8900 MM en Iss1 Ebook

8900
Linx
Maintenance Manual
8900_MMCover_EN_Iss1.PMD 1 28/05/2015, 15:46

8900
Continuous Ink Jet
Printer
MAINTENANCE
MANUAL
FA48008
Linx 8900 Maintenance Manual i Jun 2015
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FA48008
Jun 2015 (ii) Linx 8900 Maintenance Manual
Amendment record
Each page of this publication bears the date of initial issue. Subsequent amendments to this
publication will bear the amendment number and its date of issue.
Amendments should be incorporated in strict numerical order so that the technical integrity
and accuracy of the publication are retained.
Incorporation of amendments should be recorded on the Amendment Record below.
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Linx 8900 Maintenance Manual (iii) Jun 2015
FA48008
Jun 2015 (iv) Linx 8900 Maintenance Manual
Copyright
No part of this publication may be reproduced, transmitted, transcribed, stored in a
retrieval system, or translated into any human or computer language by any means or in
any form, without the express prior written permission of Linx Printing Technologies Ltd.
Neither whole nor part of the product described in this manual may be adapted or
reproduced in any material form without the express prior written permission of Linx
Printing Technologies Ltd.
Contravention of copyright may also reduce the ability of Linx Printing Technologies Ltd to
provide effective support for its equipment.
This First edition published 2015
© Linx Printing Technologies Ltd 2015
LINX and Easi-Change are registered trademarks of Linx Printing Technologies Ltd.
PIC is a registered trademark of Microchip Technology.
Manual content
The content of this manual is provided for information only. Nothing in the content of this
manual represents, or should be construed as, any contractual or other commitment on the
part of Linx Printing Technologies Ltd.
Linx products are subject to continual development and improvement, and updates to the
content of this manual will be made accordingly in the form of amendments.
Linx reserves the right to make changes without notice to both this publication and to the
products described herein.
All possible care has been taken in the preparation of this manual, and information of a
technical nature and particulars of the product and its use are given by Linx in good faith.
However, Linx makes no guarantees regarding the accuracy or completeness of this
publication.
Safety recommendation
Before attempting to use either the printer or its accessories, the information contained in
the ‘Safety’ chapter should be read. It is essential that safe operating procedures are
followed at all times, and that the equipment is maintained according to the directions
contained herein and as recommended by Linx or its authorized Distributors. It is strongly
recommended that maintenance tasks described in this manual are performed only by Linx
maintenance technicians or Linx-trained personnel.
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Linx 8900 Maintenance Manual (v) Jun 2015
About this manual
The purpose of this manual is to provide maintenance technicians with sufficient
information to safely and effectively carry out maintenance tasks on the Linx 8900
Continuous Ink Jet Printer.
The information contained in this manual is applicable to Version 1.0 System Software
unless otherwise stated.
Linx will be pleased to receive any correspondence relating to this manual and the
information contained herein; please write to us at the address below.
For further information or help with Linx products, please contact:
Linx Printing Technologies Ltd
Linx House
8 Stocks Bridge Way
Compass Point Business Park
St Ives
PE27 5JL
UK
Tel: + 44 (0) 1480 302100
Fax: + 44 (0) 1480 302116
E-mail: sales@linx.co.uk
or visit our website at www.linxglobal.com
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Jun 2015 (vi) Linx 8900 Maintenance Manual
Contents
Amendment record ............................................................................................... (iii)
Copyright ..........................................................................................................(v)
Manual content .................................................................................................(v)
Safety recommendation....................................................................................(v)
About this manual ............................................................................................ (vi)
Contents ......................................................................................................... (vii)
List of figures ........................................................................................... (xiii)
List of tables ........................................................................................... (xvii)
Document conventions .................................................................................. (xix)
Text conventions ..................................................................................... (xix)
Other conventions .................................................................................... (xx)
Additional publications.................................................................................... (xx)
CHAPTER 1: SAFETY ................................................................... 1—1

1.1 Introduction............................................................................................. 1—1
1.2 Safety warnings and cautions................................................................. 1—1
1.2.1 Warnings ....................................................................................... 1—1
1.2.2 Cautions ........................................................................................ 1—1
1.2.3 Warning symbols ........................................................................... 1—2
1.3 Lethal voltages ....................................................................................... 1—3
1.3.1 Printer ............................................................................................ 1—3
1.3.2 High voltage power module (HVPM) ............................................. 1—3
1.3.3 Printhead ....................................................................................... 1—4
1.4 Earthing .................................................................................................. 1—4
1.5 Inks and solvents.................................................................................... 1—4
1.6 Heavy equipment hazard........................................................................ 1—5
1.7 Sharp needles hazard ............................................................................ 1—5
1.8 First aid................................................................................................... 1—5
1.8.1 Procedures .................................................................................... 1—6
1.9 Electronic waste disposal ....................................................................... 1—6
1.10 Test printing.......................................................................................... 1—7
CHAPTER 2: GENERAL AND COMPLIANCE INFORMATION ... 2—1

2.1 Introduction............................................................................................. 2—1
2.2 Technical data ........................................................................................ 2—1
2.2.1 Environmental................................................................................ 2—1
2.2.2 Power specifications...................................................................... 2—1
2.2.3 Cabinet .......................................................................................... 2—1
2.2.4 High voltage power module (HVPM) ............................................. 2—2
2.2.5 Ink system ..................................................................................... 2—3
2.2.6 Printhead ....................................................................................... 2—4
2.2.7 Printing performance ..................................................................... 2—5
2.2.8 Memory capacity ........................................................................... 2—5
2.2.9 Regulatory approvals..................................................................... 2—5
2.3 Abbreviations and glossary .................................................................... 2—7
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CHAPTER 3: TECHNICAL DESCRIPTION ................................... 3—1
3.1 Introduction..............................................................................................3—1
3.2 Cabinet ....................................................................................................3—1
3.2.1 Introduction ....................................................................................3—1
3.2.2 Front top panel ...............................................................................3—2
3.2.3 Front access door ..........................................................................3—2
3.2.4 Cabinet left side .............................................................................3—2
3.2.5 Right access panel .........................................................................3—2
3.2.6 Rear access panel .........................................................................3—2
3.2.7 Cooling and air filter .......................................................................3—4
3.3 User interface ..........................................................................................3—5
3.3.1 Display ...........................................................................................3—5
3.4 Printhead components ............................................................................3—7
3.4.1 Printhead feed filter (‘last chance’ filter) .........................................3—8
3.4.2 Gun chamber and nozzle assembly ...............................................3—8
3.4.3 Charge electrode plates .................................................................3—8
3.4.4 Strobe LED.....................................................................................3—8
3.4.5 TOF sensors ..................................................................................3—9
3.4.6 Deflector plates ..............................................................................3—9
3.4.7 6-way fluid connector assembly .....................................................3—9
3.4.8 Printhead cover tube detection ....................................................3—11
3.4.9 Printhead temperature sensor......................................................3—11
3.5 Printhead theory of operation ................................................................3—13
3.5.1 Summary ......................................................................................3—13
3.5.2 Printhead types ............................................................................3—13
3.5.3 Modulation....................................................................................3—14
3.5.4 Drop charge .................................................................................3—15
3.5.5 Strobe LED...................................................................................3—16
3.5.6 Historic correction ........................................................................3—16
3.5.7 Drop deflection .............................................................................3—16
3.5.8 Guard drops .................................................................................3—17
3.5.9 Phasing ........................................................................................3—17
3.5.10 Time of flight (TOF) ....................................................................3—18
3.5.11 Viscosity control .........................................................................3—19
3.5.12 Startup and shutdown ................................................................3—20
3.5.13 Jet and nozzle alignment ...........................................................3—21
3.5.14 Print quality ................................................................................3—21
3.5.15 Printhead replacement ...............................................................3—21
3.6 Ink system .............................................................................................3—22
3.6.1 General description ......................................................................3—22
3.6.2 Ink system pipe connections ........................................................3—24
3.6.3 Spillage detector ..........................................................................3—24
3.6.4 Service module ............................................................................3—24
3.6.5 Solvent priming unit......................................................................3—25
3.6.6 Solvent Prime valve .....................................................................3—26
3.6.7 Pump and motor assembly ..........................................................3—26
3.6.8 Venturi manifold ...........................................................................3—27
3.6.9 Pressure transducer and damper assembly.................................3—28
3.6.10 Ink System Feed valve ...............................................................3—28
3.6.11 Solvent tank ...............................................................................3—29
3.6.12 Transfer pump ............................................................................3—30
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3.6.13 Solvent recovery unit ................................................................. 3—30
3.6.14 Ink and solvent cartridges.......................................................... 3—31
3.6.15 Valves manifold assembly ......................................................... 3—32
3.6.16 Solvent Add valve...................................................................... 3—33
3.6.17 Purge valve................................................................................ 3—33
3.6.18 Solvent Top-up valve................................................................. 3—33
3.6.19 Ink Cartridge valve..................................................................... 3—33
3.6.20 Solvent Cartridge valve ............................................................. 3—33
3.6.21 Vent valve.................................................................................. 3—34
3.6.22 Ink and solvent flows ................................................................. 3—35
3.7 Electrical components .......................................................................... 3—44
3.7.1 Introduction.................................................................................. 3—44
3.7.2 Mains electrical supply cable....................................................... 3—44
3.7.3 Mains electrical supply filter......................................................... 3—45
3.7.4 Mains electrical supply fuses....................................................... 3—45
3.7.5 High voltage power module (HVPM) ........................................... 3—46
3.7.6 Ink system pump and motor assembly ........................................ 3—48
3.7.7 Ink system valves ........................................................................ 3—48
3.7.8 Cooling fan .................................................................................. 3—49
3.7.9 Printhead positive air pump ......................................................... 3—49
3.8 Electronics and software ...................................................................... 3—51
3.8.1 Summary ..................................................................................... 3—51
3.8.2 System diagram........................................................................... 3—52
3.8.3 IPM Assembly.............................................................................. 3—52
3.8.4 I2C-bus ........................................................................................ 3—60
3.8.5 Software ...................................................................................... 3—60
3.9 External signals .................................................................................... 3—61
3.9.1 External print trigger .................................................................... 3—61
3.9.2 Shaft encoder .............................................................................. 3—62
3.9.3 Alarm output ................................................................................ 3—63
3.9.4 Dual alarm ................................................................................... 3—65
3.9.5 Multi-stage alarm ......................................................................... 3—66
3.9.6 Serial interface............................................................................. 3—67
3.9.7 Ethernet interface ........................................................................ 3—67
3.9.8 USB interface .............................................................................. 3—67
3.9.9 D-type connector assembly ......................................................... 3—68
CHAPTER 4: TROUBLESHOOTING............................................. 4—1

4.1 Introduction............................................................................................. 4—1
CHAPTER 5: MAINTENANCE....................................................... 5—1

5.1 Introduction............................................................................................. 5—1
5.2 Access to Maintenance options.............................................................. 5—1
5.2.1 Service level timeout ..................................................................... 5—1
5.3 Total Maintenance options ..................................................................... 5—1
5.4 Option availability ................................................................................... 5—3
5.5 Maintenance options .............................................................................. 5—7
5.5.1 Nozzle Flush.................................................................................. 5—7
5.5.2 Nozzle Clear .................................................................................. 5—8
5.5.3 Jet Monitor..................................................................................... 5—9
5.5.4 Replace Service Module.............................................................. 5—16
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5.5.5 Maintenance Times ......................................................................5—18
5.5.6 Clean Touch Screen ....................................................................5—20
5.5.7 Calibrate Touch Screen ...............................................................5—20
5.5.8 Jet Functions ................................................................................5—21
5.5.9 Jet Sequences .............................................................................5—23
5.5.10 Valve Test ..................................................................................5—26
5.5.11 Commissioning...........................................................................5—30
5.5.12 Calibration ..................................................................................5—33
5.5.13 Decommissioning .......................................................................5—39
5.5.14 From Storage .............................................................................5—42
5.5.15 Into Storage................................................................................5—42
5.5.16 Valve Reset ................................................................................5—42
5.5.17 Printhead Characteristics ...........................................................5—43
5.5.18 Consumables History .................................................................5—43
5.5.19 Software Upgrade ......................................................................5—46
5.6 Maintenance instructions.......................................................................5—47
5.6.1 Double pole/neutral fusing ...........................................................5—47
5.6.2 Introduction ..................................................................................5—47
5.6.3 Maintenance terminology .............................................................5—47
5.6.4 Antistatic precautions ...................................................................5—48
5.6.5 CE approval checklist for the 8900 printer ...................................5—49
5.6.6 Maintenance instruction documents.............................................5—49
Printer Installation ........................................................................5—51
Correct Installation of Mk11 Printheads .......................................5—53
Rear Access Panel Removal & Access Preparation....................5—57
Venturi Replacement....................................................................5—63
Main Ink Pump and Motor Assembly Replacement .....................5—65
Solvent Tank Pick-up Tube Replacement....................................5—69
Solvent Tank Level Sensor Replacement ....................................5—71
Solvent Tank Replacement ..........................................................5—75
Solvent Priming Unit and Valve Replacement .............................5—77
Pressure Transducer and Damper Replacement.........................5—81
Solvent Recovery Unit Replacement ...........................................5—85
Transfer Pump Replacement .......................................................5—87
Manifold Valves Replacement......................................................5—91
Front Access Door Removal and Installation ...............................5—95
RFID Module and Cable Replacement ........................................5—99
Front Access Door Latch Replacement .....................................5—101
Front Access Door Damper Replacement .................................5—105
Front Access Door Sensor Replacement...................................5—107
Cartridges Receptacle Replacement .........................................5—111
High Voltage Power Module Replacement ................................5—115
IPM Assembly Replacement ......................................................5—117
Touch Screen Assembly Replacement ......................................5—121
Modulation Range Checks .........................................................5—123
VFC Module Installation .............................................................5—127
Jet Alignment and Nozzle Cleaning ...........................................5—133
Ink Conversion ...........................................................................5—145
Stuck Printhead Gutter Valve Correction ...................................5—149
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CHAPTER 6: SYSTEM EVENTS ................................................... 6—1
6.1 Introduction............................................................................................. 6—1
6.2 System event types ................................................................................ 6—3
6.2.1 System Failures............................................................................. 6—3
6.2.2 Print Failures ................................................................................. 6—3
6.2.3 System Warnings .......................................................................... 6—3
6.2.4 Information events ......................................................................... 6—3
6.3 Summary of system events .................................................................... 6—4
6.4 System Failures...................................................................................... 6—6
6.4.1 “1.03 Internal Software Failure” ..................................................... 6—6
6.4.2 “1.40 EHT Board Missing” ............................................................. 6—7
6.4.3 “1.42 I2C Bus Failure” ................................................................... 6—7
6.4.4 “1.43 Watchdog Trip”..................................................................... 6—7
6.5 Print Failures .......................................................................................... 6—8
6.5.1 “2.00 Printhead Over Temperature” .............................................. 6—8
6.5.2 “2.01 EHT Trip”.............................................................................. 6—9
6.5.3 “2.02 Phase Failure” ...................................................................... 6—9
6.5.4 “2.03 Time Of Flight Failure”........................................................ 6—11
6.5.5 “2.07 Internal Spillage” ................................................................ 6—12
6.5.6 “2.08 Printer Over Temperature” ................................................. 6—12
6.5.7 “2.09 Misaligned Ink Jet” ............................................................. 6—13
6.5.8 “2.11 Pressure Limit Reached”.................................................... 6—14
6.5.9 “2.12 Viscosity Out of Range”...................................................... 6—14
6.5.10 “2.20 Ink System Empty” ........................................................... 6—15
6.5.11 “2.21 Service Module Removed” ............................................... 6—16
6.5.12 “2.23 Charge Amplifier Trip” ...................................................... 6—16
6.5.13 “2.24 Memory Low”.................................................................... 6—17
6.5.14 “2.25 Memory Storage Low” ...................................................... 6—17
6.5.15 “2.26 Modulation Amplifier Trip” ................................................ 6—17
6.5.16 “2.27 Service Module Requires Replacement”.......................... 6—17
6.5.17 “2.28 Valid UNIC Chip Not Found” ............................................ 6—18
6.5.18 “2.29 Pump Drive Failure” ......................................................... 6—18
6.5.19 “2.30 Pressure Reading at Maximum”....................................... 6—18
6.5.20 “2.31 Pressure Reading Suspect” ............................................. 6—18
6.5.21 “2.32 Pressure Reading at Minimum”........................................ 6—18
6.5.22 “2.33 Valve Drive 1 Failure”....................................................... 6—19
6.5.23 “2.34 Valve Drive 2 Failure”....................................................... 6—19
6.5.24 “2.35 Pump Stalled”................................................................... 6—19
6.5.25 “2.43 Solvent System Empty” .................................................... 6—19
6.6 System Warnings ................................................................................. 6—20
6.6.1 “3.00 Shutdown Incomplete”........................................................ 6—20
6.6.2 “3.05 Overspeed (Print Trigger)” ................................................. 6—20
6.6.3 “3.06 Overspeed (Synchronous Data)”........................................ 6—21
6.6.4 “3.07 Overspeed (Asynchronous Data)”...................................... 6—21
6.6.5 “3.08 Overspeed (Line Speed)” ................................................... 6—21
6.6.6 “3.09 Overspeed (Compensation)” .............................................. 6—22
6.6.7 “3.10 Under Speed (Line Speed)” ............................................... 6—22
6.6.8 “3.12 Printhead Cover Off” .......................................................... 6—22
6.6.9 “3.13 Cover Override Active” ....................................................... 6—23
6.6.10 “3.15 Safety Override Active” .................................................... 6—23
6.6.11 “3.16 Gutter Override Active”..................................................... 6—23
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6.6.12 “3.17 Gate Array Test Mode Active”...........................................6—24
6.6.13 “3.18 Low Pressure” ...................................................................6—24
6.6.14 “3.24 Restart In Progress” ..........................................................6—24
6.6.15 “3.29 Overspeed (No Remote Data)” .........................................6—24
6.6.16 “3.30 Remote Error” ...................................................................6—24
6.6.17 “3.40 Service Module Requires Replacement”...........................6—25
6.6.18 “3.41 Service Module Removed”................................................6—25
6.6.19 “3.42 Service Module Requires Commissioning” .......................6—25
6.6.20 “3.43 Memory Low” ....................................................................6—25
6.6.21 “3.44 Memory Storage Low”.......................................................6—26
6.6.22 “3.45 Service Module Replacement Due Within One Month”.....6—26
6.6.23 “3.46 Pump Pressure Failure” ....................................................6—26
6.6.24 “3.47 Pump RPM Failure” ..........................................................6—27
6.6.25 “3.48 Pump RPM Limit Reached”...............................................6—27
6.6.26 “3.49 Pump Current Limit Exceeded” .........................................6—27
6.6.27 “3.50 Valve Supply” ....................................................................6—27
6.6.28 “3.51 Pump Oscillating” ..............................................................6—28
6.6.29 “3.52 Pump Power Limit Reached” ............................................6—28
6.6.30 “3.56 Printhead Over Temperature” ...........................................6—28
6.6.31 “3.57 EHT Trip” ..........................................................................6—28
6.6.32 “3.58 Internal Spillage” ...............................................................6—28
6.6.33 “3.59 Low Battery” ......................................................................6—29
6.6.34 “3.60 Reset System Clock” ........................................................6—29
6.6.35 “3.65 Reverted To System Settings From Last Successful
Powerdown” ...............................................................................6—29
6.6.36 “3.66 System Settings Not Found, Reverted To Defaults” .........6—29
6.6.37 “3.68 Field Truncation” ...............................................................6—29
6.6.38 “3.69 Remote Field Not Found”..................................................6—29
6.6.39 “3.71 Jet Start Failure – Do Not Switch Off!” ..............................6—29
6.6.40 “3.73 Ink Cartridge Not Found” ..................................................6—30
6.6.41 “3.74 Solvent Cartridge Not Found” ...........................................6—30
6.6.42 “3.77 Ink Cartridge Empty” .........................................................6—30
6.6.43 “3.78 Solvent Cartridge Empty” ..................................................6—30
6.6.44 “3.79 Invalid Ink Cartridge” .........................................................6—31
6.6.45 “3.80 Invalid Solvent Cartridge”..................................................6—31
6.6.46 “3.81 Ink Cartridge Expired” .......................................................6—31
6.6.47 “3.82 Solvent Cartridge Expired” ................................................6—31
6.6.48 “3.83 Wrong Ink Type” ...............................................................6—31
6.6.49 “3.84 Wrong Solvent Type” ........................................................6—31
6.6.50 “3.85 Easi-Change Service Key Not Found” ..............................6—31
6.6.51 “3.86 Invalid Easi-Change Service Key”.....................................6—31
6.6.52 “3.87 Easi-Change Service Key Already Used” .........................6—31
INDEX .................................................................................... INDEX—1
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List of figures
Figure Page
CHAPTER 1: SAFETY ...................................................................................... 1—1

