
Vacuum

MANUAL – 40-0001-01
Main Filter
31-0051-01 82/86 Main Filter
31-0050-01 88/88S Main Filter
Filter Compression Fittings
Filter Housing with SmartFilter™ Reader
Filter Strap
Dampener
Dampener is the same on all models
20-0019-01 Dampener Assembly

Dampener Inlet
Dampening Chamber
Dampener Outlet with filter

MANUAL – 40-0001-01
Ink Fill Cup

20-0024-01 Fill, Ink Tank Assembly
Fill, SmartFill™ reader Replacement Kit
22-0027-03 Puncture, Ink Bottle
21-0023-01 Puncture, O-ring
27-0028-04B Cap, Ink
21-0007-01 Gasket, Ink Cap
Screws, Fill Fastener, M3 x 6 Flathead
Solvent Fill Cup

20-0025-01 Fill, Solvent Tank Assembly
Fill, SmartFill™ reader Replacement Kit
22-0026-03 Puncture, Solvent Bottle
21-0023-01 Puncture, O-ring
27-0028-04W Cap, Solvent
21-0007-01 Gasket, Solvent Cap
Screws, Fill Fastener, M3 x 6 Flathead

MANUAL – 40-0001-01
Fluidic Fittings
35-0001-01 Pump, ¼ Fittings, Fluid Entry/Exit
35-0019-01 Pigmented Pump, ¼ 90° fitting, Fluid Entry/Exit
Tubing
Length
36-0001-01 1/8” OD 1/16” ID tubing, per 1ft
36-0002-01 ¼” OD 1/8” ID tubing, per 1 ft
36-0002-01 Pump inlet tube 25” (635mm)
36-0002-01 Pump Outlet, Filter Inlet Tube 16” (406mm)
36-0002-01 Filter Outlet Tube 13” (330mm)
36-0001-01 Manifold Feed Tube, Green Sleeved 28” (711mm)
36-0001-01 Manifold Vacuum Tube, Black Sleeved 28” (330mm)
36-0001-01 Viscometer Feed Tube, Purple Sleeved 33” (838mm)
36-0001-01 Viscometer Return Tube, Brown Sleeved 39” (990mm)
36-0001-01 Viscometer Return Tube, Gray Sleeved 35” (889mm)
36-0001-01 Solvent Filter Inlet Tube, Orange Sleeved 12” (305mm)
36-0001-01 Solvent Filter Outlet Tube, Orange Sleeved 8” (203mm)
36-0001-01 Umbilical Tubes (Red, Blue, Yellow, White) 13’ (4m)
Tube Push Fittings

MANUAL – 40-0001-01
The brands “Speedfit” and “John Guest” are the registered trademark of John Guest International
Limited.

MANUAL – 40-0001-01
Specific Application Setup
Section 11

MANUAL – 40-0001-01
This section looks at specialized setup configurations using the Series 8 CIJ. This includes
setup of the following features;
 Large Print
 High Speed Applications
 Traversing Applications (Normal and Repeat)
 Meter Marking Applications
 Repeat Print (Medicine Blister Packs, etc)
 Remote Message Select (Binary Coded Decimal Input)
These features require advanced technical knowledge of marking and coding systems,
conveyor systems, and peripheral devices.
Large Drop Printing

A special 75 micron drop nozzle is available to allow Large Drop printing, as well as printing
from further distances with greater accuracy and print height. The 75 micron drop nozzle allows the
following;
 Up to 1”(25mm) throw distance for the drop.

 Print heights up to ¾”(19mm) tall.
 Bolder print without sacrificing line speed or print quality.
To use the Large Drop Printing nozzle, the drop generator must be replaced. BestCode will
install and calibrate with Large Drop nozzle if requested at time of order.
Use the Drop Generator replacement steps outline in “Section 10 > Printhead Service
Routines > Drop Generator Replacement” to remove the 62 micron drop generator and replace it
with the 75 micron drop generator. Modulation calibration information will be included with the
new drop generator. This should be tested for a 100V modulation window. Reference Section 10 >
Printhead Service Routines > Modulation Calibration”.
Some machines upgraded to 75 micron drop generators will need to tune the Venturi.
Notes:
Ink consumption rate will increase by 13% when using the Large Drop nozzle.
Consider this when determining annual fluid consumption values.
Firmware Version 01.02.29 or greater must be installed. This will allow activation of
“Printhead Configuration 2” in the Technician screen to allow Height 10 Print.

MANUAL – 40-0001-01
High Speed Printing

High speed printing is achieved in multiple methods. The speed charts for the Series 8 are
shown in maximum speed to produce characters with 50DPI. 50 DPI print produces a fully legible
character, and drops are not touching. For High Speed applications, these charts do not always
apply. Print can be spread out more, or may need to be very tight together. To help with achieving
this, the 88HS system and 88HS1 systems were developed.
The 88HS and 88HS1 and High Speed systems using the 65 micron nozzle. They produce and
print drops at speeds 20-30% faster than the model 88. Special modulation setup (detailed in this
manual) are required. Charge set values will vary from machine to machine, so a lengthy setup and
monitoring period for the machine is highly recommended to ensure the system will perform
continuously without error.
The next addition for high speed printing is the creation of narrow fonts, specifically for the
7 high font. The new 7*4 font is 20% smaller than the standard 7 high font. This does not allow
printed drops to be closer together, but it does allow more characters to fit in a small area. This is
crucial when printing on bottle necks, caps, and other small products. Additionally, the 7*4 font can
be used in the 2L7, 3L7, and 4L7 templates to produce shorter multi-line codes.
Traversing
BestCode Traversing Capabilities and 3rd Party Printhead Traversing System
Solution
Firmware Version Required: 1.02.24 or greater, enables Photocell 2, PE2

operation.
Fundamental Traversing Features

Application: Moving BestCode Series 8 printhead from left to right and then moving the
printhead from right to left allowing the print image to print in the correct
orientation.
Required: Series 8 systems, two BestCode photocells or inputs to trigger print/direction,
and other associated mounting and traverse mechanism for moving the
printhead.
Firmware: Use Series 8 firmware version 1.02.24 or greater.