Figure 1-1. Test printing into a non-metallic container..................................................................1—7
CHAPTER 3: TECHNICAL DESCRIPTION...................................................... 3—1

Figure 3-1. 8900 printer cabinet—main external parts .................................................................3—3
Figure 3-2. 8900 printer cabinet—main internal components.......................................................3—4
Figure 3-3. English user interface—Home screen........................................................................3—5
Figure 3-4. Mk11 Midi printhead main components......................................................................3—7
Figure 3-5. Location of the printhead feed filter ............................................................................3—8
Figure 3-6. 6-way fluid connector assembly ...............................................................................3—10
Figure 3-7. Mk11 printhead and cover-detection contacts..........................................................3—11
Figure 3-8. Modulation of the ink jet by a piezoelectric crystal ...................................................3—14
Figure 3-9. Correct drop break-off in the charge electrode.........................................................3—15
Figure 3-10. Guard drops ...........................................................................................................3—17
Figure 3-11. Phase control process............................................................................................3—18
Figure 3-12. Static ink system ....................................................................................................3—23
Figure 3-13. Service module.......................................................................................................3—24
Figure 3-14. Solvent priming unit................................................................................................3—26
Figure 3-15. Ink system pump and motor assembly...................................................................3—26
Figure 3-16. Venturi manifold assembly .....................................................................................3—27
Figure 3-17. Section view of the venturi .....................................................................................3—27
Figure 3-18. Pressure transducer and damper assembly...........................................................3—28
Figure 3-19. Solvent tank assembly ...........................................................................................3—29
Figure 3-20. Transfer pump assembly........................................................................................3—30
Figure 3-21. Solvent recovery unit..............................................................................................3—30
Figure 3-22. Valves manifold assembly......................................................................................3—32
Figure 3-23. 2-way solenoid valve ..............................................................................................3—32
Figure 3-24. Ink system primary circuit.......................................................................................3—36
Figure 3-25. Ink system secondary circuit—stage 1...................................................................3—37
Figure 3-26. Ink system secondary circuit—stage 2...................................................................3—38
Figure 3-27. Solvent addition......................................................................................................3—40
Figure 3-28. Ink addition .............................................................................................................3—42
Figure 3-29. Solvent top-up ........................................................................................................3—43
Figure 3-30. Mains electrical supply filter assembly and connector protection box ....................3—45
Figure 3-31. High voltage power module (HVPM) ......................................................................3—46
Figure 3-32. Correct connection of the printhead EHT cables....................................................3—47
Figure 3-33. Ink system pump and motor assembly...................................................................3—48
Figure 3-34. Cooling fan .............................................................................................................3—49
Figure 3-35. Positive air pump....................................................................................................3—49
Figure 3-36. IPM Assembly ........................................................................................................3—52
Figure 3-37. I/O PCB connectors................................................................................................3—53
Figure 3-38. I/O PCB test points.................................................................................................3—56
Figure 3-39. Location of header PL215 links ..............................................................................3—57
Figure 3-40. Location of the external signal connectors .............................................................3—61
Figure 3-41. Shaft encoder .........................................................................................................3—62
Figure 3-42. Pinouts for the photocell and shaft encoder connectors ........................................3—62
Figure 3-43. VFC module ...........................................................................................................3—63
Figure 3-44. Pin connections for the RS-232 interface cable .....................................................3—67
Figure 3-45. Correct assembly of the IP67 D-type connector.....................................................3—68
CHAPTER 5: MAINTENANCE.......................................................................... 5—1

Figure 5-1. Maintenance (1 of 3) screen.......................................................................................5—1
Figure 5-4. Jet Monitor screen......................................................................................................5—9
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Figure 5-5. Enter Pressure screen ............................................................................................. 5—10
Figure 5-6. Enter Modulation screen.......................................................................................... 5—12
Figure 5-7. Enter TOF screen .................................................................................................... 5—13
Figure 5-8. Enter Phase screen ................................................................................................. 5—14
Figure 5-9. Replace Service Module screen .............................................................................. 5—16
Figure 5-10. Maintenance Times screen.................................................................................... 5—18
Figure 5-11. Clean Touch Screen counter ................................................................................. 5—20
Figure 5-12. Calibrate Touch Screen ......................................................................................... 5—20
Figure 5-13. Jet Functions screen.............................................................................................. 5—21
Figure 5-14. Jet Sequences screen ........................................................................................... 5—23
Figure 5-15. Valve Test screen—Feed valve turned on............................................................. 5—26
Figure 5-16. Enter Pressure screen ........................................................................................... 5—27
Figure 5-17. Enter RPM screen ................................................................................................. 5—28
Figure 5-18. Enter Modulation screen........................................................................................ 5—29
Figure 5-19. Commissioning Valve Test screen ........................................................................ 5—30
Figure 5-20. Commissioning confirmation screen...................................................................... 5—31
Figure 5-21. Maintenance Due Within Time screen................................................................... 5—32
Figure 5-22. Calibration screen.................................................................................................. 5—33
Figure 5-23. Ref Pressure Offset (Printer) keyboard ................................................................. 5—34
Figure 5-24. Reference Pressure offset of ‘5’ entered ............................................................... 5—34
Figure 5-25. Nudge panel displayed .......................................................................................... 5—35
Figure 5-26. Reference Pressure offset value displayed in the nudge panel............................. 5—35
Figure 5-27. Reference Pressure offset adjusted to ‘7’.............................................................. 5—36
Figure 5-28. Reference Pressure offset now set to ‘7’ ............................................................... 5—36
Figure 5-29. Decommissioning kit.............................................................................................. 5—39
Figure 5-30. Removing the Service Module screen ................................................................... 5—40
Figure 5-31. Consumables History screen................................................................................. 5—43
Figure 5-32. Software Upgrade: insert a valid memory device instruction................................. 5—46
Correct Installation of Mk11 Printheads ................................................................................ 5—53

Figure 1. Direction of conduit bend and minimum bend radius.................................................. 5—53
Figure 2. Support for the conduit................................................................................................ 5—54
Figure 3. Cut-outs in guards for the conduit............................................................................... 5—54
Figure 4. Conduit support and minimum bend radius—1........................................................... 5—54
Figure 5. Conduit support and minimum bend radius—2........................................................... 5—55
Figure 6. Loop of conduit to take up the motion......................................................................... 5—55
Figure 7. Conduit supported on rollers....................................................................................... 5—55
Figure 8. Conduit only bent not twisted when printhead moves................................................. 5—56
Figure 9. Minimum space to the left side of the printer .............................................................. 5—56
Rear Access Panel Removal & Access Preparation............................................................. 5—57

Figure 1. Securing thumbscrews for the ink and electronics systems ....................................... 5—58
Figure 2. I/O PCB external connectors ...................................................................................... 5—59
Venturi Replacement ............................................................................................................... 5—63

Figure 1. Mk5 venturi ................................................................................................................. 5—63
Figure 2. Venturi manifold .......................................................................................................... 5—64
Main Ink Pump and Motor Assembly Replacement .............................................................. 5—65

Figure 1. Securing nuts for the main ink pump and motor assembly ......................................... 5—66
Figure 2. Ink pump and compression nuts ................................................................................. 5—66
Solvent Tank Pick-up Tube Replacement.............................................................................. 5—69

Figure 1. Solvent tank pick-up tube and filter assembly............................................................. 5—69
Figure 2. Pick-up tube assembly fitted to the solvent tank......................................................... 5—70
Solvent Tank Level Sensor Replacement .............................................................................. 5—71

Figure 1. Solvent level sensor.................................................................................................... 5—71
Figure 2. Level sensor assembly fitted to the solvent tank ........................................................ 5—72
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Jun 2015 (xiv) Linx 8900 Maintenance Manual
Solvent Tank Replacement ......................................................................................................5—75
Figure 1. Solvent tank connections and ink system support arm ...............................................5—76
Solvent Priming Unit and Valve Replacement .......................................................................5—77

Figure 1. Ink system support arm and securing screws .............................................................5—78
Figure 2. Solvent priming unit ports ............................................................................................5—79
Pressure Transducer and Damper Replacement...................................................................5—81

Figure 1. Securing nuts for the pressure transducer and damper assembly ..............................5—82
Figure 2. Damper ports...............................................................................................................5—82
Solvent Recovery Unit Replacement ......................................................................................5—85

Figure 2. Solvent recovery unit pipe connections .......................................................................5—86
Transfer Pump Replacement ...................................................................................................5—87

Figure 2. Transfer pump pipe connections .................................................................................5—89
Manifold Valves Replacement .................................................................................................5—91

Figure 2. Valves and valves retainers.........................................................................................5—93
Front Access Door Removal and Installation ........................................................................5—95

Figure 1. Access door right and left striker plates.......................................................................5—96
Figure 2. Door hinge rod.............................................................................................................5—96
RFID Module and Cable Replacement ....................................................................................5—99

Figure 1. Access door assembly...............................................................................................5—100
Front Access Door Latch Replacement................................................................................5—101

Figure 2. Access door latch mechanism...................................................................................5—102
Front Access Door Damper Replacement............................................................................5—105

Figure 1. Access door damper location ....................................................................................5—105
Figure 2. Access door damper assembly .................................................................................5—106
Front Access Door Sensor Replacement .............................................................................5—107

Figure 1. Access door sensor location......................................................................................5—107
Figure 2. Access door sensor ...................................................................................................5—108
Cartridges Receptacle Replacement ....................................................................................5—111

Figure 1. Cartridges receptacle assembly ................................................................................5—111
Figure 3. Needle stem assemblies removed ............................................................................5—113
High Voltage Power Module Replacement ...........................................................................5—115

Figure 1. HVPM ........................................................................................................................5—116
IPM Assembly Replacement ..................................................................................................5—117

Figure 1. IPM Assembly securing nuts .....................................................................................5—118
Touch Screen Assembly Replacement.................................................................................5—121

Figure 1. Touch screen assembly—power on switch connector and securing nuts .................5—121
Modulation Range Checks.....................................................................................................5—123

Figure 1. List of test messages in the Message Store..............................................................5—123
Figure 2. Nozzle Clear option on the Jet Functions screen ......................................................5—123
Figure 3. Start Print option on the Jet Functions screen...........................................................5—124
Figure 4. Reference Modulation value on the Jet Monitor screen ............................................5—124
Figure 5. Enter Modulation screen............................................................................................5—125
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Linx 8900 Maintenance Manual (xv) Jun 2015
Figure 6. Actual Modulation decreased by 10 volts from Reference Modulation ..................... 5—125
Figure 7. Under modulation—expected deterioration when Reference Mod is < Vm1 ............ 5—126
Figure 8. Over modulation—expected deterioration when Reference Mod is > Vm2 .............. 5—126
VFC Module Installation ........................................................................................................ 5—127

Figure 1. VFC alarm accessory................................................................................................ 5—127
Figure 2. Assembly of the VFC external alarm-equipment connector...................................... 5—130
Figure 3. VFC external alarm-equipment connector details..................................................... 5—131
Figure 4. VFC module fuses .................................................................................................... 5—132
Jet Alignment and Nozzle Cleaning ..................................................................................... 5—133

Figure 1. Jet Test-Start option on the Jet Functions screen .................................................... 5—134
Figure 2. Correct alignment of the jet into the gutter................................................................ 5—135
Figure 3. Correct alignment of the jet from the nozzle ............................................................. 5—136
Figure 4. Nozzle Clear option on the Maintenance screen ...................................................... 5—136
Figure 5. Nozzle Clear sequence—solvent applied to the nozzle face .................................... 5—137
Figure 6. The nozzle assembly hung in a beaker of solvent .................................................... 5—138
Figure 7. Lower part of the nozzle alignment tool fitted to the nozzle ...................................... 5—140
Figure 8. Upper part of the nozzle alignment tool fitted to the nozzle ...................................... 5—141
Figure 9. Examples of nozzle alignment problems and correction methods—1 ...................... 5—142
Figure 10. Examples of nozzle alignment problems and correction methods—2 .................... 5—143
Figure 11. Correct nozzle alignment ........................................................................................ 5—144
Ink Conversion ....................................................................................................................... 5—145

Figure 1. Removing the Service Module screen ...................................................................... 5—146
Figure 2. Ink/Solvent Selection screen..................................................................................... 5—146
Stuck Printhead Gutter Valve Correction ............................................................................ 5—149

Figure 1. Valve Test screen ..................................................................................................... 5—150
Figure 2. Removal of the printhead end plate .......................................................................... 5—150
CHAPTER 6: SYSTEM EVENTS.......................................................................6—1

Figure 6-1. Faults & Warnings Notification screen....................................................................... 6—1
Figure 6-2. Current Faults & Warnings screen............................................................................. 6—2
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Jun 2015 (xvi) Linx 8900 Maintenance Manual
List of tables
Table Page
CHAPTER 3: TECHNICAL DESCRIPTION...................................................... 3—1

Table 3-1. VFC alarm output conditions .....................................................................................3—64
Table 3-2. VFC alarm external connections ...............................................................................3—65
Table 3-3. VFC alarm external connections—multi-stage alarm ................................................3—66
CHAPTER 5: MAINTENANCE.......................................................................... 5—1

Table 5-1. Availability of the Maintenance options .......................................................................5—4
VFC Module Installation .........................................................................................................5—127

Table 1. VFC module external alarm ratings specification .......................................................5—129
Table 2. Cable specification for the external alarm-equipment connector ................................5—130
CHAPTER 6: SYSTEM EVENTS ...................................................................... 6—1

Table 6-1. Summary table of system events ................................................................................6—4
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Document conventions
Text conventions
The following text conventions are used throughout this maintenance manual for
identification and emphasis.
Display elements
Bold text is used in descriptions and procedures to identify the following:
 Screen names and items. For example, the Main Menu screen; the Maintenance screen;
the Solvent Add item on the Jet Monitor screen.
 Options and command buttons. For example, the Nozzle Flush option on the
Maintenance screen; the Start Printing button on the Home screen; the Exit button on
the Jet Functions screen.
 Operator input, for example:
On the Enter Pressure screen, enter ‘255’
Options and command buttons are always 'touched' to have an effect. A description of this
action in procedures is shown in the following example:
… touch Next to continue …
… touch Nozzle Flush to access …
or sometimes to prevent confusion:
… touch the Next button to continue …
… touch the Nozzle Flush option to access …
The following convention is used in descriptions and procedures to show the location of an
item or option in the menu structure of the printer:
... the Valve Test screen (Main Menu > Maintenance (1 of 2) > Valve Test) …
Cross-references
Where a cross-reference is made, for example, to another chapter, section, subsection or
figure within this manual (an internal cross-reference), the reference is shown as follows:
... refer to ‘Technical Data’ in Chapter 2: ‘General and Compliance Information’ …
... refer to the section ‘User Interface’ on page 3—6 for more information …
... refer to ‘Default Settings’ earlier in this chapter …
... refer to Figure 7 on page 4—8 …
Where a cross-reference is made to another publication (an external cross-reference), the
reference is shown in italics, as follows:
… refer to the Linx 8900 Quick Start Guide …
Component positional references

IMPORTANT: When the locations of external cabinet components are referred to in this
manual, the left, right, front and rear sides of the printer are with respect to
the printer when looked at from the front.
The internal components can be seen only when the rear access panel is
removed. Therefore, the locations of these parts are referred to as left, right,
front or rear as seen from the rear of the printer.
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Linx 8900 Maintenance Manual (xix) Jun 2015
Amended content
Changed and additional text and illustrations on amendment pages are indicated by a
vertical line in the left margin.
Units of measurement
This manual uses metric units of measurement. To change metric millimetres into
equivalent British imperial inches, multiply by 0.0394. For example, 50 mm × 0.0394 =
1.97 inches.
Other conventions
The following types of annotation are used in this manual to identify and to draw the
attention of the reader to particular types of information.
Important note symbol

The pointing hand symbol is shown next to an IMPORTANT Note to indicate that the
information given is essential to the completion of a task.
Notes
Notes are used to provide additional information that can apply in special cases. For
example, memory limitations, printer configuration, or details that apply to specific
versions of system software.
Additional publications
Additional information about the Linx 8900 Continuous Ink Jet Printer is provided in the
following publications:
 Linx 8900 Quick Start Guide (part number TP1A001-1)
This document provides instructions on the basic operator functions of the printer, and
describes how to perform routine maintenance. The guide is included on the Linx 8900
User Information CD (part number FA48010), which is supplied with each printer. The
guide is also included on the Linx 8900 Service Information CD (part number FA48009)
and is available to download from ExtraLinx.
 Linx 8900 Operating Manual (part number TP1A002)
This document describes how to use the more advanced functions of the printer. The
manual is included on the Linx 8900 User Information CD (part number FA48010), which
is supplied with each printer. The manual is also included on the Linx 8900 Service
Information CD (part number FA48009) and is available to download from ExtraLinx.
 8900 How To Select the Service Module Replacement Hours (part number TP1B021)
This guide describes how to set the service module replacement interval for the 8900
printer, which depends on ink type and the environmental conditions of the
application. The guide is included on the Linx 8900 Service Information CD (part number
FA48009) and is also available to download from ExtraLinx.
 Linx 8900 Continuous Ink Jet Printers Parts List
This document contains spare parts information for the 8900 printer. The parts list is
included on the Linx 8900 Service Information CD (part number FA48009) and is also
available to download from ExtraLinx.
 Linx 8900 Service Information CD (part number FA48009)

The CD is included in each 8900 printer maintenance manual.
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Jun 2015 (xx) Linx 8900 Maintenance Manual
CHAPTER 1: SAFETY
1.1 Introduction
WARNING: GENERAL SAFETY. REGARDLESS OF THE LEVEL OF PERCEIVED HAZARD, THE

SAFETY PROCEDURES DESCRIBED IN THIS MANUAL MUST BE FOLLOWED.
READ, UNDERSTAND AND FOLLOW ALL OF THE SAFETY INFORMATION IN THIS SAFETY
CHAPTER BEFORE THE PRINTER IS INSTALLED, OPERATED OR ANY MAINTENANCE WORK
IS DONE. ALWAYS FOLLOW THE SAFETY INFORMATION IN ALL WARNING AND CAUTION
STATEMENTS IN THIS MANUAL.
IF THERE IS ANY PART OF THIS SAFETY CHAPTER THAT YOU DO NOT UNDERSTAND, DO
NOT USE THE PRINTER.
INCORRECT INSTALLATION, SETUP, OPERATION, MAINTENANCE OR MODIFICATION OF
THE PRINTER CAN CREATE A HAZARD TO THE HEALTH AND SAFETY OF PERSONNEL AND
THE ENVIRONMENT.
This chapter provides important information about the precautions to be taken to make
sure that all operations and maintenance related to inks and solvents are performed with
the maximum possible safety. First aid information is also included.
For maximum safety the printer must always be operated with the spare parts approved by
Linx. Linx recommends that any maintenance work is performed only by Linx maintenance
technicians or personnel trained by Linx. The use of spare parts that are not approved, and
the performance of maintenance work by personnel who are not trained can make the
printer unsafe to use.
1.2 Safety warnings and cautions

Warning and Caution statements are provided within the text of this manual. These
statements advise the reader of potential hazards, how to prevent them and how to safely
use a product. A Warning statement always includes a related warning symbol. The
definitions of Warning and Caution statements are given below, with the text conventions
used in this manual.
1.2.1 Warnings
A Warning advises the reader of a hazard that can cause loss of life, injury or illness. The
statement is printed in bold capital letters and includes a warning symbol that identifies the
type of hazard.
1.2.2 Cautions
A Caution advises the reader of actions that can damage equipment or the environment,
but are not a direct danger to personnel. The statement is printed in bold lower-case letters
and does not include a symbol.
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Linx 8900 Maintenance Manual 1—1 Jun 2015
1.2.3 Warning symbols
The different types of warning symbols used in this manual are described below.
Eye protection
The mandatory Eye Protection warning symbol is an indication that safety glasses must be
worn when any work is done that includes inks or solvents. The safety glasses must be of a
type according to European and international safety standards.
Hand protection
The mandatory Hand Protection warning symbol is an indication that solvent-resistant

protective gloves must be worn when any work is done that includes the use of inks or
solvents.
Irritant substance hazard
The Irritant Warning symbol is an indication that a substance can cause irritation to the eyes
and the respiratory system if the correct safety precautions are not taken.
Electric shock hazard
The Lethal Voltage warning symbol is an indication that there is a risk of electric shock from
possible lethal voltages if the correct safety precautions are not taken.
Fire hazard
The Highly Flammable warning symbol is an indication that there is a risk of fire from a
highly flammable type of material if the correct safety precautions are not taken.
Hot surface hazard
The Hot Surface Warning symbol is an indication that there is a risk of skin burns from
contact with a hot surface if the correct safety precautions are not taken.
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Jun 2015 1—2 Linx 8900 Maintenance Manual
General hazard
The General warning symbol is shown with a Warning statement that does not have a
special symbol to indicate the hazard. The Warning advises the reader of other activities
that can be harmful or lethal.
1.3 Lethal voltages

When mains electrical power is applied to the printer and the rear access panel is removed,
the 4.4kV EHT, 300 V DC supply, and mains electrical supply can be accessed. Accidental
contact with these voltages is possible.
1.3.1 Printer
WARNING: LETHAL VOLTAGE HAZARD. DANGEROUS VOLTAGES EXIST IN THIS

EQUIPMENT WHEN MAINS ELECTRICAL POWER IS APPLIED.
MAXIMUM CAUTION MUST BE USED WHEN WORK IS DONE ON THE PRINTER WHILE MAINS
ELECTRICAL POWER IS APPLIED AND THE REAR ACCESS PANEL IS REMOVED. THE
CORRECT, STANDARD ELECTRICAL SAFETY PRECAUTIONS MUST BE TAKEN.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS SAFETY
WARNING IS IGNORED.
WARNING: LETHAL VOLTAGE HAZARD—DOUBLE POLE/NEUTRAL FUSING. THIS

EQUIPMENT IS PROTECTED BY DOUBLE-POLE FUSING. THAT IS, FUSES ARE FITTED IN THE
LIVE AND NEUTRAL CONDUCTORS OF THE MAINS ELECTRICAL SUPPLY. IF THE NEUTRAL
FUSE OPERATES, PARTS OF THE EQUIPMENT THAT REMAIN ENERGIZED CAN BE AN
ELECTRICAL HAZARD DURING MAINTENANCE WORK.
TURN OFF AND DISCONNECT THE PRINTER FROM THE MAINS ELECTRICAL SUPPLY
BEFORE THE REAR ACCESS PANEL IS REMOVED.
WARNING IS IGNORED.
1.3.2 High voltage power module (HVPM)
A warning label is attached to the side of the HVPM to indicate that there are lethal voltages
in the HVPM.
WARNING: LETHAL VOLTAGE HAZARD. DANGEROUS VOLTAGES OF ±4.4 KV DC AND
300 V DC EXIST IN THE HIGH VOLTAGE POWER MODULE (HVPM) WHEN MAINS ELECTRICAL
POWER IS APPLIED.
WARNING IS IGNORED.
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1.3.3 Printhead
To protect against the danger of electric shock, printing is stopped when the printhead
cover tube is removed. Also, the charge electrode voltage is decreased to less than 10 volts
instead of the normal 300 volts, and the ±4.4 kV EHT supplies to the deflector plates are
turned off.
1.4 Earthing
WARNING: THIS PRINTER MUST BE EARTHED.
All earth cables must be securely connected to the protective earth (PE) blade terminals on
the HVPM mounting plate when the printer is turned on. These earth terminals are
identified by an adjacent PE label.
1.5 Inks and solvents
WARNING: HAZARDOUS SUBSTANCES. THIS PRINTER USES SOLVENT AND

SOLVENT-BASED INKS THAT CAN BE HAZARDOUS. THESE INKS AND SOLVENTS ARE
HIGHLY FLAMMABLE, AND THE LIQUID, VAPOUR OR SPRAY CAN CAUSE IRRITATION TO
THE EYES AND SKIN.
WEAR SAFETY GLASSES AND SOLVENT-RESISTANT PROTECTIVE GLOVES WHEN THERE IS
DIRECT CONTACT WITH THE INKS AND SOLVENTS, WHEN WORK IS DONE ON THE PRINTER,
AND WHEN THE PRINTER IS CLEANED.
THERE IS A RISK OF SEVERE IRRITATION AND TEMPORARY (REVERSIBLE) DAMAGE TO
THE EYES, AND IRRITATION OF THE SKIN IF THIS SAFETY WARNING IS IGNORED.
Solvents and inks can be harmful. When inks and solvents are used, the following necessary
precautions must be taken:
 Before work is started on the printer, read the applicable ink and solvent Safety Data
Sheets. If you do not fully understand the information, or are not sure, contact Linx for
instruction.
 If the Safety Data Sheets have not been supplied or are not available, contact Linx for
copies. Always refer to the Safety Data Sheets before inks and solvents are used.
 Do not smoke or use open flames near the printer, or ink and solvent storage areas and
containers.
 Make sure that the printing area has good ventilation when the printer is in operation,
when work is done on the printer, and when inks and solvents are used.
 Wear safety glasses when inks and solvents are used, or when the printer is examined
or repaired. The safety glasses must be of a type according to the applicable European
and international safety standards. The Eye Protection Warning symbol is shown in this
manual, where applicable, to indicate the mandatory requirement to wear safety
glasses.
FA48008
 Wear solvent-resistant gloves when inks and solvents are used, when the printer is
examined or repaired, or at any time that hand contact with inks or solvents is possible.
The Hand Protection Warning symbol is shown in this manual, where applicable, to
indicate the mandatory requirement to wear safety gloves.
Barrier creams can help to protect areas of bare skin, but they do not give the same level
of protection as safety gloves. Barrier creams must not be applied after exposure to ink
or solvent has occurred.
 Never look into the end of the printhead or point the printhead at any person while the
printer is turned on.
 Remove all ink and solvent spillage immediately from the interior and exterior of the
printer, and from the area around the printer. Use the correct solvent type for the
related ink type to remove ink spillage.
 Remove any increased ink deposits from the interior of the printer with the correct
solvent type for the related ink type.
 Store all inks and solvents in their original containers, which must be tightly closed.
Store the containers in a cabinet with good air circulation or in a recommended
flameproof storage container. Inks and solvents must be kept away from any source of
heat or ignition.
 All waste ink and solvent must be discarded correctly, according to local regulations
and must not be allowed to enter the water drainage system.
1.6 Heavy equipment hazard
WARNING: HEAVY EQUIPMENT HAZARD. THE WEIGHT OF THE 8900 PRINTER IS

APPROXIMATELY 24.0 KG WHEN THE INK AND SOLVENT CARTRIDGES, SOLVENT TANK
AND SERVICE MODULE ARE FULL.
CAUTION MUST BE USED WHEN THE PRINTER IS MOVED.
THERE IS A RISK OF PERSONAL INJURY IF THE CORRECT GUIDELINES FOR THE SAFE
MANUAL HANDLING OF HEAVY OBJECTS ARE NOT FOLLOWED.
1.7 Sharp needles hazard
WARNING: SHARP NEEDLES HAZARD. THE INK AND SOLVENT REFILL MECHANISM ON THE
8900 PRINTER USES RETRACTABLE SAFETY NEEDLES TO PIERCE THE CARTRIDGE CAPS.
CAUTION MUST BE USED WHEN THE INK AND SOLVENT CARTRIDGES ARE REPLACED.
THERE IS A RISK OF PERSONAL INJURY IF THE CORRECT GUIDELINES FOR THE
REPLACEMENT OF INK AND SOLVENT CARTRIDGES ARE NOT FOLLOWED.
1.8 First aid

Ideally, all maintenance personnel should be trained in first aid and know the possible
effects from the use of flammable and toxic materials.
All maintenance personnel must have access to the ink and solvent Safety Data Sheets,
which describe the hazards and the actions to be taken if first aid is necessary.
Maintenance personnel must make sure that the first aid information is easily available if
ink and solvent ingestion, inhalation, or contact with the eyes or skin occurs.
FA48008
1.8.1 Procedures
The following paragraphs contain first aid procedures for inks and solvents from the Safety
Data Sheets. For complete and up to date information, always refer to the Safety Data Sheet
for the related ink or solvent.
Eye contact with inks or solvents

Remove contact lenses, if necessary, before the eyes are flushed. Hold the eyelids open,
flush the eyes with clean water and continue this process for at least 10 minutes. Get
medical attention.
Skin contact with inks or solvents

Remove any contaminated clothes. Wash the affected area completely with soap and water,
or use a proprietary skin cleaner. Do not use solvents to remove ink from skin. Get medical
attention if irritation occurs or continues after the skin has been washed.
Ingestion of inks or solvents

If accidentally swallowed, do not cause the affected person to vomit. Get medical attention
immediately. Flush the mouth completely with water and give large amounts of water to
drink if the person is conscious. Make sure that the person does not move, keep the person
warm and provide fresh air.
Inhalation of solvent fumes

Remove the affected person to fresh air immediately. If the person stops breathing, give
artificial respiration and get medical attention immediately. Make sure that the person does
not move and keep the person warm.
1.9 Electronic waste disposal
The 8900 printer and ink and solvent cartridges contain electrical and electronic equipment
(EEE). At the end of its life, waste electrical and electronic equipment (WEEE) from the
printer must be disposed of according to local environmental regulations (European Union
WEEE Directive 2012/19/EU, or the local equivalent).
FA48008
1.10 Test printing
Printing drops hold a charge, which is not discharged until the drops contact the substrate.
If test printing is performed into a container, a charge can occur and increase in the
collected ink. This charge can eventually, suddenly discharge to earth, which causes the ink
to ignite.
To prevent this risk of fire, it is extremely important to make sure that the ink is earthed so
that the charge does not occur. If a metal container is used, connect the container to an earth
point. If a non-metallic container is used (for example, glass or plastic), put one end of a
length of wire directly into the ink, and connect the other end to an earth point (see
Figure 1-1). The knurled securing screw for the printhead cover tube can be used as an earth
point.
IMPORTANT: To make sure that the printer operates correctly, this safety procedure is the
only time that the cover tube securing screw is to be used as an earth point.
40001
Figure 1-1. Test printing into a non-metallic container
FA48008
FA48008
CHAPTER 2: GENERAL AND
COMPLIANCE INFORMATION
2.1 Introduction
The Linx 8900 Continuous Ink Jet Printer is a fast, reliable, non-contact printer that can
apply sell-by dates, batch codes, logos and other variable information to a wide range of
substrates on the production line.
2.2 Technical data

2.2.1 Environmental
Operating temperature: +5 °C to +45 °C ambient temperature
Operating altitude: maximum 2000 m
Humidity range: maximum of 90% relative humidity, non-condensing
Acoustic emission: does not exceed 57 dBA
Protection rating: enclosure protected to IP55 in respect of water and dust
2.2.2 Power specifications

Supply voltage: single phase, 100 V AC to 230 V AC, 50/60 Hz
Supply fuses: 20 mm, ceramic, 4 A time-delay
Power consumption: 38 W typical while printing
This equipment is a Class 1 earthed appliance as defined by EN 60950. Electrical
connections on the side of the cabinet comply with the extra low voltage safety
requirements as defined by EN 60950.
WARNING: ELECTRICAL SAFETY. THIS PRINTER MUST BE CONNECTED TO AN

ELECTRICAL EARTH.
The safety status of the insulation resistance between the live and neutral conductors and
earth has been tested according to the test defined in EN 60950.
The safety status of the protective earth conductors has been tested according to the test
defined in EN 60950.
2.2.3 Cabinet
Construction
Spillage tray: stainless steel
Chassis: stainless steel