Photocell: Install a photocell into PE1 (J14).
Install a photocell into PE2 (J17).
*Photocell inputs are located in the upper left corner of the CPU board.
 Create a New Message (simple test message).

 Go to Advanced Settings > AutoPrint

MANUAL – 40-0001-01
 Set Print Mode to “Reverse Print”.

o Set the Repeat and Pitch to 0.
Move the head or transport table beneath the printhead, and trigger the PhotoEye connected
to J14, PE 1. The print will print in the selected rotation for that message. (Normal, Mirror, Flip,
Mirror Flip).
Next, traverse the head in the opposite direction and trigger the PhotoEye connected to J17, PE
2. The print will print in the reverse of the selected rotation for the message. This will cause the
print to be in the desired readable format while the head moves in the opposite direction.
Next, set the Repeat to 3 and the Pitch to 1000.
Move the head or transport table beneath the printhead, and trigger the PhotoEye connected
to J14, PE 1. The print will print in the selected rotation for that message (Normal, Mirror, Flip,
Mirror Flip) 4 times, once from the trigger, then 3 more times repeated.
Next, traverse the head in the opposite direction and trigger the PhotoEye connected to J17, PE
2. The print will print in the reverse of the selected rotation for the message. This will cause the
print to be in the desired readable format while the head moves in the opposite direction. The
message will be printed 4 times, once from the trigger, and then 3 more times repeated.
Integrating an existing Traversing system
For most smart traversing systems, the only requirement is to correctly input the signals
from the Traversing system into the Series 8 CIJ.
Use the External Peripheral Schematics in Section 9 to properly integrate the Traversing
system signals into the Series 8 CIJ.
Most smart traversing systems will also determine print position. It will likely not be
required to use any delay value or a repeat value, even if print will be repeatedly printed in the
same travel direction. Understand your traversing system and determine if using Repeat Function
and Pitch values is the correct decision.
If pitch and repeat values must be used, remember that 1 pitch value is equal to 5 drops
count before printing the next message. This value is from the start of a message to the start of the
next message.
Use the following equation to determine the proper Pitch.
Pitch = (Distance * 13000) / Line Speed
For distance of 2 inches on 16 High Font at Fast Speed, moving 5in/s, the distance would
be

MANUAL – 40-0001-01
Pitch = (2inch* 13000) / 5in/s = 5200 for 2 inch distance between prints
* Calculation must be done using line speed in distance/s, not distance/min.
Use the repeat Value to determine the number of times to repeat the message in each
traversing direction.
Meter Marking Applications
Application: Meter marking is very common in wire, rope, tape, and extrusion applications.
Lengthy product is moving past the printhead at slow or high speeds. Message
prints should be accurately spaced.
Requirements: For most accurate results, the use of an encoder (internal or external) is
recommended. PhotoEye may be used, but typically is not required. For non-
encoder applications, line speed must be great than 12 in/min (5.7mm/s).
Firmware: Use Series 8 firmware version 1.02.24.

 Set Print Mode to “Auto Print”.
Set the pitch value to the desired distance of the meter mark.
Non-encoder applications
Pitch = (Distance * 13000) / Line Speed
For distance of 2 meters with the line moving 0.1 meter/s, the pitch would be
Pitch = (2 meters * 13000) / 0.1 meter/s = 260000 for 2 meters marking
Encoder applications
With a shaft encoder, the pitch is equal to shaft encoder pulses prior to Width divisions but
after pulse multiplication (setup >Encoder>Multiply). If a non-bestcode encoder is used, the
effective resolution must be determined.
Pitch = Meter Distance* Effective Resolution / Wheel Diameter

MANUAL – 40-0001-01
For distance of 2 meters, any Font size, any speed, using BestCode Default Encoder with
8x multiplication (6” (152.4mm) wheel) , the following would be calculated.
Pitch = (2 meters * 1800*8) / 0.152 = 189474 for 2 meters marking
Repeat Print (Pills Packs, etc)

Application: Repeat print is applications most common in for pill packaging applications. Pill
packs are attached to one another, so there is no gap for PhotoEye to detect
rising and falling edges.
Requirements: PhotoEye
Firmware: Use Series 8 firmware version 1.02.24.

 Set Print Mode to “Repeat Print”.
Non-Encoder Applications
Set the delay value to the desired distance of print position onto the 1st packet from the
trigger.
Use the following equation to determine the proper Delay.
Delay = (Distance * 13000) / Line Speed
For delay of 1/2 inches, moving 50in/s, the delay would be
Delay = (1/2inch* 13000) / 50in/s = 130 for 1/2 inch distance delay from trigger
Next, measure the distance from the start of the 1st print to the desired position of the next
print. This is used to calculate the Pitch.
Pitch = (Distance *13000) / Line Speed
For Pitch of 2inches moving 50in/s, the pitch would be
Delay = (2inch* 13000) / 50in/s = 520 for 2 inch distance pitch from previous print

MANUAL – 40-0001-01
Encoder Applications
With a shaft encoder, the pitch is equal to shaft encoder pulses prior to Width divisions but
after pulse multiplication(setup >Encoder>Multiply). If a non-bestcode encoder is used, the effective
resolution must be determined.
Use the following equation to determine the proper Delay.
Delay = Delay Distance* Encoder Resolution *Multiplier / Wheel Diameter
For delay of 1/2 inches on any font, any speed, moving 50in/s, Using the BestCode
Default Encoder and a Multiply value of 16, the delay would be;
Delay = 1/2inch* 1800 * 16 / 6 = 2400 for ½” delay distance from trigger
Next, measure the distance from the start of the 1st print to the desired position of the next print.
This is used to calculate the Pitch.
Pitch = Distance* Encoder Resolution *Multiplier / Wheel Diameter
For pitch of 2 inches on any font, any speed, moving 50in/s, Using the BestCode Default
Encoder, the pitch would be;
Delay = 2inch* 1800* 16 / 6 = 9600 for 2 inch distance pitch from previous print