Cabinet: stainless steel
FA48008
Dimensions
External height: 500 mm
External width: 440 mm
External depth: 355 mm
Weight
Wet weight: 23.6 kg, approximately (includes printhead with 2-metre
conduit; full service module, ink and solvent cartridges,
and solvent tank; excludes accessories and packaging)
Dry weight: 21.8 kg, approximately (includes printhead with 2-metre
conduit; service module and ink and solvent cartridges
removed; empty solvent tank; excludes accessories and
packaging)
Add 0.8 kg for a 4-metre conduit
Add 1.6 kg for a 6-metre conduit

Low voltage power supply unit (LVPSU)
Input: 85 V AC to 264 V AC, 50/60 Hz
Output: +24 V DC; maximum continuous output current 6 A
300 volts power supply

Input: +24 V DC
Output: 2 x 300 V DC; maximum continuous output current 8 mA
Modulation amplifier
Input: +24 V DC and 300 V DC
Output: 0 V to 90 V rms, 80 kHz; maximum output current
45 mA rms
EHT power supply

Input: +24 V DC
Output: 0 V to +4.4 kV DC ±5%; maximum continuous output
current 8 µA
0 V to –4.4 kV DC ±5%; maximum continuous output
current 8 µA
FA48008
2.2.5 Ink system
IMPORTANT: The Linx 8900 Continuous Ink Jet Printer cannot be used in some
environments. For example, on offshore oil and gas installations, in
petro-chemical plants, mines, inappropriate areas in flour mills, and other
areas where a potentially explosive atmosphere may exist.
Construction
Ink system chassis: stainless steel
Solvent tank: natural colour HDPE
Service module: natural colour polypropylene
Ink and solvent cartridges: natural colour HDPE
Tubing: PTFE
Environmental
Protection rating: Electrical compartment protected from the ink system to a
rating of IP65.
Tilt angle
Operational tilt angle: maximum 2 degrees from the horizontal
Tilt angle when moved: maximum 45 degrees from the horizontal with full ink and
solvent tanks
Electrical connections within the ink system

Construction: (i) double insulated
(ii) chemical-resistant insulation
Pressure
Pressure range: 0 p.s.i.g. to 65 p.s.i.g. normal operating pressure
Cartridges
Material: HDPE
Ink cartridge capacity: approximately 500 ml
Solvent cartridge capacity: approximately 1000 ml
Service module
External height: 84 mm
External width: 149 mm
External depth: 159 mm
Capacity: 700 ml
Solvent tank
Capacity: approximately 520 ml
Fluid level control

Service module sense low: warning reported at approximately 500 ml
Service module sense high: approximately 640 ml
Solvent tank sense low: warning reported at approximately 250 ml
FA48008
Filtration
Ink and solvent cartridges: 40 µm in-line feed filters
Service module: 10 µm main ink filter
Solvent tank pick-up tube: 20 µm stainless steel filter
6-way fluid connector: 15 µm in-line ink filter; 15 µm in-line solvent filter
Printhead feed: 15 µm ‘last chance’ filter
NOTE: All filter sizes referred to here are nominal ratings.
Performance
Solvent consumption: Contact Linx for information about solvent consumption
(consumption depends on the ink type, the printer
configuration, and the environment in which the printer
operates).
2.2.6 Printhead
Type
Midi: Mk11 (62 µm nozzle jewel diameter)
Construction
Body: thermoplastic polyphthalamide
Cover tube: stainless steel
Conduit adaptor: stainless steel
Dimensions
Printhead body length: Straight printhead 225 mm; excludes conduit fitting (see
also conduit minimum bend radius below for clearance).
Printhead body diameter: 42 mm
Conduit
Length: 2 m, 4 m and 6 m
Minimum bend radius: static applications—60 mm
dynamic applications (traversing printhead)—180 mm
with a recommended 4-metre or 6-metre conduit
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2.2.7 Printing performance
Midi (62 µm)
Lines of print: up to three lines of 7 High characters
Maximum line speed*: one line of print: 2.6 m/s; 1.3 m/s
two lines of print: 1.3 m/s
three lines of print: 0.69 m/s
Maximum number of
characters per second*: 1200
Maximum message length: greater than 1 m
Message height range: 1.8 mm to 8.8 mm as standard.
Character width range*: 1.7 mm to 5.7 mm
* Figures given are for solid printed characters without spaces between printed drops.
Faster print speeds and wider print can be achieved easily if the horizontal space between
printed drops is increased. Refer to the separate Linx 8900 print samples sheet that is shipped
with the printer for more information.
Printhead to substrate distance (recommended)

Midi: 12 mm
2.2.8 Memory capacity

Storage capacity in flash: A maximum of approximately 150 MB of storage space for
user data (messages, logos, bar codes and configuration
settings). More messages can be stored on a USB memory
device.
2.2.9 Regulatory approvals

40389
Applicable to 8900 printers from serial number GQ201.
Safety
CE marking declaration
Low Voltage Directive

2006/95/EC
Radio and Telecommunications Terminal Equipment (R&TTE) Directive

1999/5/EC
Applicable European safety standards

EN 60950-1:2006+A2:2013: Information technology equipment. Safety. General
requirements.
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Electromagnetic compatibility (EMC)
EMC Directive
2004/108/EC
Applicable European EMC standards

EN 300 330-1 & -2: Electromagnetic compatibility and Radio spectrum
Matters (ERM); Short Range Devices (SRD); Radio
equipment in the frequency range 9 kHz to 25 MHz and
inductive loop systems in the frequency range 9 kHz to
30 MHz.
EN 61000-3-2:2006+A1/A2: Electromagnetic compatibility (EMC). Limits. Limits for
harmonic current emissions (equipment input current
 16 A per phase).
EN 61000-3-3:2008: Electromagnetic compatibility (EMC). Limits. Limitation
of voltage changes, voltage fluctuations and flicker in
public low-voltage supply systems, for equipment with
rated current  16 A per phase and not subject to
conditional connection.
EN 61000-6-2:2005: Electromagnetic compatibility (EMC). Generic standards.
Immunity for industrial environments.
EN 61000-6-4:2007+A1:2011: Electromagnetic compatibility (EMC). Generic standards.
Emission standard for industrial environments.
Applicable USA EMC standards

FCC CFR 47, Part 15,
subpart B: Code of Federal Regulations Title 47: Telecommunications;
Part 15: Radio Frequency Devices; Subpart B:
Unintentional Radiators (Class A devices)
Environmental
RoHS Directive
2011/65/EU: Restriction of the use of certain hazardous substances in
electrical and electronic equipment.
Battery Directive
2006/66/EC: Batteries and accumulators and waste batteries and
accumulators.
WEEE Directive
2012/19/EU: Disposal of Waste Electrical and Electronic Equipment
(WEEE).
Enclosure protection
BS EN 60529:1992+A2:2013: Specification for degrees of protection provided by
enclosures (IP code).
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2.3 Abbreviations and glossary
µm micrometre (micron)
A ampere
AC alternating current
BIST built-in self-test
BS British standard
CD compact disk
CE conformité Européenne (European conformity)
CETOF charge electrode and time of flight (assembly)
CFR code of federal regulations
CIJ continuous ink jet
CPU central processing unit
CSD cross section diameter
DAC digital to analogue converter
dBA decibels above reference noise, adjusted
DC direct current
DIP dual in-line package
DVM digital voltmeter
EHT extra high tension (voltage)
EIA Electronic Industries Association
EMC electromagnetic compatibility
EN European norm (standard)
ESD electrostatic discharge
FCC Federal Communications Commission
FEP fluorinated ethylene propylene
flash memory non-volatile, read/write memory
FPGA field-programmable gate array
GB gigabyte
HDMI high-definition multimedia interface
HDPE high-density polyethylene
HVPM high voltage power module
Hz hertz
I/O input/output
IC
2
inter-integrated circuit. A multi-master, serial, single-ended
computer bus that is used to attach low-speed peripherals to a
main board.
IC integrated circuit
ID identification or inside diameter
IEC International Electrotechnical Commission
in. inch
IP ingress protection or Internet protocol
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IPM integrated processor module
kg kilogram
kHz kilohertz
kV kilovolt
LCD liquid crystal display
LED light-emitting diode
LPB Linx pressure bits
LVPSU low voltage power supply unit
m metre
mA milliamp
MB megabyte
MEK methyl ethyl ketone
Mk mark (followed by a number that indicates a single design, model,
version, for example, ‘Mk9 Printhead’)
ml millilitre
mm millimetre
ms millisecond
mV millivolt
NC normally closed (relay contact)
NiMH nickel metal hydride
NO normally open (relay contact)
NPN negative-positive-negative (transistor)
NRV non-return valve
o.d. outside diameter
p.s.i.g. pounds-force per square inch gauge (pressure relative to the
surrounding atmosphere)
PCB printed circuit board
PIC® peripheral interface controller
PIN personal identification number
PL plug (connector with male pins/contacts)
PLC programmable logic controller
PNP positive-negative-positive (transistor type)
Print Go An internal logic signal that starts print, normally after a print
trigger.
print registration The horizontal position of a printed message on a substrate.
print trigger A logic signal generated inside the printer or by a product sensor,
which starts the printing of a single message.
PSU power supply unit
PTFE polytetrafluoroethylene
PWM pulse-width modulation
RAM random-access memory
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raster A variable line of drops printed at 90 degrees to the direction of
production line travel, which creates characters that are made up
of one or more rasters.
RFID radio frequency identification
RCI remote communications interface
RoHS restriction of hazardous substances
ROM read-only memory
rpm revolutions per minute
S/W software
SCP simple communications protocol
SDRAM synchronous dynamic random access memory
SI système international d'unités (international system of units)
SK socket (connector with female pins/contacts)
substrate surface (product) on which printing is done
TCP transmission control protocol
TOF time of flight
UNIC unique number identification chip
USB universal serial bus
V volt
VA volt-ampere (apparent power)
VFC volt-free contact (relay)
VGA video graphics array
W watt
WEEE Waste Electrical and Electronic Equipment (EU Directive)
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FA48008
CHAPTER 3: TECHNICAL
DESCRIPTION
3.1 Introduction
This chapter provides a technical description of the different sub-systems, modules and
components that are part of the Linx 8900 Continuous Ink Jet Printer. The following topics
are covered in this chapter:
3.2 Cabinet .............................................................................................................................. 3–1
3.3 User interface ................................................................................................................... 3–5
3.4 Printhead components.................................................................................................... 3–7
3.5 Printhead theory of operation ..................................................................................... 3–13
3.6 Ink system....................................................................................................................... 3–22
3.7 Electrical components ................................................................................................... 3–44
3.8 Electronics and software............................................................................................... 3–51
3.9 External signals .............................................................................................................. 3–61
IMPORTANT: When the locations of external cabinet components are referred to in the
following descriptions, the left, right, front and rear sides of the printer are
with respect to the printer when looked at from the front.
The internal components can be seen only when the rear access panel is
removed. Therefore, the locations of these parts are referred to as left, right,
front or rear as seen from the rear of the printer.
3.2 Cabinet
3.2.1 Introduction
The printer spillage tray, cabinet, and external panels are made from stainless steel.
The printer cabinet is protected to a minimum ingress protection (IP) rating of IP55 in
respect of water and dust.
The cabinet contains the following main components:
 User interface touch screen.
 Ink system that includes the service module.
 Electronics system: IPM Assembly (I/O PCB and CPU PCB).
 High voltage power module (HVPM).
 Mains electrical supply unit.
 Cooling fan and air filter.
 Optional printhead positive air pump.
Figure 3-1 on page 3—3 shows the main external parts of the 8900 printer, and Figure 3-2 on
page 3—4 shows the locations of the main internal components.
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3.2.2 Front top panel
The front top panel contains the user interface TFT LCD touch screen and the power on
switch.
Power on switch
When the mains electrical supply is connected to the printer, 24 volts DC is available at the
PSU in the printer at all times, even when the printer has powered down. The green ‘power
on’ switch on the right of the display enables the 24 volts DC, which turns on the printer.
3.2.3 Front access door

Access to the ink and solvent cartridges for removal and insertion is by a single
stainless-steel door on the front of the printer. The door is a push-to-open/push-to-close
device with no external handle or latch. Door opening is spring assisted and the door opens
fully without operator assistance.
The cartridges are presented to the operator (cartridges receptacle lifted) when the door is
opened, and are not pierced until the door is fully closed. The ink cartridge cannot be
inserted into the solvent aperture, and the solvent cartridge cannot be inserted into the ink
aperture.
3.2.4 Cabinet left side

The following parts are mounted on the left side of the cabinet:
 Protection box for the mains electrical supply connector.
 Options plates for VFC module and RS-232.
 External signals connectors: print trigger input and shaft encoder inputs (two paralleled
connectors), external alarm output, USB interface, and Ethernet interface.
 Mounting plate for the printhead conduit.
 Left access panel—fastened by four screws which allows access to the service module.
3.2.5 Right access panel

The right access panel is fastened by two thumbscrews and allows access to the air filter.
3.2.6 Rear access panel

This access panel on the rear of the printer allows access to the electronics system and the
ink system. The bottom of the panel has two tabs that fit into two slots in the cabinet, and
the panel is fastened to the cabinet by two screws at the top.
The air filter housing and filter are part of the rear access panel assembly, which is removed
from the printer as a single unit. Attached to the rear access panel are four baffle vents: the
two upper vents are for the electronics system and the two lower vents are for the ink
system.
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89003
G
B
D
C
89004
K
M
A. Power on switch E. External signals connectors (x5) K. Rear access panel

B. User interface touch screen F. Printhead conduit mounting plate L. Ink system baffle vents
C. Front access door (for ink and G. Option plate M. Right (air filter) access panel
solvent cartridges) H. Protection box for the mains
D. Left access panel (service electrical supply connector
module) J. Electronics system baffle vents
Figure 3-1. 8900 printer cabinet—main external parts
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NOTE: The electrical cables, ink system pipes, and L-shaped support arm for the ink
system are not shown in the following illustration, for clarity.
89005
P
A
B
O
N
D
E
M
L
G
H
K
A. Mains electrical supply filter and fuses (x2) J. Solvent recovery unit
B. CPU PCB (part of the IPM Assembly) K. Solvent tank
C. I/O PCB (part of the IPM Assembly) L. Damper (part of the pressure transducer and
D. 6-way fluid connector (includes ink and solvent damper assembly)
15 µm in-line filters) M. Pressure transducer (part of the pressure
E. Solvent priming unit (fitted to support arm—not transducer and damper assembly)
shown) N. Ink system pump and motor assembly
F. Venturi manifold O. Transfer pump
G. Service module P. High voltage power module (HVPM)
H. Valves manifold
Figure 3-2. 8900 printer cabinet—main internal components
3.2.7 Cooling and air filter

A cooling fan is fitted to the underside of the air filter housing above the IPM Assembly. A
cabinet air filter is fitted in the air filter housing above the cooling fan. The air filter housing
assembly is attached to the inside of the rear access panel.
The air intake for the cooling fan is through the baffle vent on the rear access panel behind
the IPM Assembly. The air is drawn in through the air filter and the fan, and then flows
down over the IPM Assembly and the HVPM. From here the air leaves the printer through
the baffle vent on the rear access panel behind the HVPM.
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The air filter can be removed to allow the filter to be cleaned or replaced. A tab on the front
edge of the filter makes it easy to remove. The filter can be cleaned with compressed air
blown through in the reverse direction to the normal airflow. If the air filter has a severe
blockage or is damaged, the filter must be replaced.
IMPORTANT: Make sure that the filter is fitted with the foam side facing up (metal mesh
side facing down).
There is a natural air vent for the ink system through the two lower baffle vents on the rear
access panel.
Linx recommends that the air filter is replaced at the same time as the service module. Refer
to ‘Maintenance Times’ on page 5—18 of Chapter 5: ‘Maintenance’ for the maximum
replacement interval.
3.3 User interface

The user interface is a TFT LCD touch screen, and there are no separate controls or
keyboard.
Figure 3-3 shows the standard English user interface of the 8900 printer.
89065
Figure 3-3. English user interface—Home screen
3.3.1 Display
The display is a 10-inch WSVGA, colour TFT LCD, projected capacitive touch screen with a
white LED backlight. The unit is fitted in the front top panel of the printer.
Operator controls
CAUTION: Touch Screen Damage. The surface of the user interface touch screen can be easily
damaged if items like pens and other tools are used to activate the on-screen functions. To
prevent damage, use only a finger to activate the functions. The use of incorrect items can
cause scratches on the touch screen.
All printer operation functions, which include the green Start Printing button, amber Pause
Printing and red Stop Jet button, are activated through the touch screen. The on-screen
options and symbols are lightly touched to activate the function and navigate through the
screens.
The Start Printing button starts the jet and starts printing if a message has been selected,
and restarts printing if printing has been paused (Pause Printing button). The Stop Jet
button stops printing and shuts down the jet.
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Keyboard
The user interface includes a QWERTY layout, on-screen keyboard, through which
messages are entered and edited.
Messages
Before printing can occur, a message or messages must be created. A message is a structure
that describes the text or pattern to be printed. Each message has one or more fields, which
can be of a number of types. For example, a text field is simply fixed text that does not
change from one print to the next. A time field displays the current time (or the time offset
by a set amount) and changes from one print to the next. Refer to the Linx 8900 Quick Start
Guide for details about how to create and edit messages.
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3.4 Printhead components
This section identifies the main components of the printhead and describes their basic
functions. Figure 3-4 shows the location of the main printhead components.
NOTE: All filter sizes referred to in the descriptions are nominal ratings.
40003
Printhead conduit from

control system and ink system
Printhead conduit strain relief
Cover tube
securing screw
Body
Printhead feed filter

('last chance' filter)
Nozzle cover
Nozzle with jewel Charge electrode plates
Strobe LED
(below charge electrode plates)
TOF sensors
+4.4 kV deflector plate
–4.4 kV deflector plate
Gutter
Figure 3-4. Mk11 Midi printhead main components
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3.4.1 Printhead feed filter (‘last chance’ filter)
The 15 µm printhead feed filter (also called the ‘last chance’ filter) is the last fluid filtration
before the jet is created. The filter is fitted in the feed line at the inlet to the gun chamber and
nozzle assembly.
Access to the filter for replacement is from the outside of the printhead. The filter is fitted in
the end of a plug that is removed with a hexagonal key (see Figure 3-5).
40012
Figure 3-5. Location of the printhead feed filter
3.4.2 Gun chamber and nozzle assembly

The printhead operation requires ink to be supplied under pressure from the ink system to
the ink gun chamber and then out of the nozzle.
The gun chamber is inside the potted printhead body, behind the nozzle assembly. Inside
the chamber the ink is pulsed (modulated) by the effect of a piezoelectric crystal, which
causes the ink jet to separate into drops.
The modulated jet is ejected from the nozzle assembly through an accurately cut, 62 µm
diameter hole in a small jewel contained in the nozzle cap.
3.4.3 Charge electrode plates

The charge electrode plates apply an electrical charge to each ink drop as the drop separates
from the ink jet. Drops that are required for printing are charged, while drops that are not
required for printing remain without a charge and pass to the gutter, and then return to the
service module for use again.
3.4.4 Strobe LED

A red light-emitting diode (LED) is fitted between and below the charge electrode plates, so
that the LED is behind the jet break-up point when viewed from the front of the printhead.
The LED illuminates when the printhead cover tube is removed. The stroboscopic effect of
the LED allows the position of the jet break-up to be examined with a magnifying eyeglass,
which can be useful for fault diagnosis.
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3.4.5 TOF sensors
Two time of flight (TOF) sensors are contained in a ceramic plate after the charge electrode
plates, and together these components are called the charge electrode and time of flight
(CETOF) assembly. These sensors monitor the jet to make sure that the printer is operating
correctly.
During startup, and at intervals between printing patterns, the system monitors the jet
performance. The two sensors detect signals from the passing drops and the printer uses
these signals for two functions. The first function makes sure that the drops receive the
correct charge at the correct time for continuous print quality—this process is called phasing.
The second function calculates the speed of the jet. The system measures the time the drops
take to pass between two fixed points—the TOF sensors—and uses this information to
calculate the jet speed. This process is called the time of flight measurement.
The phase and TOF readings are checked at regular intervals, between printing patterns, to
maximize print quality.
3.4.6 Deflector plates

An electrostatic field is generated between the two deflector plates. When the ink jet passes
through the field, charged (printing) drops are deflected in proportion to the amount of
charge each drop carries. Drops without a charge (non-printing) are not affected by the
electrostatic field, are not deflected and enter the gutter. These drops are then drawn back
through the system to the service module for use again.
The combination of the speed of the drops through the field and the charge given to the
drops is accurately calculated to make sure that each drop is put in the correct position on
the substrate (the surface onto which the pattern is to be printed).
3.4.7 6-way fluid connector assembly

A 6-way fluid connector assembly connects the fluid lines of the ink system and the positive
air line to the printhead. The assembly allows the printhead to be quickly and easily
removed and replaced.
The assembly has three parts: a manifold block and two 3-way fluid connectors (refer to
Figure 3-6). The manifold block is part of the ink system and the fluid connectors are part of
the printhead conduit. Each of the fluid connectors is fitted to the manifold block with a
cross-head screw, and the six ports are sealed by O-rings when the parts are assembled.
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89006
B
S
R C
Q
D
P
N E
M
F
L
G
K
J H
A. Solvent fluid connector G. O-ring x6 N. Positive air pump line
B. Ink filter holder H. Manifold block P. Solvent filter holder
C. Printhead feed line J. Ink system purge line Q. Printhead solvent line
D. Printhead purge line K. Ink system gutter line R. Printhead positive air line
E. Printhead gutter line L. Ink system feed line S. Assembly screws
F. Ink fluid connector M. Ink system solvent line
Figure 3-6. 6-way fluid connector assembly

The ink fluid connector connects the feed line, gutter line and purge line to the printhead.
The solvent connector connects the solvent line and the positive air line to the printhead.
The air and fluid lines are colour coded for easy identification and connection:
 Feed line – red stripe
 Gutter line – no stripe
 Purge line – blue stripe
 Solvent line – green stripe
 Positive air line – yellow stripe
In-line filter
A stainless steel, in-line filter is fitted in each 3-way fluid connector. The 15 µm filter is fitted
in the feed line of the ink connector and the solvent line of the solvent connector.
The filter element is part of a disposable, screw-in holder that is easily removed with a
hexagonal key for replacement (refer to Figure 3-6).
The filter provides increased printhead protection from possible contamination in the ink
and solvent, which can cause a blockage in the nozzle.
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3.4.8 Printhead cover tube detection
When the cover tube is fitted to the printhead, two contacts on the printhead body make
connection with the cover tube, which creates a closed circuit between the contacts. The
presence of the cover tube is detected, and the deflector plate EHT and the charge voltage
supplies are turned on, which enables the printing process. When the cover tube is moved
away from the two contacts, the circuit is broken. This action disables the EHT and charge
voltage supplies, and printing is paused. Printing is continued a few seconds after the
printhead cover tube is refitted.
The contacts can be removed easily for adjustment or replacement, and Figure 3-7 shows
how the contacts are fitted into the printhead.
AS386
Figure 3-7. Mk11 printhead and cover-detection contacts
3.4.9 Printhead temperature sensor

The printhead is fitted with a temperature sensor, which has two functions—‘over
temperature’ and ‘ink density’.
Over temperature
First, the sensor is a safety device. When a local printhead temperature greater than 63 °C is
detected, the printer is immediately shut down in a controlled process. The Print Failure
message “2.00 Printhead Over Temperature” is also displayed to advise that the printhead
has an ‘over temperature’ condition.
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Ink density
Second, the system uses the temperature monitored by the sensor to adjust for changes in
ink density at the maximum and minimum operating temperatures of the printer.
Under normal operating conditions, the Set Pressure is adjusted to maintain a constant TOF
as the ink viscosity changes.
For example, as the ink viscosity increases caused by solvent evaporation, the Set Pressure
is increased to maintain a fixed TOF (at the Reference TOF) with the thicker ink. If the Set
Pressure reaches the known Solvent Add Pressure, solvent is added to the ink to decrease
the viscosity and so maintain the Actual TOF at Reference TOF. Refer to ‘Solvent addition’
on page 3—39 later in this chapter.
Although the pressure required to reach the correct TOF depends on the viscosity of the
ink, pressure is also affected by temperature and, more importantly, by ink density. For
example, at lower temperatures when the ink is at a greater density, the jet must be driven
at a higher pressure to maintain the correct TOF. Therefore, the printhead temperature is
monitored and the Set Pressure is adjusted as necessary to allow for the greater ink density.
The Solvent Add Pressure is offset by an amount that depends on the printhead
temperature. This control prevents the printer from adding solvent too early to make the
ink thinner at low temperatures, when the ink is at a higher density but is at the best
viscosity.
The above rule applies, but in reverse, when there is a high printhead temperature and the
ink density is low.
This pressure adjustment is the reason why, at maximum and minimum operating
temperatures, the Solvent Add Pressure can be seen to change on the Jet Monitor screen
(Main Menu > Maintenance > Jet Monitor).
See also:
 ‘Viscosity control’ (in the section ‘Printhead theory of operation’) on page 3—19.
 ‘Solvent addition’ (in the section ‘Ink system’) on page 3—39.
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3.5 Printhead theory of operation
3.5.1 Summary
The following is a short summary of the basic theory of operation of the ink jet printhead.
This summary is followed by a full description of each part of the process.
A character is created on the substrate from ink drops discharged from the printhead. The
structure of the character depends on drops being printed or discarded. The drops are
discharged from the printhead in lines that are called rasters, and each raster has a preset
number of drops that controls the potential height of a character. The characters are created
from rasters printed one after the other as the substrate moves past the printhead.
Inside the printhead, electrically-conductive ink is fed under pressure through an
accurately-cut hole in an industrial jewel in the printhead nozzle cap to create the ink jet.
Before the jet leaves the nozzle, the ink is pulsed (modulated) to generate a continuous jet of
modulated ink. This modulated jet leaves the nozzle and passes between the charge electrode
plates where the jet divides into separate ink drops. The jet continues to a gutter, which
collects the non-printing drops and returns these drops under vacuum to the service
module.
Ink drops that are to be printed receive an electrostatic charge. This process occurs between
the charge electrode plates, which is at the point in the jet flight path where the jet naturally
separates into drops. The electrostatic charge causes a flow of electrons onto each drop as it
is created. The printing drop now has a negative electric charge.
This electrically charged drop moves with the main jet of drops until it enters the area
between two deflector plates. The electrostatic field generated between the plates applies a
force to the drop, which deflects the drop from its original straight path and draws it
towards the positive potential plate. The drop is deflected by an amount that is
proportional to the charge on the drop and the potential across the two deflector plates.
A measurement of jet speed (time of flight) is performed. Both of the time of flight (TOF)
sensors are used to measure the time taken for drops to move the known distance between
the two sensors. This time period provides an accurate evaluation of jet speed, which is
used by the printer to adjust the pressure at which the ink is ejected from the nozzle. Jet
speed is also used with the pressure to monitor ink viscosity at the printhead.
To make sure that the printing drops are correctly charged at the correct time (phase), a
regular test of the charging function is performed. Phase is determined from the presence of
good TOF measurements at a specific phase.
3.5.2 Printhead types

The Linx 8900 Continuous Ink Jet Printer uses a Mk11 Midi printhead, which has a nozzle
orifice size (measured in micrometres) of 62 µm.
The Midi printhead prints a maximum of three lines, or a single line of a maximum of 34
High characters.
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3.5.3 Modulation
The jet of ink from the nozzle is broken into drops of equal size and spacing by a process
that is called modulation.
A jet of fluid naturally breaks into approximately equal size drops because of the effects of
aerodynamic drag and noise. The jet break-up (drop break-off) can be accurately controlled
by the introduction of a disturbance or excitation into the fluid. This excitation is done in
the Linx printheads by the oscillation of a piezoelectric crystal that is in contact with the ink.
Charge electrode plates.

NOTE: charge electrode assembly
shown rotated through
90 degrees for ease Gun chamber
of representation 40004
Nozzle
Modulation signal
Ink drop break-off (jet break-up)

occurs in the charge electrode
caused by excitation from
the piezoelectric crystal
Piezoelectric crystal
pulsed by the
modulation signal
Ink delivered under pressure

from the ink system
through the ink feed line
NOT DRAWN TO SCALE

Figure 3-8. Modulation of the ink jet by a piezoelectric crystal
If a voltage is applied to a piezoelectric crystal, the crystal bends, and the amount that the
crystal bends depends on the amplitude of the applied voltage. Two opposite-polarity,
bimorph piezoelectric crystals are used in the printhead gun chamber, joined together so
that the crystals bend in sympathy with a fixed-frequency sine wave. This process gives a
direct and very controlled modulation to the ink. Because the edges are fixed, the crystal
deflects and moves a small volume of ink. This movement is transmitted through the ink
and causes disturbance in the jet, which then separates into equal size drops.
The frequency of the sine wave (modulation frequency) applied to the piezoelectric crystal
controls the rate of drop production. This drop production rate is a fixed value for each type
of printhead and is 80 kHz for the Midi printhead.
The amplitude of the sine wave (modulation voltage) applied to the piezoelectric crystal
controls exactly where the ink jet forms into drops, and depends on:
 The type of printhead.
 The different characteristics of each separate printhead.
 The type of ink that is used.
This modulation voltage is a value calibrated at Linx between 0 and 255 volts AC, and is
unique to every printhead. The value is referred to as the Reference Modulation and is part of
the printhead code, and is also printed on each printhead conduit label.
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As described earlier, the modulation amplitude controls the point at which the ink jet
separates into drops. This point changes and depends on the viscosity of the ink—if the ink
is thicker, the drop break-off occurs at a later point than for thinner ink. The correct point of
drop break-off is within the charge electrode plates where printing drops are required to be
charged.
40005
Printhead nozzle
Ink jet pulsed by the

piezoelectric crystal
Drop break-off
begins to occur Charge electrode
plates (x2)
Strobe LED
Point of drop break-off (jet break-up).

This must occur within the central Charged drops
area of the charge electrode for the
drops to receive the correct charge
Figure 3-9. Correct drop break-off in the charge electrode
3.5.4 Drop charge

To build a pattern, each drop has to be directed to an exact position on the substrate. To get
this accuracy, each drop is charged and deflected separately by a defined amount.
Each drop to be printed receives an electric charge, so that the drop can be deflected by the
electrostatic field between the deflector plates. The amount that the drop is charged is
controlled by the planned position of the drop on the substrate. The further the drop has to
be deflected, the greater the electric charge on it.
To charge a drop, a positive voltage of between 0 volts and +255 volts is applied to the
charge electrode for the time (1/modulation frequency) required to create one complete
drop. The drop now has a negative charge. This charge is created by capacitive coupling, by
which a flow of electrons is induced from the nozzle (which is at earth potential), through
the electrically conductive ink onto the ink drop as it takes shape. When the drop separates
from the ink jet, the charging voltage is removed from the charge electrode and the drop
holds the given charge.
The charge timing is such that the exact point of drop break-off occurs at the end of the
charge pulse. To make the end of the charge pulse occur at the exact drop break-off point is
very important. Accurate timing makes sure that the drop has been given the full charge,
which increases the accuracy of the printed position of the drop on the substrate.
If the following drop is to be printed, the voltage on the charge electrode is set to the
applicable level for the time period of the drop production. If the next drop is not for
printing (and is, therefore, passed straight to the gutter), a small correction voltage of 12.5%
of the previous charge voltage is applied. This action is called historic correction, which is
described later in this section (refer to ‘Historic correction’ on page 3—16).
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3.5.5 Strobe LED
A red light-emitting diode (LED) is fitted at the bottom of the charge electrode plates, so
that the light is behind the jet break-up point when looked at from the front of the
printhead. The light is fed through a pipe that focuses the light into a bar the same length as
the charge electrode plates.
The LED electrical supply is enabled when the printhead cover tube is removed, and the
LED is pulsed at the same frequency as the modulation signal. The stroboscopic effect of the
light causes the ink jet to appear stationary between the charge electrode plates when
looked at with a magnifying eyeglass. This feature allows the jet break-up to be examined,
which can be useful for fault diagnosis purposes. When the ink jet break-up is examined
with a magnifying glass of x10 or x20 magnification, the example shown in Figure 3-9 on
page 3—15 is seen.
For safety reasons, the deflector plates and the charge electrode must be set to a safe state
before these components are touched or work is done on the printhead. Refer to ‘Printhead
cover tube detection’ on page 3—11 for more information. Refer also to the descriptions of
the Safety Override link and the Cover Override link in the section, ‘Electronics and
software’ on page 3—51.
3.5.6 Historic correction

Historic correction is used to remove the positive charge induced in a non-printing drop
from a printing drop. The historic correction voltage makes sure that non-printing drops
have zero charge when they leave the charge electrode, and so pass straight to the gutter.
A non-printing drop that follows a charged drop can be induced by capacitive coupling
from the charged drop. This induction puts a small, but significant, positive charge on the
non-printing drop. To remove this unwanted charge, an historic correction voltage of 12.5%
of the previous charge voltage is applied to the charge electrode for all non-printing drops.
For example, a printing drop has 100 volts applied to the charge electrode for the time
period for the production of that drop. The following drop is a non-printing drop, and
therefore must pass to the gutter. To remove the positive charge that is induced in the
non-printing drop from the previous printing drop, 12.5 volts is applied to the charge
electrode for the time period for the production of the non-printing drop to set its charge at
zero.
3.5.7 Drop deflection

When drops have been charged to the correct level, the drops continue along the flight path
and pass between the deflector (EHT) plates. A fixed high voltage of 8.8 kV maximum is
applied across the plates, which creates an electrostatic field. The drops that have a negative
charge (printing drops) are deflected in this field towards the positive plate. The drops are
deflected by an amount that is proportional to the field strength and the amount of charge
on each drop.
The printing drops then exit through the slot in the printhead cover tube and are applied to
the substrate in rasters to create the characters, bar code or logo. The speed of the drops
through the field and the charge given to the drops are accurately measured to make sure
that each drop is put in the correct position on the substrate.
Non-printing drops are given zero charge, which causes zero deflection, and so the drops
continue along a straight flight path and enter the gutter. A vacuum applied to the gutter
draws the ink drops back through the system to the service module to be used again.
IMPORTANT: The deflector plates and mountings must always remain clean and without
ink deposits, otherwise a decrease in print quality can occur. The
mountings for the deflector plates are black in colour, and so ink deposits
are not always easily seen.
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3.5.8 Guard drops
Because all printing drops have a negative charge, each drop tries to repel adjacent drops in
the flight path, which can cause a decrease in print quality. The most deflected drops in a
raster carry a higher negative charge and therefore have a greater repulsion effect on
adjacent drops. This effect is greater in large characters, which causes a greater decrease in
print quality. Because of this effect, it would not normally be possible to have drops that
touch on the substrate, which would ideally give a higher-quality print.
However, where high-quality print is required (with printed drops that touch on the
substrate), the drops in the flight path must be separated to remove the drop repulsion
effect. To get this separation, guard drops are inserted.
Guard drops are low-charge, non-printing drops that are inserted into each raster between
printing drops to separate the drops in flight, which decreases their interactive effect. When
large characters are printed, more guard drops are inserted between the most deflected
(higher charged) drops to decrease their greater interactive effect.
6248
No guard drops, therefore,

much greater repulsion
Low charge, non-printing

guard drops inserted
to reduce repulsion
Gutter Gutter
Figure 3-10. Guard drops
3.5.9 Phasing
The deflection of each ink drop is controlled by the voltage that is applied to the charge
electrode immediately before the drop separates from the main ink jet. For the correct
drop-charge to occur, the voltage on the charge electrode must be there at the exact time
that the drop separates from the main ink jet. The method that makes sure that
synchronization between the charge and the jet break-up time is called phase control.
The charging circuit is a capacitance-resistance (CR) network and these circuits have a CR
time constant to charge completely. Therefore, if a voltage is applied to the charge
electrode, it can take 2 µs to 3 µs before the charge reaches the final level. For example, the
earlier Mk7 Micro printhead creates drops every 8 µs, and so the production of incorrectly
charged drops is possible unless there is synchronization of the process.
To perform phase control, a series of half-width charge pulses (called a phase packet) is
generated at a low voltage, which is not high enough to deflect the charged drops from the
gutter. Normally, a phase packet is eight drops charged by 10 volts. The half-width pulses
are moved in 1/16 cycle steps (phase positions) relative to the modulation signal, and any
charge result is detected by the TOF sensors.
FA48008
A half-width pulse only induces charge onto drops for eight out of the 16 steps in a cycle.
Therefore, it is a simple process to move the position by one step until an edge between
charge and no charge is detected. This position sets the timing that allows full-width
printing pulses to be placed, which then gives correct printing. An illustration of the
phasing process is shown in Figure 3-11.
40006
Jet break-up
Instant of drop break-off
Modulation signal
Phasing signal Phase sensor