MANUAL – 40-0001-01
Using Barcode Scanner to Select Messages
Barcode scanners can be used to Select Messages for printing based on a scanned product or label.
This is helpful for quickly selecting new message data for printing.
Option 1 – purchase scanner from BestCode – pre-programmed ready for use:
44-0120-01 Scanner, Message Select $1500.00
Message name must be defined as the Barcode being scanned.
Option 2 – purchase scanner locally and program locally:
Scanner specs –
RS232, 115Kbaud, 8 data bits, 1 stop bit.
Must be able to have a pre-amble programmed and post-amble programmed.
Pre-amble program: ^SM
Post-amble program: <CR>
Command Explanation:
^SM – Select Message
This command provides a means of selecting a message on a BestCode device. Therefore, the
message must exist on the device before selection can be made.
^SM messageName
Select the provided “messageName” for printing.
If the “messageName” scanned in by the barcode scanner matches a message name on the Series 8
CIJ, it will be selected and ready for printing immediately.

MANUAL – 40-0001-01
Common Questions
Common Questions

MANUAL – 40-0001-01
Common Questions
How long does my filter last?
Signs of Filter Due for Change:
- Phase Failure
- Messy Starts/Stops due to restricted flow.
- Increased RPS values, but not always will be the case.
- Pressure Failure, Pump Pressure did not detect any change fault.
- On Screen SmartFilter™ Prompt will appear
See Maintenance “Maintenance Intervals”
How do I fix bad Start/Stops?
A number of issues can cause bad Starts and Stops. Solutions to these issues can be found by
reading the sections in the links below.
See Troubleshooting ”Jet” and Troubleshooting “Gutter”
What is the correct way to remove and clean the nozzle?
BestCode has recently updated the correct process for Removing and Cleaning the Nozzle.
Please read the sections in the link below.
See “Changing or Cleaning Nozzle”
Why do I constantly have to re-align the Jet?
Constant Jet re-alignment is NOT normal. The jet only needs to be moved when there is a nozzle or
drop generator replacement. Please read the sections in the link below to help diagnose the
problem causing re-alignment.
See “Jet is moving/flickering inside the gutter”

MANUAL – 40-0001-01
Common Questions
When Should I Use a Positive Air Kit
 If machine is in poorly controlled environment (Factory open to yearly weather)
 Freezer rooms
 High Steam areas or areas that are steam washed
 Dusty and Dirty environments
More information on Positive Air kits are available here “Positive Air Kits”

MANUAL – 40-0001-01
Ink Data Sheets
Ink Data Sheets
BESTCODE SERIES 8 399 Jan 2017

MANUAL – 40-0001-01
Ink Data Sheets
51-0001-01 Ink, MEK Black
Description:
MEK Black “General Purpose” Ink is a dark black dye based ink for use in Series 8 printing systems. This ink is a fast
drying, MEK based ink designed for excellent adhesion to a wide range of substrates including glass, metals and plastics.
Benefits:
Ink is dry to the touch in 1-2 seconds and is rub resistant in 1-2 minutes depending on the substrate and environment
conditions.
For use in:
82, 86, 88 Systems.
Dry Time and Other Information:
Drying time is within 1-2 seconds depending on humidity, printing on cold surfaces or wet environments will slow dry
times. The ink has excellent abrasion resistance.
Associated Fluids:
Makeup - 52-0001-01 Makeup, MEK
Cleaner - 50-0001-01 Cleaner, MEK
Storage and Shelf Life:
Best use before/expiration date: 12 months from date of manufacture
Batch number and Expiry date clearly marked on label.
Optimum storage between 40°F - 90°F (4°C-32°C)

MANUAL – 40-0001-01
Ink Data Sheets
51-0002-01 Ink, MEK Red Soft Pigment
Description:
A red pigmented ink for use in standard Series 8 printers. No stirring or agitation is required during operation of the
printer. Contains red pigment dispersion which prevents migration of the ink, resists transfer on PVC, UV and heat
damage resistance. Red pigment provides a red code on light and dark colored surfaces without requiring a pigmented
printer. Methyl Ethyl Ketone (MEK) based ink.
Applications:
 PVC jacketing (hot or cold)
 Rigid or flexible
 Metal
 Packaging
 Coated and uncoated paper
 Films
For use in:
82, 86, 88 Systems.
Drying time is typically less than 2 seconds depending on humidity, printing on cold surfaces or wet environments will
slow dry times up to 4 seconds.
Associated Fluids:
Cleaner- 50-0001-01 Cleaner, MEK

MANUAL – 40-0001-01
Ink Data Sheets
51-0003-01 Ink, MEK Blue Soft Pigment
Description:
The Blue Soft Pigment Ink is for use in standard Series 8 printing systems. No stirring or agitation is required to operate
this ink in a Series 8 printer as the pigment is a polymer, soft pigment. The Blue pigment dispersion prevents migration
of the ink, resists transfer on PVC, is light fast (UV resistant), and resists damage by heat. Blue pigment provides a Blue
code on light and dark colored surfaces without requiring a pigmented printer. Methyl Ethyl Ketone (MEK) based ink.
Applications:
 Metal
 Packaging
 Films
For use in:
Models 82, 86, 88.
Associated Fluids:

MANUAL – 40-0001-01
Ink Data Sheets
51-0004-01 Ink, MEK Green Soft Pigment
Description:
The Green Soft Pigment Ink is for use in standard Series 8 printing systems. No stirring or agitation is required to operate
this ink in a Series 8 printer as the pigment is a polymer, soft pigment. The Green pigment dispersion prevents migration
of the ink, resists transfer on PVC, is light fast (UV resistant), and resists damage by heat. Green pigment provides a
Green code on light and dark colored surfaces without requiring a pigmented printer. Methyl Ethyl Ketone (MEK) based
ink.
Applications:
 Metal
 Packaging
 Films
For use in:
Models 82, 86, 88.
Associated Fluids:

MANUAL – 40-0001-01
Ink Data Sheets
51-0005-01 Ink, MEK Yellow Soft Pigment
Description:
The Yellow Soft Pigment Ink is for use in standard Series 8 printing systems. No stirring or agitation is required to
operate this ink in a Series 8 printer as the pigment is a polymer, soft pigment. The yellow pigment dispersion prevents
migration of the ink, resists transfer on PVC, is light fast (UV resistant), and resists damage by heat. Yellow pigment
provides a yellow code on light and dark colored surfaces without requiring a pigmented printer. Methyl Ethyl Ketone
(MEK) based ink.
Applications:
 Metal
 Packaging
 Films
For use in:
Models 82, 86, 88.
Associated Fluids:

MANUAL – 40-0001-01
Ink Data Sheets
51-0006-01 Ink, Acetone White Opaque
Description:
Acetone White Pigment Ink is a white heavy pigment ink for use in Series 8 88SOP systems. Contains white pigment
dispersion: prevents migration of the ink, resists transfer on PVC, light fast, resists damage by heat. The pigment
provides a super bright code on dark colored surfaces. Designed specifically for the wire and cable applications. HAPS
Free (Hazardous Air Pollutant Free).
Applications:
 Films
 Metal
 Packaging
 Formed and vulcanized rubber parts.
 Faster drying times than MEK based inks.
For use in:
88SOP Systems
Shake Well - before using.
Drying time is typically less than 1 second depending on humidity, printing on cold surfaces or wet environments will
Associated Fluids:
Solvent - 52-0001-01 Solvent, MEK
Cleaner- 50-0001-01 Cleaning, MEK

MANUAL – 40-0001-01
Ink Data Sheets
51-0007-01 Ink, MEK Flex Plus Black
Description:
MEK Flex Plus Black Ink is a dark black dye based ink for use in Series 8 CIJ printing systems. This ink is a fast drying, MEK
based ink designed specifically to print on plastic substrates, such as HDPE, LDPE, Polyethylene and Polypropylene as
well as glass and metals. This ink is designed for sterilization applications.
Applications:
Sterilization capabilities – survives retort processes, being subjected to water bath at 120C for 40 minutes with no color
change. Fast dry ink with excellent adhesion to plastics, specifically:
 Polyethylene
 Polypropylene (TetraPak)
 Low Density Polyethylene (LDPE)
 High Density Polyethylene (HDPE)
 Bi-axially oriented Polypropylene (BOPP)
 Oriented Polypropylene (OPP).
Other substrates include glass, metals and coated paper stock. Excellent adhesion to coated plastic cards used in the
telecommunications and credit card industry. Ink is capable to penetrate a thin layer of oil and achieving sufficient
adhesion as long as not subject to hard abrasion. This ink will survive retort processes.
For use in:
82, 86, 88 Systems.
Associated Fluids:
Makeup - 52-0007-01 Makeup, MEK Flex

MANUAL – 40-0001-01
Ink Data Sheets
51-0010-01 Ink, Invisible UV
Description:
The Invisible UV Ink is an invisible ink that fluoresces when exposed to UV light. The ink is a dye based, Methyl Ethyl
Ketone (MEK) ink, for use in security applications where codes should be readable but not visible.
Applications:
 Ink fluoresces when exposed to UV light
 Fast dry within 1-3 seconds on most substrates
 Rub resistant within 1-2 minutes
 Survives retort process without discoloration
For use in:
82, 86, 88 Models
Associated Fluids:
Makeup - 51-0010-01 Makeup, Invisible UV

MANUAL – 40-0001-01
Ink Data Sheets
51-0011-01 Ink, Acetone Black
Description:
Acetone Black “General Purpose” Ink is a dark black dye based ink for use in Series 8 printing systems. This ink is a fast
drying, Acetone based ink designed for excellent adhesion to a wide range of substrates including glass, metals and
plastics. It is recommended or general purpose coding when the customer is concerned about VOC (volatile organic
compounds).
Benefits:
conditions. Solvents are exempt from VOC reports.
For use in:
82, 86, 88 Systems.
times.
Associated Fluids:
Makeup - 52-0002-01 Makeup, Acetone
Cleaner - 50-0002-01 Cleaner, Acetone

MANUAL – 40-0001-01
Ink Data Sheets
51-0012-01 Ink, Ethanol Black
Description:
Ethanol Black “General Purpose” Ink is a dark black dye based ink for use in Series 8 printing systems. This ink is an
Ethanol based ink designed for excellent adhesion to a wide range of substrates including glass, metals and plastics. It is
recommended for general purpose coding when the customer is concerned about evaporation or MEK scent.
Benefits:
conditions.
For use in:
82, 86, 88 Systems.
times.
Associated Fluids:
Makeup - 52-0012-01 Makeup, Ethanol Black

MANUAL – 40-0001-01
Ink Data Sheets
51-0013-01 Ink, Acetone/Ethanol Black
Description:
Acetone/Ethanol Black “General Purpose” Ink is a dark black dye based ink for use in Series 8 printing systems. This ink is a fast
drying, Acetone/Ethanol based ink designed for excellent adhesion to a wide range of substrates including glass, metals and
plastics. Nearly equivalent to MEK Provides a good performance on a very wide range of substrates, with a print quality and
drying time nearly equivalent to that of MEK based inks on many materials.
Benefits:
conditions. Use for both porous and non-porous applications.
HAPS (Hazardous Air Pollution) Free Ink. MEK Free-Low odor.
For use in:
82, 86, 88 Systems.
times.
Associated Fluids:
Makeup - 52-0027-01 Makeup, Acetone/Ethanol

MANUAL – 40-0001-01
Ink Data Sheets
51-0014-01 Ink, MEK Glass Bottle Black
Description:
Black Glass Bottle Ink is a dark black dye based ink for use in Series 8 CIJ printing systems. This ink produces crisp black
codes that adhere to the surface of glass and wet glass bottles. Methyl Ethyl Ketone (MEK) based ink.
Applications:
Print returnable or non-returnable glass bottles with expiration and manufacturing information. Printed codes survive
pasteurization and exposure to condensation on cool bottles.
Additionally, adheres well to:
 PET, metal, a wide variety of plastics.