(½ width pulses) output
Step 1
Step 2
(moved right by one phase position)
Step 3
(moved right by one phase position)
Phase found
Charging pulses
Figure 3-11. Phase control process

The process performs a continuous sequence of phase cycles if the printer is in the ‘Idle’
state. If the printer is printing, a single phase cycle is performed at the end of each message.
3.5.10 Time of flight (TOF)

During printer operation, solvent evaporates from the ink in the service module. This
natural occurrence causes the ink to become thicker, that is, the viscosity of the ink
increases. If this were not controlled, a decrease in jet speed would occur. The lower jet
speed would cause a change in the position of the printed drops on the substrate, because
the drops take longer to pass between the deflector plates. To prevent this effect, and to
maintain continuous print quality, the control function of the printer monitors the jet speed
and adjusts the pressure to allow for any changes.
The measurement and control of the jet speed is called time of flight (TOF), where 10 volts is
applied to the charge electrode to charge a number of TOF drops. This packet of drops
passes the first TOF sensor (contained in the CETOF assembly) where a current is induced
in the sensor, which starts a counter. The count continues until the same packet of TOF
drops passes the TOF sensor (also contained in the CETOF assembly). When the TOF packet
passes the second TOF sensor, it induces a current in the sensor, which stops the counter.
The counter value is the Actual TOF.
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This Actual TOF value is compared with a Reference TOF. An evaluation of jet speed is made
and the system pressure is increased or decreased, as necessary, to maintain a fixed jet
speed, according to the following rules:
 If Actual TOF is equal to Reference TOF (±0.5%), system pressure is not changed.
 If Actual TOF is greater than Reference TOF (+0.5%), system pressure is increased.
 If Actual TOF is less than Reference TOF (–0.5%), system pressure is decreased.
The process to create the phase and TOF signals is the same. The difference between the
phase and TOF operations is in how the software processes the received signal.
3.5.11 Viscosity control

The viscosity of the ink changes during printer operation (described earlier in ‘Ink density’
on page 3—12). The viscosity of the ink at the printhead is calculated by the control system
from the Set Pressure required to maintain the Actual TOF at the Reference TOF value. The
Set Pressure is adjusted as the viscosity changes to maintain a fixed TOF. When the
viscosity reaches a known level, solvent is added to the service module from the solvent
tank. This known level is when the Set Pressure is greater than a value called the Solvent
Add Pressure. The Solvent Add Pressure value comes from a Reference Pressure, which is a
calibrated value that is unique to each printhead (and which forms part of the printhead
code).
See also:‘Printhead temperature sensor’ on page 3—11.
For each of the printhead types, the Solvent Add Pressure is defined as the Reference
Pressure + 4 LPB.
A solvent addition occurs only if all of the following four conditions apply:
 The Set Pressure is greater than the Solvent Add Pressure.
 The Actual TOF is within ±0.5% of the Reference TOF.
 The warm-up time has expired (that is, the jet has been in operation for 45 minutes).
 The solvent level is acceptable (that is, the printer solvent level is above the minimum
required and the Print Failure “2.43 Solvent System Empty” has not occurred).
When solvent is added to the ink in the service module, the viscosity of the ink is lowered.
This thinner ink reaches the printhead within 3 minutes, and the jet speed increases. The Set
Pressure is then decreased to maintain the jet speed at the Reference TOF. If after 2 minutes
(the Viscosity Settle Time), the Set Pressure value remains above the Solvent Add Pressure
value, more solvent is added to the service module.
To prevent too much solvent being added to the ink, the printer allows a maximum number
of 25 consecutive solvent additions, where the Set Pressure has not decreased to less than
the Solvent Add Pressure.
If after these solvent additions, more solvent is required, the printer fails with Print Failure
“2.12 Viscosity Out of Range”.
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3.5.12 Startup and shutdown
The theory of continuous ink jet printing is accepted as the best method of printing with an
ink that is required to dry immediately (within a second) on almost any surface. If ink is
required to dry quickly on the product, the ink can also dry in the printhead nozzle and
cause a blockage.
The continuous ink jet printer uses a pump to control this problem, which continuously
circulates the ink through the printhead and the ink system. Although the ink is
evaporating quickly during printer operation, the ink does not cause a nozzle blockage
because there is a continuous replacement of ink in the nozzle.
A problem occurs at shutdown when ink is left in the printhead nozzle. Because the ink
dries very quickly, it causes a blockage in the nozzle. To prevent this blockage, special
functions are necessary to clear the nozzle.
Immediately before final shutdown, solvent is fed into the ink gun and is circulated
through the nozzle and out to the gutter, which clears ink from these very important
components. Because this process is performed automatically at every shutdown, it is not
necessary to manually clean the printhead after shutdown.
During startup, a series of actions occurs automatically:
 The electronic circuitry is checked.
 The solvent priming unit is reprimed.
 The ink system allows solvent to circulate through to the printhead and a solvent jet is
created.
 A gradual introduction of ink into the solvent jet occurs until finally the solvent jet
becomes a full ink jet.
 Pressure is increased to normal operating pressure and the ink jet is pulsed by the
modulation process to cause drop break-off.
 The TOF is adjusted to a value close to the Reference TOF, that is, jet speed is corrected.
The printer goes to the ‘Printing’ state only when the above functions are operating
correctly.
 The phasing and modulation are checked automatically for the best position.
 When a signal is received from the ‘Print Go’ sensor (for example, a photocell), the
printer prints the previous message that was entered. The message is automatically
updated for items like dates and sequential numbers.
All these actions occur automatically, and under normal operating conditions it is not
necessary to remove the printhead cover tube and perform any maintenance during startup
or shutdown. However, under some conditions, it can be necessary to remove the printhead
cover tube and manually clean the printhead at regular intervals.
CAUTION: Printhead Damage and Print Failures. The printhead can be damaged or the printer
can fail if the wrong solvent is allowed to enter the solvent tank. Make sure that the solvent
used to clean the printhead is the correct type for the ink and solvent used in the printer. Use
MEK solvent for MEK-based inks, ethanol solvent for ethanol-based inks, and mixed-base
solvents for mixed-base inks.
The Normal Startup sequence is dynamic and adjusts the process, time taken, and the
amount of solvent used, which depend on the following factors:
 Ink type.
 Ambient temperature.
 Printhead height.
 Normal or incorrect shutdown. An incorrect shutdown is where the mains electrical
supply was disconnected while the jet was running.
The typical duration of a Normal Startup is approximately 3 minutes.
NOTE: At the next jet start after an incorrect shutdown, the sequence can take
approximately 5 minutes. The extended sequence is also performed at the next jet
start after the Jet Test-Stop function has been used.
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3.5.13 Jet and nozzle alignment
The performance of the printhead depends on the very accurate alignment of the ink jet.
There are two requirements:
 To make sure that the ink drops are charged correctly, the jet must pass through the
centre of the space between the charge electrode plates.
 The non-printing drops must enter the gutter accurately, that is, the jet must not hit the
edge of the gutter.
The position of the charge electrode, the deflector plates or the gutter cannot be adjusted. A
small amount of movement of the nozzle is possible to correct the jet alignment.
3.5.14 Print quality

During manufacturing, a series of performance and quality tests are performed on each
printer to identify the different characteristics of each printhead. These characteristics are
related to the type of printhead and the variant (for example, type 62 µm; variant Midi) and
are:
 Reference Pressure.
 Reference Modulation voltage.
 Charge Gain.
These parameters are different for each printhead and are set to give continuous and
reliable print quality. The parameters are stored in the printhead and read by the printer at
power-up and displayed on the Calibration screen (Main Menu > Maintenance >
Calibration). Refer to ‘Calibration’ on page 5—33.
3.5.15 Printhead replacement

When a printhead is replaced, the parameters for the new printhead are automatically read
by the printer from the printhead.
Before the printhead is removed for replacement, the printer must be allowed to complete a
full Normal Shutdown. This process removes any ink that remains in the nozzle, and the
purge and gutter lines. Ink will still remain in the feed line.
IMPORTANT: The 8900 printer cannot flush the printhead before removal. If the
printhead is removed for shipment to Linx for analysis, a blanking cap
must be fitted to the 3-way ink fluid connector of the printhead to seal the
feed line.
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3.6 Ink system
3.6.1 General description
NOTE: All given filter sizes are nominal ratings.
The ink system is contained within an enclosure in the lower part of the cabinet. All of the
ink system components, except the ink and solvent cartridges, are contained on a sliding
tray module that can be withdrawn from the cabinet for maintenance access. A stainless
steel spillage tray is included in the base of the cabinet, which contains any ink or solvent
spillage from the ink system.
An ink cartridge and a solvent cartridge are fitted inside the cabinet, behind a
spring-assisted access door on the front of the printer.
The ink system includes the following main components (also refer to the static ink system
diagram in Figure 3-12 on page 3—23):
 Spillage detector (page 3—24)
 Service module (page 3—24)
 Solvent priming unit (page 3—25)
 Solvent Prime valve (page 3—26)
 Pump and motor assembly (page 3—26)
 Venturi manifold (page 3—27)
 Pressure transducer and damper assembly (page 3—28)
 Ink System Feed valve (page 3—28)
 Solvent tank (page 3—29)
 Transfer pump (page 3—30)
 Solvent recovery unit (page 3—30)
 Ink and solvent cartridges (page 3—31)
 Valves manifold assembly (page 3—32)
 Solvent Add valve (page 3—33)
 Purge valve (page 3—33)
 Solvent Top-up valve (page 3—33)
 Ink Cartridge valve (page 3—33)
 Solvent Cartridge valve (page 3—33)
 Vent valve (page 3—34)
NOTE: The symbol ‘µm’ stands for micrometre, which is the SI unit of length and
previously called the micron.
FA48008
Linx 8900 Maintenance Manual
FA48008
INK 89002_01_Stat
SOLVENT
Purge line
Gutter
Feed line
Solvent line
Printhead Gutter line Printhead positive air line to printhead
15 µm in-line
solvent filter 15 µm in-line
ink filter
Positive 6-way fluid

Manifold valves
Solvent air pump connector
Ink identification
cartridge assembly
cartridge 1 — Solvent Add
2 — Ink Cartridge CLOSED CLOSED CLOSED CLOSED CLOSED CLOSED
Figure 3-12. Static ink system
3 — Purge
4 — Solvent Top-up
5 — Vent 6 5 4 3 2 1 Solvent
6 — Solvent Cartridge recovery unit
40 µm
solvent filter
3—23
40 µm Valves
ink filter manifold Vent to
ink system tray
Solvent return (atmosphere)
from solvent
recovery unit
Vent to Service module

Solvent
ink system tray return
CLOSED
priming unit
(atmosphere) OFF
Vent to solvent Solvent Prime
Transfer recovery unit valve
pump
Service CLOSED
module
Venturi OFF
Ink System
Feed valve
10 µm main
ink filter
Vent Ink
PRV Venturi pump Pressure
Damper
transducer
20 µm
filter
manifold
Static Ink System
after a Normal Shutdown
Jun 2015
Restrictor
Solvent
tank
3.6.2 Ink system pipe connections
Festo fittings and barb fittings are used to make the pipe connections to the ink system
components. The barbs are inserted by interference fit to create a seal and cannot be
removed, and so cannot be replaced.
3.6.3 Spillage detector

There is one spillage detector fitted through (but insulated from) the floor of the stainless
steel spillage tray. The detector is fitted to a screw at the rear end of the right slide for the
ink system module.
If a fluid leak occurs from an ink system pipe or component (for example, manifold
assembly, pump head), the fluid collects in the spillage tray. When the spillage occurs, a
short circuit is made between the detector and the tray through the conductive fluid. This
short circuit is sensed by the microprocessor on the I/O PCB, and the Print Failure “2.07
Internal Spillage” is reported. The system stops the pump within 5 seconds of a spillage
detection (that is, there is no jet shutdown).
When the printer is horizontal (no tilt), the maximum amount of fluid in the tray before a
spillage is detected is 100 ml.
The spillage detector has a single cable that is part of the ‘I/O PCB to Door and Spill Sensor
Cable Assembly’, which is connected to a 4-way connector (PL201) on the I/O PCB.
3.6.4 Service module

The 8900 printer uses a service module, which is a replaceable and disposable tank made
from polypropylene.
The service module is fitted into a housing that is attached to the ink system tray. Access to
the module is through an access panel on the left side of the printer cabinet.
40013
Figure 3-13. Service module

The service module holds an ink and solvent mixture for use by the ink system. This fluid
mixture passes through a 10 µm main ink filter within the service module and is drawn into
the ink system by the pump. The main ink filter provides the primary filtration within the ink
system, and removes any particles from the ink before it reaches the venturi and the printhead.
Under normal operating conditions the service module has a default replacement interval
of 2000 hours. The life can be extended to a maximum of 13000 hours for most of the inks in
some environmental conditions. However, the maximum service interval is 18 months
regardless of running hours. Refer to the 8900 How To Select the Service Module Replacement
Hours Maintenance Level document for more information.
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Fluid level sensor
During operation the service module has a maintained fluid level of greater than 500 ml,
and a maximum level of 700 ml.
There are two fluid level sensors that detect the ‘fluid low’ and ‘fluid high’ conditions of the
service module. The level sensors are Hall-effect devices, which are fitted to the inside rear
of the service module housing. The sensors are triggered by a permanent magnet contained
in a float that is fitted inside the service module.
The output from the sensor is high (3.3 volts) when the magnet is out of range of the sensor,
and low (0.0 volts) when the magnet is within range of the sensor. For the low fluid level
condition, the float and sensor are configured to give a ‘high’ output when the fluid level in
the service module is greater than 500 ml. A ‘low’ output is given when the fluid level is less
than 500 ml. For the high fluid level condition, the float and sensor are configured to give a
‘high’ output when the fluid level in the service module is greater than 700 ml. A ‘low’
output is given when the fluid level is less than 700 ml.
When a high fluid level is detected in the service module, further solvent additions to the
module are restricted and ink additions are prevented to avoid an overfill.
The sensors each have a single cable that is part of the ‘I/O PCB to Service Module Cable
Assembly’, which is connected to a 10-way connector (PL223) on the I/O PCB.
Present detector
A service module ‘present’ detector identifies that there is a service module in the printer
and that the module is installed correctly. The printer will not operate unless the service
module is correctly engaged. The detector is a Hall-effect device, which is fitted to the top of
the service module housing.
The detector has a single cable that is part of the ‘I/O PCB to Service Module Cable
Assembly’, which is connected to a 10-way connector (PL223) on the I/O PCB.
Service module replacement

Before the service module is replaced, ink must be removed from the pipes connected to the
module. The Replace Service Module option in the user interface runs the pump
backwards at 2000 rpm for 30 seconds to clear ink from the pipes in the primary ink circuit.
The removed service module will normally contain a quantity of ink, but the replacement
service module will be empty. During the replacement process, the printer automatically
adds ink to the replacement service module from the ink cartridge until the module contains
the nominal 500 ml. When the nominal level is reached, which can require the operator to add
a cartridge of ink, the printer performs the jet startup sequence. While the jet is in operation,
the printer adds ink to keep the ink at or above the nominal 500 ml, regardless of the viscosity.
Each service module is shipped with a unique and separate RFID (radio frequency
identification) ‘paddle’ tag (the tag is not attached to the service module). This RFID tag is
called the Easi-Change® Service Key. The RFID tag data identifies that the service module
is acceptable for use in the 8900 printer. When the service module is replaced, the
Easi-Change® Service Key must be inserted between the ink and solvent cartridges so that
it can be read by the RFID module. If the service module identification is correct, the
Easi-Change® Service Key is removed from the printer. The Easi-Change® Service Key is a
one-time use item—it cannot be used again on the printer, and it cannot be used on any
other printer.
The printer will not function unless a valid Easi-Change® Service Key for the service
module is detected by the RFID module.
3.6.5 Solvent priming unit