 Produce crisp durable codes on many types of polypropylene packaging
 Excellent adhesion to Nylon 6.
Caustic removable with most common additives - 2% caustic for 2 minutes typically removes codes.
For use in:
82, 86, 88 Models.
slow dry times.
Associated Fluids:
Makeup - 52-0014-01 Makeup, MEK Glass Bottle Black

MANUAL – 40-0001-01
Ink Data Sheets
51-0015-01 Ink, Red Food Grade

Description:
Red Food Grade Ink is specifically designed printing direct to food products and egg shells. The ink and makeup are USDA
approved and registered, Kosher certified and uses only FDA approved ingredients for direct contact with Food,
compliant as a food additive.
- High temperature water bath, steam resistant codes.

- Self-disinfecting formulation.
Applications:
Print lot / date / identifying marks direct to food products.
Information:
Color: Red Base: Alcohol

Application: Direct marking to food products and egg shells. Approval: USDA
Certified: Kosher Kosher Status: Pareve, non-Passover
Kosher Logo: KLBD Registered: USDA
Compliant: FDA
For use in:
88S Food Grade Systems
Drying time is typically 7-10 seconds on non-porous food products and immediate on porous food products.
Associated Fluids:
Makeup - 52-0015-01 Solvent Food Red

MANUAL – 40-0001-01
Ink Data Sheets
51-0020-01 Ink, MEK Black Pigment
Description:
MEK Black soft pigmented ink is a carbon black which prevents migration of the ink, resists transfer on PVC, light fast, UV
(sun) light resistant, resists damage by heat, IR readable to aid in bar code applications. Methyl Ethyl Ketone (MEK)
based ink.
Applications:
 PVC jacketing (hot or cold) Rigid or Flexible
 Resists fading by UV (sun) light
 Packaging Films
 Metal
 Dry glass
 Coated & uncoated paper
Other substrates include glass, metals and coated paper stock.
For use in:
82, 86, 88 Models.
Associated Fluids:

MANUAL – 40-0001-01
Ink Data Sheets
51-0021-01 Ink, UV Red High Visible
Description:
The UV Red is a highly visible red ink that fluoresces when exposed to UV light. The ink is dye based and is visible on dark
colored substrates, allowing the marks/ codes to be more visible than regular dye based inks in dark colored substrates-
glass, metal, and plastics. Methyl Ethyl Ketone (MEK) based ink.
Applications:
 Ink fluoresces when exposed to UV light
 Fast dry within 1-3 seconds on most substrates
 Rub resistant within 1-2 minutes
For use in:
82, 86, 88 Models
Associated Fluids:
Makeup - 51-0021-01 Makeup, UV Red High Visible

MANUAL – 40-0001-01
Ink Data Sheets
51-0022-01 Ink, Black to Blue
Description:
Black to Blue Ink is purposed for printing metal cans, plastic pouches before a retort or sterilization process. The mark or
code withstands the high temperature process and changes color from Black to Blue to indicate the retort or sterilization
process has been completed.
Applications:
Print directly to cans and plastics pouches before retort / sterilization process and have indication that the product has
gone through the process.
• Change from Black to Blue Color with steam (at ~185F).

• Ink withstands the high temperature retort / sterilization process.
• Fast dry within 1-2 seconds on most substrates.
• Rub resistant within 1-2 minutes.
The ink is also well suited for general purpose marking and coding applications.
For use in:
Model 82, 86, 88 Systems.
Associated Fluids:
Makeup - 52-0022-01 Makeup, Black to Blue

MANUAL – 40-0001-01
Ink Data Sheets
51-0023-01 Yellow Glass Bottling Ink
Description:
Yellow Glass Bottling Ink is specifically designed for coding returnable bottles during the cold fill process. The ink is a soft
pigment ink for operating in standard Series 8 systems. The ink is capable to penetrate a thin layer of condensation that
occurs when the bottle is filled with fluids/beverages at temperatures in the range of 30-40F (0-10C). The ink is caustic
washable when bottles a returned. This ink produces crisp yellow codes that adhere to the surface of glass and wet glass
bottles and will resist ice immersion.
Applications:
Print returnable or non-returnable glass bottles with expiration and manufacturing information. Printed codes survive
pasteurization and exposure to condensation on cool bottles.
 Superior adhesion to cold-filled glass bottles with a very thin layer of condensation.
 A cure time of one hour is required to resist the ice immersion soak test for up to 24 hours. This ink passes the
ice immersion test.
 Caustic removable with most common additives.
 Excellent adhesion to glass, plastics, most metals, and coated paper
 Also adheres well to PET, metal, a wide variety of plastics.
For use in:
Associated Fluids:
Solvent - 52-0023-01 Solvent, Yellow Glass Bottling
Cleaner - 50-0001-01 Cleaning, MEK

MANUAL – 40-0001-01
Ink Data Sheets
51-0024-01 Ink, MEK White Opaque
Description:
MEK White Pigment Ink is a white heavy pigment ink for use in Series 8 88SOP systems. Contains white pigment
dispersion: prevents migration of the ink, resists transfer on PVC, light fast, resists damage by heat. The pigment
provides a super bright code on dark colored surfaces. Designed specifically for the wire and cable applications.
Applications:
 Films
 Metal
 Packaging
 Formed and vulcanized rubber parts.
For use in:
88SOP Systems
Associated Fluids:
Solvent - 52-0001-01 Solvent, MEK
Cleaner- 50-0001-01 Cleaning, MEK

MANUAL – 40-0001-01
Ink Data Sheets
51-0025-01 Ink, MEK Light Blue Opaque
Description:
MEK Light Blue Pigment Ink is a light blue heavy pigment ink for use in 88S Heavy Pigment systems. Contains a
combination of white and blue pigment dispersions: prevents migration of the ink, resists transfer on PVC, light fast,
resists damage by heat. The pigment provides a light blue code on light and dark colored surfaces.
Applications:
 Films
 Metal
 Packaging
 Formed and Vulcanized rubber parts.
For use in:
88SOP Systems
Associated Fluids:

MANUAL – 40-0001-01
Ink Data Sheets
51-0026-01 Ink, Acetone/Ethanol Super Flex Black
Description:
Acetone based Super Flex Ink is a low VOC fast drying black ink ideally suited for most plastics such as Polyethylene,
Polypropylene, LDPE and HDPE as well as glass and metals.
Applications:
Fast dry ink with excellent adhesion to plastics, specifically Polyethylene, Polypropylene (TetraPak), Low Density
Polyethylene (LDPE) and High Density Polyethylene (HDPE), Bi-axially oriented Polypropylene (BOPP) and Oriented
Polypropylene (OPP). Other substrates include glass, metals and coated paper stock. Excellent adhesion also on coated
plastic cards used in telecommunications and credit card industry. This is a low VOC (Volatile Organic Compound) ink.
 Excellent adhesion on plastics, metal and glass

 Excellent abrasion resistance
 Very fast drying – 1 -2 seconds depending on the substrates and environment
 It is a low VOC ink.
For use in:
82, 86, 88 Models.
Drying time is within 1-2 seconds depending on humidity, printing on cold surfaces. The ink has excellent abrasion
resistance.
Associated Fluids:
Makeup - 52-0026-01 Makeup, Acetone/Ethanol Super Flex

MANUAL – 40-0001-01
Ink Data Sheets
51-0027-01 Ink, MEK Flex Black

Description:
MEK Flex Black Ink is designed to print on Plastic/Flexible substrates and Tetra Paks. The ink performs
exceptionally well for cold-fill applications due to its fast-dry feature, capable to penetrate a thin layer of
condensation, with excellent adhesion characteristics.
Applications:
Fast dry ink with excellent adhesion to plastics:
 Polyethylene and Polypropylene (TetraPak)
 Low Density Polyethylene (LDPE) and High Density Polyethylene (HDPE)
 Bi-axially oriented Polypropylene (BOPP) and Oriented Polypropylene (OPP).
 Print plastic, tetra paks, metal, glass (returnable and non-returnable), coated paper stock, PET bottles,
Polyolefin caps.
 Penetrates thin layer of condensation, fast dry (1-2 seconds); excellent adhesion.
 Penetrates and adheres to waxy and greasy substrates as materials used the juice and dairy industries.
 Excellent penetration and adhesion to waxy and greasy substrates such as packaging used in the dairy
industry and juice products
 Provides excellent resistance to condensation that can occur during the refrigeration process.
 Excellent adhesion to treated and untreated polyethylene and polypropylene.
For use in:
82, 86, 88 Models
resistance.
Associated Fluids:
Makeup - 52-0007-01 Makeup, MEK Flex

MANUAL – 40-0001-01
Ink Data Sheets
51-0028-01 Ink, MEK Orange Soft Pigment
Description:
The Orange Soft Pigment Ink is for use in standard Series 8 printing systems. No stirring or agitation is required to
operate this ink in a Series 8 printer as the pigment is a polymer, soft pigment. The Orange pigment dispersion prevents
migration of the ink, resists transfer on PVC, is light fast (UV resistant), and resists damage by heat. Orange pigment
provides a Orange code on light and dark colored surfaces without requiring a pigmented printer. Methyl Ethyl Ketone
(MEK) based ink.
Applications:
 Metal
 Packaging
 Films
For use in:
Models 82, 86, 88.
Associated Fluids:

MANUAL – 40-0001-01
Ink Data Sheets
51-0029-01 Ink, Black to Red
Description:
Black to Red Ink is purposed for printing metal cans, plastic pouches before a retort or sterilization process. The mark or
code withstands the high temperature process and changes color from Black to Red to indicate the retort or sterilization
process has been completed.
Applications:
Print directly to cans and plastics pouches before retort / sterilization process and have indication that the product has
gone through the process.
• Change from Black to Red Color with steam (at ~185F).

• Ink withstands the high temperature retort / sterilization process.
• Fast dry within 1-2 seconds on most substrates.
• Rub resistant within 1-2 minutes.
The ink is also well suited for general purpose marking and coding applications.
For use in:
Associated Fluids:
Makeup - 52-0029-01 Makeup, Black to Red

MANUAL – 40-0001-01
Ink Data Sheets
51-0031-01 MEK Washable Ink
Description:
MEK Water Washable Black Ink offers excellent adhesion to a wide range of substrates, including glass, metal,
and plastic. This ink will be touch dry in 1-2 seconds and will be rub resistant in 1 minute depending on the
substrate and environmental conditions. This ink can be washed off with tap water.
Applications:
• Water washable ink is a fast drying ink with 1-2 second dry time on most substrates.
• The ink can be washed off with tap water.
For use in:
82, 86, 88 Systems.
resistance.
Associated Fluids:
Solvent - 52-0031-01 Makeup Solvent, Alcohol Resistant
Cleaner - 50-0001-01 Cleaning, MEK

MANUAL – 40-0001-01
Ink Data Sheets
51-0032-01 Ink, Alcohol Resistant Black
Description:
Alcohol Resistant black ink is a fast drying black, ketone based product, exhibiting superior alcohol rub resistance and
adhesion on a wide range of plastic, metal and glass substrates. This ink will be the ink of choice for applications where
containers are filled with an alcohol-based product, or cleaned with either isopropyl alcohol, or certain types of
denatured ethanol.
Applications:
 Superior alcohol rub resistance; this ink is also resistant to most ethanol based products.
 Pharmaceutical, cosmetic, wine and spirits bottling, wire, and cable.
 This ink has enhanced chemical resistance to soaps, alkali and lubricants. The ink is UV resistant and
abrasion resistant.
For use in:
Associated Fluids:
Makeup - 52-0022-01 Makeup, Black to Blue

MANUAL – 40-0001-01
Ink Data Sheets

MANUAL – 40-0001-01
Appendix and BestCode Forms
Print Samples Request Form
Company Details:
Company Name Name of Contact
Return Shipping Address
Sample Information:
Item Number* Item Description
Line Speed Temperature at print Print Color
Material Maximum Print Length
Other Info:
Message Details: **
PASTE IMAGE OF MESSAGE HERE
ATTACH .MSG BACKUP FILE IF POSSIBLE
ATTACH PRINTED GRAPHIC IN SAME EMAIL AS THIS REQUEST