The solvent priming unit supplies solvent to the printhead to create the startup solvent jet.
The unit is filled with solvent when the piston in the unit moves backwards as the ink
pressure on the piston is decreased during the previous jet shutdown.
FA48008
During the startup process, the ink pressure pushes the piston forwards, which ejects
solvent from the cylinder. The solvent is fed to the printhead and the startup solvent jet is
created. The piston remains in this position under the pressure of the ink during normal
printer operation.
The unit is fitted to the inside vertical face of the L-shaped support arm for the ink system,
above the solvent tank.
89007 B
C
F
A
A. Ink inlet from the venturi manifold D. Solvent Prime valve retainer
B. Solvent outlet to the printhead E. Solvent Prime valve
C. Solvent inlet from the solvent tank F. Valve electrical supply
Figure 3-14. Solvent priming unit
3.6.6 Solvent Prime valve

The Solvent Prime valve is a 2-way, 24-volt solenoid-operated valve, which is fitted to the
body of the solvent priming unit. The valve allows solvent to fill the cylinder of the solvent
priming unit during the previous jet shutdown.
3.6.7 Pump and motor assembly

The ink system pump and motor assembly circulates ink around the ink system at different
pressures, as required by the ink system control electronics. These pressure values depend
on the different functions performed by the printer during startup, normal operation, and
shutdown.
Motor 89010
Inlet from the

valves manifold
Outlet to the
venturi manifold
Pump
Compression
nuts
Figure 3-15. Ink system pump and motor assembly

The motor is controlled by a signal from the I/O PCB and its value depends on the
requested pressure.
The assembly is fitted vertically to a mounting plate on the rear wall of the ink system,
above the solvent tank.
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3.6.8 Venturi manifold
The venturi manifold assembly contains the venturi and has moulded internal
interconnecting bores. These bores enter and exit the manifold block at ports which route
the ink to and from the ink system and through the venturi.
The assembly is fitted to the left side of the service module housing.
J 89008
H
G
F A
B
C
E
A. Compression nut D. Mk5 venturi G. Outlet to the damper
B. Festo fitting E. Venturi manifold H. Inlet from the ink pump
C. Sealing washer F. Outlet to the solvent priming unit J. Suction on the gutter
Figure 3-16. Venturi manifold assembly
Vacuum venturi
When ink flows through the venturi, a vacuum is created, which is applied to the printhead
gutter during normal operation to draw surplus ink back into the system.
Venturi vacuum suction

A true venturi has a tapered mixing chamber, which creates a vacuum to provide suction.
The method used by Linx follows this theory, but uses the turbulence caused by a high
pressure ink as it passes through a small bore directly into a larger bore. The turbulence
creates a vacuum around the ink flow, and this vacuum is routed through a bore that is at
right angles to the ink flow. The following illustration is a section view of an example venturi.
Ink flow from the pump
at Set Pressure
89009
Small bore drilling
Groove around the circumference of

the venturi to allow equalization of
vacuum at both tappings
Suction connected
to the printhead gutter
Area of low pressure around

the ink flow caused by turbulence
Venturi housing
Large bore drilling
Ink and air returned

to the service module
Figure 3-17. Section view of the venturi
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3.6.9 Pressure transducer and damper assembly
The pressure transducer and damper assembly is fitted to the rear wall of the ink system,
behind the solvent tank.
89012
D B
F A
A. Damper inlet E. Ink System Feed valve outlet

B. Pressure transducer F. Ink System Feed valve (hidden)
C. Valve electrical supply G. Damper
D. Transducer clamp and valve retainer
Figure 3-18. Pressure transducer and damper assembly
Pressure transducer
The pressure transducer monitors the current ink pressure (Actual Pressure) in the ink
system and provides a feedback signal for pressure control.
Every pressure transducer has a calibration value that is stored in non-volatile memory on
the I/O PCB. When the pressure transducer is replaced, the calibration value for the new
unit must be entered into the printer with the IPM: Pressure Transducer (mV) button
(Main Menu > Maintenance > Calibration). This calibration value is written on the pressure
transducer.
Electrical power for the pressure transducer is +5 volts DC supplied from the I/O PCB, and
the feedback signal for pressure control is sent to the I/O PCB. The pressure transducer has
a single cable that is part of the 'I/O PCB to Damper Cable Assembly', which is connected to
a 5-way connector (PL225) on the I/O PCB.
Damper
The damper minimizes any ink pressure fluctuations within the primary circuit, and
isolates the printhead from pressure fluctuations. A restrictor is fitted in the inlet pipe to the
damper (fed from the venturi manifold). This restrictor must be fitted, otherwise the
damper will not operate correctly.
3.6.10 Ink System Feed valve

The Ink System Feed valve is a 2-way, 24-volt solenoid-operated valve, which is fitted to the
damper (refer to Figure 3-18).
When the Ink System Feed valve opens during the startup sequence, the valve feeds ink to
the printhead to replace the solvent jet for normal operation.
FA48008
3.6.11 Solvent tank
The ink system includes an HDPE solvent tank that has a capacity of approximately
520 ml.The tank is fitted into retaining brackets in the front left corner of the ink system
tray.
A pressure relief valve (PRV) is fitted to the top of the tank.
The solvent is drawn from the tank through the solvent pick-up tube, which is fitted into
the top of the tank and includes a 20 µm in-line filter.
89014
B
C
D
A
A. Solvent tank C. Solvent pick-up tube

B. Fluid level sensor D. Pressure relief valve
Figure 3-19. Solvent tank assembly
Fluid level sensor

The tank is fitted with a fluid level sensor (float switch) to detect when the level of solvent is
below a minimum point.The sensor is a reed switch device, which is contained in a shaft.
The sensor is triggered by a permanent magnet contained in a float that slides vertically on
the shaft. When the solvent level in the tank becomes low (approximately 250 ml of
solvent), the sensor switch opens. When the solvent level in the tank is acceptable, the
sensor switch is closed.
The solvent level sensor has a single cable, which is the ‘I/O PCB to Solvent Tank Cable
Assembly’ and is connected to a 2-way connector (PL222) on the I/O PCB.
Solvent level event reporting

The level at which the sensor activates depends on the solvent type and the solvent
temperature, which is calculated by the software.
When the sensor detects a low solvent level, the System Warning “3.78 Solvent Cartridge
Empty” is reported. If the solvent low condition is allowed to continue while the jet is in
operation, the system fails after a period of time with the Print Failure “2.43 Solvent System
Empty”. The period of time is variable and depends on the environmental temperature and
the rate of solvent use, but is a maximum of 12 hours. This safety time prevents the solvent
from being used completely.
FA48008
3.6.12 Transfer pump
The ink system includes an additional diaphragm pump, which is fitted vertically to the
rear wall of the ink system, next to the ink system pump.
89015
A. Inlet from the valves manifold D. Electrical supply cable

B. Outlet to the service module E. Vent to the ink system tray (atmosphere)
C. Pump F. Motor
Figure 3-20. Transfer pump assembly

The primary use for the transfer pump is to extract ink and solvent from the cartridges. The
pump is also used for solvent additions to the service module, solvent top-up of the solvent
tank, applying vacuum to the purge line, and draining the solvent recovery unit. Refer to
the applicable valve descriptions earlier in this section for how the transfer pump performs
these operations.
The transfer pump is connected to a 4-way connector (PL218) on the I/O PCB.
3.6.13 Solvent recovery unit

The solvent recovery unit is fitted to the bottom of the ink system tray between the solvent
tank and the service module housing.
C 89041
A. Inlet from the Vent valve C. Inlet from the service module
B. Vent to the ink system tray (atmosphere)
Figure 3-21. Solvent recovery unit

This unit collects vented solvent vapour from the service module. Refer to ‘Drain the
solvent recovery unit’ on page 3—34 for a description of how the solvent is recovered.
FA48008
3.6.14 Ink and solvent cartridges
Ink and solvent are added to the printer by inserting an ink or solvent cartridge into an
aperture in the front access door of the printer. Refer to ‘Front access door’ on page 3—2 in
the section ‘Cabinet’ for more information.
The cartridges are made from HDPE, and contain a maximum of 500 ml of ink or 1000 ml of
solvent.
Attached to each cartridge is a unique RFID (radio frequency identification) tag. The RFID
tag data identifies that the cartridge is acceptable for use in the 8900 printer. When a
cartridge is inserted into the receptacle in the front access door, the RFID tag is read by the
adjacent RFID module.
The RFID tag includes the following data:
 Tag ID. Identifies that it is a Linx tag and what type of tag (ink cartridge, solvent
cartridge, or service module).
 Expiry date.
 Volume remaining. Updated by the printer from data about the amount of ink or
solvent that has been used during operation.
 Empty/full. Set by the printer when the cartridge is almost empty to prevent refilling of
the cartridge. When the tag is considered to be ‘empty’, the tag is locked and cannot be
written to or overridden, and therefore the cartridge is unusable.
Ink and solvent cartridge filters

A 40 µm, in-line disc filter is fitted in each cartridge outlet pipe. These filters can be
replaced.
NOTE: There is no flow direction to consider when the filters are replaced.
FA48008
3.6.15 Valves manifold assembly
The central part of the ink system is the valves manifold assembly, which routes the ink and
solvent distribution in the system. The assembly includes a manifold block and six valves,
and is fitted to the rear of the service module housing.
The main component is the manifold block which has moulded internal interconnecting
bores. These bores enter and exit the manifold block at ports to which are connected the six
valves and the interconnecting pipes to other components in the ink system.
The six valves are:
 Solvent Add valve
 Ink Cartridge valve
 Purge valve
 Solvent Top-up valve
 Vent valve
 Solvent Cartridge valve
These solenoid-operated valves control the flow of ink and solvent through the system. The
valves are sealed and cannot be disassembled.
89011
G
F
E
D
C
B
A
A. Solvent Add valve D. Purge valve G. Solvent Cartridge valve
B. Ink Cartridge valve E. Solvent Top-up valve
C. Manifold block F. Vent valve
Figure 3-22. Valves manifold assembly

The following illustration shows a 2-way solenoid valve. The longer spigot of the valve fits
into the manifold.
89013
Figure 3-23. 2-way solenoid valve
FA48008
3.6.16 Solvent Add valve
The Solvent Add valve is a 2-way, 24-volt solenoid-operated valve, which is fitted to the
valves manifold block (see Figure 3-22 on page 3—32).
The Solvent Add valve is used to add solvent to the service module to control the ink
viscosity. During a solvent addition sequence, the Vent valve opens to release any pressure
build-up in the solvent tank through the solvent recovery unit. The transfer pump turns on
and then the Solvent Add valve opens. The suction from the transfer pump draws solvent
from the solvent tank, through the open Solvent Add valve and the transfer pump to the
valves manifold. At the valves manifold, the solvent mixes with the ink in the primary
circuit that is returning to the service module. The now lower viscosity ink and solvent
mixture in the service module is then fed to the printhead.
Refer to ‘Solvent addition’ on page 3—39 for more information about the solvent addition
process.
3.6.17 Purge valve

The Purge valve is a 2-way, 24-volt solenoid-operated valve, which is fitted to the valves
manifold block (see Figure 3-22 on page 3—32).
During jet shutdown, the transfer pump turns on and the Purge valve opens. The vacuum
suction applied to the purge line by the transfer pump removes the ink from the nozzle and
the gun chamber. The ink is drawn through the open Purge valve and the transfer pump to
the valves manifold, and then returned to the service module.
Immediately before final shutdown, solvent is fed into the gun chamber and through the
nozzle to the gutter. This action clears ink from these important components.
The Purge valve is also used during the ink prime, nozzle clear, and nozzle flush sequences.
3.6.18 Solvent Top-up valve

The Solvent Top-up valve is a 2-way, 24-volt solenoid-operated valve, which is fitted to the
The Solvent Top-up valve is used to add solvent to the solvent tank from the solvent
cartridge. Refer to ‘Solvent tank top-up’ on page 3—41 for a description of the solvent
top-up sequence.
3.6.19 Ink Cartridge valve

The Ink Cartridge valve is a 2-way, 24-volt solenoid-operated valve, which is fitted to the
The Ink Cartridge valve is used to add ink to the service module from the ink cartridge.
Refer to ‘Ink addition’ on page 3—41 for a description of the ink addition sequence.
3.6.20 Solvent Cartridge valve

The Solvent Cartridge valve is a 2-way, 24-volt solenoid-operated valve, which is fitted to
the valves manifold block (see Figure 3-22 on page 3—32).
The Solvent Cartridge valve is used with the Solvent Top-up valve to add solvent to the
solvent tank from the solvent cartridge. Refer to ‘Solvent tank top-up’ on page 3—41 for a
description of the operation of this valve and the solvent top-up sequence.
FA48008
3.6.21 Vent valve
The Vent valve is a 2-way, 24-volt solenoid-operated valve, which is fitted to the valves
manifold block (see Figure 3-22 on page 3—32).
The Vent valve is used in different valve sequences during normal operation of the printer.
The following are the valve sequences and ink system conditions under which the Vent
valve is used.
Solvent addition
Refer to ‘Solvent Add valve’ on page 3—33 for a description of the solvent addition
sequence.
Solvent tank top-up

Refer to ‘Solvent tank top-up’ on page 3—41 for a description of the top-up sequence.
Vent the solvent cartridge

During this sequence the Vent valve and Solvent Cartridge valve are opened. All of the
following conditions must apply before this sequence is performed:
 The remaining solvent in the solvent cartridge is less than or equal to 60%.
 A solvent top-up has just been completed.
 The jet is running or the printer is being commissioned.
 No other sequence is in progress.
 A valid solvent cartridge is fitted.
 The solvent cartridge is not empty.
Vent the ink cartridge

During this sequence the Vent valve, Ink Cartridge valve, and Solvent Top-up valve are
opened. All of the following conditions must apply before this sequence is performed:
 The remaining ink in the ink cartridge is less than or equal to 60%.
 An ink addition has just been completed.
 The jet is running, or the service module is being replaced, or the printer is being
commissioned.
 A valid ink cartridge is fitted.
Vent the solvent tank

This sequence is performed during solvent addition, and during power up to release any
pressure build-up in the solvent tank before the jet is started. During this sequence, only the
Vent valve is opened.
Drain the solvent recovery unit

The sequence is performed every 60 minutes. The jet must be running and no other
sequence must be in progress before this sequence can be performed.
To begin the sequence the transfer pump turns on, and then the Solvent Top-up valve
opens, which allows a vacuum to build up in the solvent tank. The Vent valve opens and
the vacuum created in the tank by the transfer pump draws solvent from the solvent
recovery unit. The solvent flows from the recovery unit, through the open Vent valve and
returned to the solvent tank. At the end of the sequence, the transfer pump turns off, the
Solvent Top-up and Vent valves close, and then the solvent tank is vented again (the Vent
valve opens to release any pressure build-up in the solvent tank, and then closes).
FA48008
3.6.22 Ink and solvent flows
The following paragraphs describe the functions of the applicable ink and solvent flow
diagrams shown on the following pages.
During the previous jet shutdown sequence, the Solvent Prime valve opens. The piston in
the solvent priming unit moves backwards as the ink pressure decreases during the jet
shutdown, and the unit is filled with solvent. When the solvent priming unit is full, the
Solvent Prime valve closes. The solvent priming unit is also reprimed during each jet
startup sequence.
When the jet is in operation under normal operating conditions, there are two ink flow
circuits in operation: a primary circuit and a secondary circuit.
Primary circuit
Refer to Figure 3-24 on page 3—36.
During the primary circuit operation, the pump starts and draws ink from the service
module through the internal main ink filter. The ink is then fed under pressure into the
venturi manifold block to the venturi. The pressurized ink flows through the venturi, where
the vacuum is generated, and then returns to the service module
Secondary circuit—stage 1
The operation of the secondary ink flow circuit is in two stages. During stage 1, the Solvent
Prime valve closes and the ink pressure pushes the piston in the solvent priming unit
forwards, which ejects solvent from the cylinder. (The piston remains in this position under
the pressure of the ink during normal printer operation.) The solvent passes through the
in-line solvent filter in the 6-way fluid connector assembly to the printhead, and the startup
solvent jet is created. This solvent jet cleans the printhead components in preparation for
the start of the ink jet.
The solvent jet enters the printhead gutter, and then passes out of the printhead and
through the 6-way fluid connector assembly. The solvent then passes to the venturi
manifold block where the vacuum draws the solvent through the venturi and into the
service module.
Secondary circuit—stage 2
Stage 2 starts when the Ink System Feed valve opens. There is an internal connection in the
venturi manifold block that feeds ink from the primary circuit before the venturi to the
pressure transducer and damper assembly. When the Ink System Feed valve opens, the
pressurized ink passes from the pressure transducer and damper through the in-line ink
filter in the 6-way fluid connector assembly to the printhead. This action replaces the
solvent jet with an ink jet as the solvent jet decreases.
The pressure transducer monitors the current ink pressure (Actual Pressure) in the ink
system and provides a feedback signal to the electronics for pressure control.
The ink jet enters the printhead gutter, and then passes out of the printhead and through
the 6-way fluid connector assembly. The ink then passes to the venturi manifold block
where the vacuum draws the ink through the venturi and returns the ink to the service
module.
FA48008
Jun 2015
INK 89002_02_Pri
SOLVENT
Purge line
Gutter
Feed line
Solvent line
15 µm in-line
ink filter

Manifold valves
Figure 3-24. Ink system primary circuit
Ink identification
cartridge assembly
3 — Purge
5 — Vent 6 5 4 3 2 1 Solvent
40 µm
solvent filter
3—36
40 µm Valves
ink system tray
from solvent
recovery unit