*Please Label each sample if multiples are sent.
**Unless all messages are the same, each sample must have its own Print Sample Request Form.
BestCode CIJ Maintenance Check-List
Customer: ___________________________________________________
Technician: ___________________________________________________
Date: ___________________________________________________
Serial Number: ___________________________________________________
INK FILTER MAINTENANCE LIST
Model: 82 86 88 88S
Filter Type Installed: 2000 Hour 5000 Hour 10000 Hour
Next Ink Maintenance Date: ______________________________________________
AIR FILTER SYSTEM MAINTENANCE LIST
Model: 82 86 88 88S
Filter Type Installed: IP 55 - 82/86 IP 65 - 88 & 88S
Next Electronic Maintenance Date (Est. 12 months): ______________________________________________

System Installation Checklist
Controller Mounting
__________ Place Controller on level surface
__________ Install power cable Printhead Mounting
__________ Install the printhead clamp

__________ Attach printhead to printhead mounting bracket
Fluid System Commissioning

___________ Check the solvent and ink status (Both status should read low)
___________ Set ink type (Login with Technician > Service > Tools > Technician > Commission Ink Type)***
___________ Commission 1 bottle of ink
___________ Commission 2 bottles of makeup
___________ Test the Printhead Valve in the Fluid Screen
___________ Test the Flush Valve in the Fluid Screen
___________ Test the Add Solvent Valve in the Fluid Screen
___________ Test the Gutter Valve in the Fluid Screen
___________ Test the Tank Solvent Valve in the Fluid Screen
___________ Test the Viscometer Valve in the Fluid Screen
___________ Test the Bleed Valve in the Fluid Screen
___________ Test Pump in the Fluid Screen (no more than 15 RPS)
___________ Prime the Ink Lines (Pump 15 RPS, Valves 1,4 and 7) 1 minute
___________ Prime the Solvent Lines (Pump 15 RPS, Valves 3,5 and 6) 1 minute
___________ Prime the Flush Line (Pump 15 RPS, Valves 2 and 4) 1 minute
___________ Exit Fluidic Screen and Start the Jet Normally
___________ Calibrate Modulation when Viscosity reaches 4.5cP
Final Checks before Completion of Fluidics

__________ Check for any leaks in fluidic compartment
__________ Check drop break-up
__________ Test print using “BestCode” default message. Keep for records.
Page 1 of 2
System Installation Checklist (Cont)
Line Setup
___________ Assemble and Install Printhead Mounting kit
___________ Position the controller on approved cart or mounting system.
___________ Install Printhead onto the Line
___________ Configure Message and Adjust Settings to customer requirements
___________ Install Peripheral devices (Alarms, PhotoEye, Shaft Encoder, Etc)
___________ Monitor the system for 1-2 hours to ensure good print quality and modulation set point.
___________ Test the modulation value once again 50V above and 50V below the set point.
Customer Training
__________ Customer has created their own message correctly (Correct Font in Correct Template)
__________ Customer has adjusted message to provide good print on their product.
_________ Customer has been trained to create and manage passwords for end users.
__________ Customer has been provided cleaning tools for the Printhead
__________ Customer has been trained to clean the printhead and perform backflush.
__________ Customer is able to backup and restore messages from USB
Page 2 of 2
End User Training Guide
SAFETY MEASURES TO FOLLOW
PERSONAL INJURY: ALWAYS WEAR RUBBER GLOVES AND SAFETY GLASSES WHEN
HANDLING INKS AND SOLVENTS.
PERSONAL INJURY: ALWAYS WEAR RUBBER GLOVES AND SAFETY GLASSES DURING
FLUIDIC MAINTENANCE.
PERSONAL INJURY: DO NOT USE SOLVENT TO WASH INK FROM SKIN. IF EXPOSED,
GENTLY RINSE AREA WITH SOAPY WATER. IF IRRITATION PERSISTS, SEEK MEDICAL
ATTENTION.
FIRE HAZARD: INKS AND SOLVENTS ARE HIGHLY FLAMMABLE. NO SMOKING OR OPEN
FLAMES NEAR PRINTER OR FLUID STORAGE.

DOOR IS OPEN.
EQUIPMENT DAMAGE: THE PRINTHEAD MUST BE DRY BEFORE STARTING PRINTER.
EQUIPMENT DAMAGE: THE PRINTHEAD SHOULD NEVER BE COMPLETELY
SUBMERGED IN SOLVENT.
Page 1 of 9
SAFELY POWERING ON/OFF YOUR SYSTEM
EQUIPMENT DAMAGE: THE SERIES 8 CIJ REQUIRES A
DEDICATED GROUND. FAILURE TO PROVIDE ADEQUATE GROUNDING CAN RESULT IN

DAMAGE TO THE DEVICE AND MAY POTENTIALLY INJURE OPERATORS.
EQUIPMENT DAMAGE: THE SERIES 8 CIJ IS NOT TESTED WITH THE USE OF POWER
CABLE EXTENSIONS OR ANY OTHER CABLE THAN THE ONE PROVIDED. USE OF
ALTERNATIVE CABLES OR EXTENSION CORDS WILL VOID YOUR WARRANTY.
Power On
 Touch and hold blank screen
Power Off
 Press
Page 2 of 9
ADDING FLUIDS TO YOUR SYSTEM (HOW AND WHEN)
EQUIPMENT DAMAGE: DO NOT ADD FLUIDS UNLESS
INSTRUCTED BY INDICATORS. ADDING FLUIDS BEFORE INSTRUCTED WILL CAUSE

OVERFLOW OF THE TANKS AND THE FLUID WILL BE PERMANENTLY LOST.
Consumable and Delivery
Tank Capacity
Ink: 1.7 Liters
Solvent: 2.7 Liters
Bottle Size
Ink Bottle
Solvent Bottle
Page 3 of 9
HOW TO CREATE MESSAGES CORRECTLY
Template must match with the overall font height in the message editor. If it does not,
print quality and speed will suffer.
For multi-line messages, use the multi-line templates to give best speed and print quality.
Page 4 of 9
STARTING AND STOPPING THE JET
Starting/Stopping Jet.
Starting the Jet – Aproximately 75 Seconds
1. Touch “Start” to Start Jet

2. Icon changes to “Starting” while the jet is starting
3. Icon Changes to “Ready” when the printer is ready to print
Stopping the Jet - Aproximately 5 mnutes
1. Touch “Stop” to Stop Jet

1. Icon Changes to “Stopping” while the jet is stopping
2. Icon changes to “Stopped” when the jet is stopped
Machine will automatically clean on stops and starts if more than 1 hour has elapsed since the last start or stop.
Page 5 of 9
HOW TO ADJUST PRINT LENGTH, HEIGHT, AND ROTATION
 These features are duplicates of adjust settings in Message Editor.
 Adjust settings are message dependent.
 Adjustments can be made while the jet is running.
Adjustments are automatically updated to quickly allow message setup.
Page 6 of 9
MANUAL CLEANING OF THE PRINTHEAD (HOW AND WHEN)
Greatly depends on environment. Very dirty environment will require daily cleaning of the printhead.
For all others, clean only when instructed by the machine (Alert on Screen).
How to BackFlush the Nozzle
 Press the Back Flush Nozzle button
 Rinse nozzle with solvent for 15

seconds.
 This cleaning should always be
performed before making the

decision to remove the nozzle.
Page 7 of 9
Other Features to Discuss
 Password Creation
 Correct orientation of the printhead
 Status screen (Displays time to next service/Filter Replacement)
 How to copy messages to another machine
 If using Heavy Pigment inks, explain need to shake ink bottles for 2 minutes before installing.
 Customer Specific Items for successful printing
o Shaft Encoder positioning
o Correct angle for best print (tilted down for side coding, etc)
What not to do
 Do not give end user the Technician Password

 Do not give end user the Technician Manual
 Do not train end user to adjust or remove the nozzle.
Page 8 of 9

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Bestcode Next Series 8:: Technical Manual

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BestCode Next Series 8:

BESTCODE NEXT SERIES 8 1 Jan 2017

Next Series 8 CIJ Technical Manual

Volume 1.13, January, 2017

For Replacement Guides:

CIJ Technical Manual: 41-0001-01

CIJ Operator’s Guide: 41-0002-01

Copyright BestCode 2011-2017

BESTCODE NEXT SERIES 8 3 Jan 2017

How to use this manual

will automatically jump to that page.

Distributors may contact info@bestcode.co for Technician Level Password.

BESTCODE NEXT SERIES 8 4 Jan 2017

BESTCODE NEXT SERIES 8 5 Jan 2017

BESTCODE NEXT SERIES 8 6 Jan 2017

BESTCODE NEXT SERIES 8 7 Jan 2017

BESTCODE NEXT SERIES 8 8 Jan 2017

Two (2) Year Warranty

BestCode warrants the equipment conforms to BestCode’s published specifications and is

THE FOREGOING WARRANTIES ARE IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR

BESTCODE NEXT SERIES 8 9 Jan 2017

What is not covered by this warranty?

BESTCODE NEXT SERIES 8 10 Jan 2017

BESTCODE NEXT SERIES 8 11 Jan 2017

BESTCODE NEXT SERIES 8 12 Jan 2017

BESTCODE NEXT SERIES 8 13 Jan 2017

BESTCODE NEXT SERIES 8 14 Jan 2017

BESTCODE NEXT SERIES 8 15 Jan 2017

BESTCODE NEXT SERIES 8 16 Jan 2017

BestCode Next Series 8 System

Model 82 86,87 88 88HS & 88S 88SOP

Screen 10.4” LCD with Touch Screen

Power 100-240Vac @ 120V, 60hz – 45V Amps (.45 watts

Machine Interface RS232, Ethernet

Enclosure Stainless Steel Enclosure

Air Filter MERV 8 MERV 13

Inks MEK, Ethanol, Acetone, Blend, Food MEK White, Acetone

BESTCODE NEXT SERIES 8 17 Jan 2017

Speed Ink Filter Air Filter

Print Formatting / Model Numbers

BESTCODE NEXT SERIES 8 18 Jan 2017

PERSONAL INJURY: ALWAYS WEAR RUBBER GLOVES AND SAFETY

PERSONAL INJURY: ALWAYS WEAR RUBBER GLOVES AND SAFETY

PERSONAL INJURY: INKS AND SOLVENTS ARE POISONOUS, DO NOT

PERSONAL INJURY: DO NOT USE SOLVENT TO WASH INK FROM SKIN.

BESTCODE NEXT SERIES 8 19 Jan 2017

EQUIPMENT DAMAGE: DO NOT ADD FLUIDS UNLESS INSTRUCTED BY

EQUIPMENT DAMAGE: THE PRINTHEAD MUST BE DRY BEFORE

EQUIPMENT DAMAGE: THE PRINTHEAD SHOULD NEVER BE

COMPLETELY SUBMERGED IN SOLVENT.

EQUIPMENT DAMAGE: DO NOT ATTEMPT TO USE MULTIMETER TO

TAKE MEASUREMENTS ON ANY COMPONENT WHILE THE MACHINE IS

EQUIPMENT DAMAGE: DO USE MULTIMETER TO ATTEMPT TO

FIRE HAZARD: INKS AND SOLVENTS ARE HIGHLY FLAMMABLE. NO

ELECTRICAL SHOCK: DISCONNECT MAIN POWER CABLE PRIOR TO

ELECTRICAL SHOCK: NEVER RUN MACHINE WHILE ELECTRONICS

COMPARTMENT DOOR IS OPEN.

BESTCODE NEXT SERIES 8 20 Jan 2017

BESTCODE NEXT SERIES 8 21 Jan 2017

System Overview and Detailed

BESTCODE NEXT SERIES 8 22 Jan 2017

Item Number Description Part Number

BESTCODE NEXT SERIES 8 23 Jan 2017