Solvent
CLOSED
priming unit
(atmosphere) OFF
pump
Service CLOSED
module
Venturi ON
Ink System
Feed valve
10 µm main
ink filter
Vent Ink
Damper
transducer
20 µm
filter
manifold
Primary Circuit
during Startup
FA48008
Restrictor
Solvent
tank
FA48008
INK 89002_03_Sec1
SOLVENT
Purge line
Gutter
Feed line
Solvent line
15 µm in-line
ink filter
Figure 3-25. Ink system secondary circuit—stage 1

Manifold valves
Ink identification
cartridge assembly
3 — Purge
5 — Vent 6 5 4 3 2 1 Solvent
40 µm
solvent filter
3—37
40 µm Valves
ink system tray
from solvent
recovery unit

Solvent
CLOSED
priming unit
(atmosphere) OFF
pump
Service CLOSED
module
Venturi ON
Ink System
Feed valve
10 µm main
ink filter
Vent Ink
Damper
manifold transducer
20 µm
filter
Secondary Circuit—Stage 1
Jun 2015
Restrictor
Solvent
tank
Jun 2015
INK 89002_04_Sec2
SOLVENT
Purge line
Gutter
Feed line
Solvent line
15 µm in-line
ink filter
Figure 3-26. Ink system secondary circuit—stage 2

Manifold valves
Ink identification
cartridge assembly
3 — Purge
5 — Vent 6 5 4 3 2 1 Solvent
40 µm
solvent filter
3—38
40 µm Valves
ink system tray
from solvent
recovery unit

Solvent
CLOSED
priming unit
(atmosphere) OFF
pump
Service OPEN
module
Venturi ON
Ink System
Feed valve
10 µm main
ink filter
Vent Ink
Damper
manifold transducer
20 µm
filter
Secondary Circuit—Stage 2
FA48008
Restrictor
Solvent
tank
Solvent addition
Under normal operating conditions, the Set Pressure is adjusted as the ink viscosity changes
to maintain a regular TOF. For example, as the ink viscosity increases caused by solvent
evaporation, the Set Pressure is increased to maintain a fixed TOF (at the Reference TOF)
with the thicker ink. If the Set Pressure reaches the known Solvent Add Pressure, solvent is
added to the ink to decrease the viscosity and so maintain the Actual TOF at Reference TOF.
A solvent addition occurs only if all of the following four conditions apply:
 The Set Pressure is greater than the Solvent Add Pressure.
 The Actual TOF is within ±0.5% of the Reference TOF.
 The warm-up time has expired (that is, the jet has been in operation for 45 minutes).
 The solvent level is acceptable (that is, the printer solvent level is above the minimum
required and the Print Failure “2.43 Solvent System Empty” has not occurred).
When a solvent addition is performed, the printer operation is as described earlier in
‘Secondary circuit—stage 2’, that is, there is ink flow in both the primary and secondary
circuits.
During a solvent addition sequence, the Vent valve opens to release any pressure build-up
in the solvent tank through the solvent recovery unit. The transfer pump turns on and then
the Solvent Add valve opens. The suction from the transfer pump draws solvent from the
solvent tank, through the open Solvent Add valve and the transfer pump to the valves
manifold. At the valves manifold, the solvent mixes with the ink in the primary circuit that
is returning to the service module. The now lower viscosity ink and solvent mixture in the
service module is then fed to the printhead.
The Solvent Add valve is opened for a set time, which is calculated to allow an exact
quantity of solvent to be added in a single ‘solvent add’ sequence. This Solvent Add Time
depends on the ink type and printhead type.
When solvent is added to the ink in the service module, the viscosity of the ink is lowered.
This thinner ink reaches the printhead within 3 minutes, and the jet speed increases. The Set
Pressure is then decreased to maintain the jet speed at the Reference TOF. If after 2 minutes
(the Viscosity Settle Time), the Set Pressure value remains above the Solvent Add Pressure
value, more solvent is added to the service module.
After solvent is added, further solvent additions are prevented for the Viscosity Settle Time.
This time allows the solvent to mix in the service module, and for the effects of the solvent
addition to begin to be seen at the printhead.
To prevent too much solvent being added to the ink, the printer allows a maximum number
of 25 consecutive solvent additions, where the Set Pressure has not decreased to less than
the Solvent Add Pressure.
If after these solvent additions, more solvent is required, the printer fails with Print Failure
“2.12 Viscosity Out of Range”.
FA48008
Jun 2015
INK 89002_05_SolvAdd
SOLVENT
Purge line
Gutter
Feed line
Solvent line
15 µm in-line
ink filter

Manifold valves
Ink identification
cartridge assembly
2 — Ink Cartridge CLOSED OPEN CLOSED CLOSED CLOSED OPEN
Figure 3-27. Solvent addition
3 — Purge
5 — Vent 5 1
6 4 3 2 Solvent
40 µm
solvent filter
3—40
40 µm Valves
ink system tray
from solvent
recovery unit

Solvent
CLOSED
priming unit
(atmosphere) ON
pump
Service OPEN
module
Venturi ON
Ink System
Feed valve
10 µm main
ink filter
Vent Ink
Damper
manifold transducer
20 µm
filter
Solvent Addition
FA48008
Restrictor
Solvent
tank
Ink addition
All of the following conditions must apply before an ink addition sequence is performed:
 The service module level is ‘low’.
 The service module level is not ‘high’.
 The jet is running.
 A valid ink cartridge is fitted.
 The ink cartridge is not empty.
 The access door for the ink and solvent cartridges is closed.
During an ink addition sequence, the Ink Cartridge valve opens and the transfer pump
turns on, which draws ink from the ink cartridge. The ink is drawn through the open Ink
Cartridge valve and the transfer pump to the valves manifold, and then fed to the service
module. The sequence is repeated until the service module level sensor detects that the ink
level is correct (500 ml).
When a service module is replaced, the Commissioning option (Main Menu > Maintenance
> Commissioning) is used to add ink to the service module.
Solvent tank top-up

All of the following conditions must apply before a solvent top-up sequence is performed:
 The solvent tank level is ‘low’.
 The jet is running.
 A valid solvent cartridge is fitted
 The solvent cartridge is not empty.
Before a solvent top-up sequence starts, the Vent valve opens to release any pressure
build-up in the solvent tank through the solvent recovery unit, and then the Vent valve
closes. The transfer pump turns on, and then the Solvent Top-up valve opens, which allows
a vacuum to build up in the solvent tank. The Solvent Cartridge valve opens and the
vacuum created in the tank by the transfer pump draws solvent from the solvent cartridge.
The solvent flows from the cartridge, through the open Solvent Cartridge valve to the
solvent tank. At the end of the sequence, the transfer pump turns off, the Solvent Cartridge
and Solvent Top-up valves close, and then the solvent tank is vented again (the Vent valve
opens to release any pressure build-up in the solvent tank, and then closes).
FA48008
Jun 2015
INK 89002_06_InkAdd
SOLVENT
Purge line
Gutter
Feed line
Solvent line
15 µm in-line
ink filter

Manifold valves
Ink identification
cartridge assembly
2 — Ink Cartridge CLOSED CLOSED CLOSED CLOSED OPEN CLOSED
3 — Purge
Figure 3-28. Ink addition
5 — Vent 2
6 5 4 3 1 Solvent
40 µm
solvent filter
3—42
40 µm Valves
ink system tray
from solvent
recovery unit

Solvent
CLOSED
priming unit
(atmosphere) ON
pump
Service OPEN
module
Venturi ON
Ink System
Feed valve
10 µm main
ink filter
Vent Ink
Damper
manifold transducer
20 µm
filter
Ink Addition
FA48008
Restrictor
Solvent
tank
FA48008
INK 89002_07_SolvTop-up
SOLVENT
Purge line
Gutter
Feed line
Solvent line
15 µm in-line
ink filter

Manifold valves
Ink identification
cartridge assembly
2 — Ink Cartridge OPEN CLOSED OPEN CLOSED CLOSED CLOSED
3 — Purge
Figure 3-29. Solvent top-up
5 — Vent 6 4
5 3 2 1 Solvent
40 µm
solvent filter
3—43
40 µm Valves
ink system tray
from solvent
recovery unit

Solvent
CLOSED
priming unit
(atmosphere) ON
pump
Service OPEN
module
Venturi ON
Ink System
Feed valve
10 µm main
ink filter
Vent Ink
Damper
manifold transducer
20 µm
filter
Solvent Tank Top-up
Jun 2015
Restrictor
Solvent
tank
3.7 Electrical components
3.7.1 Introduction
The 8900 printer has the following main electrical components:
 Mains electrical supply cable and connector
 Mains electrical supply filter and fuses
 High voltage power module (HVPM)
 Ink system pump and motor assembly
 Ink system valves
 Cooling fan
 Printhead positive air pump (optional)
3.7.2 Mains electrical supply cable

The 2-metre mains electrical supply cable connects to the printer on the left side of the
cabinet, above the mounting plate for the printhead conduit.
IMPORTANT: For the printer to comply with EN 60950-1:2006 Information technology
equipment. Safety. General requirements, the printer must be connected to the
mains electrical supply by one of the following two methods:
 A plug and socket arrangement.
 A hard-wired connection to the mains electrical supply. If this method
is used, a mains disconnecting device must be used between the printer
and the mains electrical supply.
Cable connector protection

The mains electrical supply cable connector is protected by an environmentally-sealed box
with a hinged cover (see Figure 3-30), which must be opened to disconnect the cable from
the printer. The cover is secured by three screws, and the cable is routed out of the box
through an opening in the bottom. Orientation of the cable exit cannot be altered.
FA48008
3.7.3 Mains electrical supply filter
The mains electrical supply filter assembly is fitted on the inside of the cabinet, behind the
protection box for the mains electrical supply cable connector. The assembly includes the
mains electrical supply filter, fuses holder, and mains electrical supply connector. The
connector is a 3-pin IEC chassis plug.
C 89017
E
D
F
A
A. Protection box E. Protection box cover

B. Mains electrical supply filter F. Mains electrical supply cable seal
C. Mains electrical supply connector G. Protection box cover screws x3
D. Mains electrical supply fuses holder
Figure 3-30. Mains electrical supply filter assembly and connector protection box
This unit isolates the mains electrical supply input and prevents electrical noise and ‘spikes’
that can have an effect on the operation of the printer. The filter also prevents any
transmission of electrical noise from the printer to the mains electrical supply wiring.
3.7.4 Mains electrical supply fuses

WARNING IS IGNORED.
Two input fuses for the live and neutral conductors of the mains electrical supply are
housed in a dual fuse holder, which is part of the mains electrical supply filter assembly. To
gain access to the fuses, the protection box for the mains electrical supply cable connector
must be removed.
The fuses are 20 mm, ceramic, time-delay, rated at 4 A for both 115 volts and 230 volts AC
operation.
FA48008
This module contains four separate units: the low voltage power supply unit (LVPSU), the
300 volts power supply, the modulation amplifier, and the EHT power supply.
89018
A. 300 volts power supply (hidden) C. Modulation amplifier

B. Low voltage power supply unit D. EHT power supply
Figure 3-31. High voltage power module (HVPM)

The HVPM is fitted on the left side of the electronics shelf in the upper compartment of the
cabinet.
A description of each HVPM unit follows.
Low voltage power supply unit (LVPSU)

The LVPSU is a switch-mode power supply that provides +24 volts DC for different
functions within the printer. The unit is attached to the top of the HVPM.
The input voltage range of the unit is 90 volts to 264 volts AC, 50/60 Hz. A 3-way Molex
connector on the unit receives the input voltage from the mains electrical supply filter.
There is one output of +24 V DC, which is fed to 5-way connector PL220 on the I/O PCB.
The I/O PCB uses the +24 volts to generate other low voltages for different functions. A 2 A
fuse is fitted on the HVPM PCB, which protects the +24 volts output from the low voltage
power supply unit. If the fuse fails, the I2C-bus, 300 volts supply, and EHT fail.
300 volts power supply

The supply voltage for the 300 volts power supply is +24 volts DC from 10-way connector
PL204 on the I/O PCB (the source of the +24 volts is the LVPSU).
There are two outputs of +300 V DC. Output 1 supplies the modulation amplifier in the
HVPM, and output 2 supplies the charge amplifier in the printhead. On the detection of
output over current, the 300 volts outputs to both the modulation amplifier and the charge
amplifier fall to 0 volts. (See also Print Failure ‘“2.23 Charge Amplifier Trip”’ in
Chapter 6: ‘System Events’.)
FA48008
Modulation amplifier
The modulation amplifier supplies the excitation voltage for the piezoelectric crystal in the
printhead to control jet break up (drop production). It is a fixed-gain amplifier which
amplifies a variable-amplitude sine wave generated by the FPGA on the I/O PCB.
The output range of the modulation voltage is 0 volts to 90 volts rms at a fixed frequency of
80 kHz.
The supply voltages for the modulation amplifier are +24 volts DC from 10-way connector
PL204 on the I/O PCB (the source of the +24 volts is the LVPSU) and +300 V DC from the
300 volts power supply. Control signals for the modulation amplifier also come from
10-way connector PL204 on the I/O PCB.
(Also refer to ‘Modulation’ on page 3—14.)
EHT power supply

This unit generates the EHT voltages for the printhead deflector plates to deflect the
separate ink drops.
The supply voltage for the EHT power supply is +24 volts DC from 10-way connector
PL204 on the I/O PCB (the source of the +24 volts is the LVPSU).
Two variable EHT outputs of 0 volts to +4.4 kV DC and 0 volts to –4.4 kV DC are generated.
These outputs are used to create the 8.8 kV electrostatic field between the printhead
deflector plates.
Control of the output voltages is done by a separate control voltage that is transmitted to
the unit through the I2C-bus. If the HVPM is replaced, there is no calibration required
because the unit is accurately calibrated during manufacturing. The calibration value for
the printhead EHT Gain is stored in the printhead. The value can be seen on the Calibration
screen (Main Menu > Maintenance > Calibration > EHT Gain).
A trip signal from the HVPM disables both EHT outputs if either output current increases
to more than the trip level. This signal is read by the I/O PCB. (See also Print Failure ‘“2.01
EHT Trip”’ in Chapter 6: ‘System Events’.)
The printhead EHT cables are connected to the output sockets of the EHT power supply by
two Highvol-style connectors. Both of the connectors are white and the EHT cables are red,
but the –4.4 kV cable is identified by a white sleeve. The following illustration shows the
correct connection of the printhead EHT cables.
89019
+4.4 kv connector
–4.4 kv connector
Identification sleeve
Figure 3-32. Correct connection of the printhead EHT cables
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3.7.6 Ink system pump and motor assembly
This unit is a pump and DC motor assembly. The assembly is fitted vertically to a mounting
plate on the rear wall of the ink system, above the solvent tank.
Motor 89010
Inlet from the

valves manifold
Outlet to the
venturi manifold
Pump
Compression
nuts
Figure 3-33. Ink system pump and motor assembly

The ink system pump and motor assembly circulates ink around the ink system at different
pressures, as required by the ink system control electronics. These pressure values depend
on the different functions performed by the printer during startup, normal operation, and
shutdown.
Magnetic coupling from the motor to the pump gives separation of the ink from the
electrical drive parts.
The drive power for the DC motor is a pulse-width modulation (PWM) signal that comes
from the demand signal and the pressure transducer feedback signal. PL200 on the I/O
PCB provides the drive power for the motor, and the pressure transducer signal is on
PL225, which is also on the I/O PCB.
3.7.7 Ink system valves

There are eight solenoid-operated valves in the ink system:
 Ink System Feed valve fitted to the pressure transducer and damper assembly.
 Solvent Prime valve fitted to the solvent priming unit.
The following six valves are fitted to the valves manifold block:
 Solvent Add valve
 Ink Cartridge valve
 Purge valve
 Solvent Top-up valve
 Vent valve
 Solvent Cartridge valve
To open the valves, +24 volts DC is applied first, which is then decreased to a hold-on
voltage of +4 volts.
The drive voltages for the valves are supplied by the valve drive circuits on the I/O PCB.
These drive voltages are routed to the valves from the following I/O PCB connectors:
 PL225 for the Ink System Feed valve.
 PL217 for the Solvent Prime valve.
 PL226 for the six valves fitted to the valves manifold.
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3.7.8 Cooling fan
A fan circulates air around the cabinet to provide cooling for the electrical control system.
The cooling fan is fitted to the underside of the air filter housing above the IPM Assembly.
Connected to PL211
on the I/O PCB
89020
Figure 3-34. Cooling fan

The fan has a rating of 2.4 watts and the supply voltage is +24 volts DC from connector
PL211 on the I/O PCB.
The cooling fan operates continuously while the printer is turned on, and the air intake is
through the baffle vent on the rear access panel behind the IPM Assembly. The air is drawn
in through the air filter and the fan, and then flows down over the IPM Assembly and the
HVPM. From here the air leaves the printer through the baffle vent on the rear access panel
behind the HVPM.
The cabinet air temperature is monitored by a thermistor set at a limit of 75 °C. If the air
temperature increases to more than 75 °C (for example, because of a fan failure or a
blockage in the air filter), the printer fails and the Print Failure “2.08 Printer Over
Temperature” is reported. (See also Print Failure ‘“2.08 Printer Over Temperature”’ in
Chapter 6: ‘System Events’.)
3.7.9 Printhead positive air pump

The positive air pump is an optional accessory, which improves printer performance in
environments where there is dust, damp, or condensation. The unit is fitted to the front left
corner of the electronics shelf in the upper compartment of the cabinet, in front of the
HVPM.
40375
Air outlet ‘P’

(pressure)
Air inlet ‘V’

(vacuum)
Figure 3-35. Positive air pump

A positive air pressure is supplied to the printhead to minimize the ingress of airborne
particles. The unit pumps air from inside the printer cabinet through a filter, along the
printhead conduit to a stainless steel outlet fitting on the printhead. The airflow to the
printhead is greater than that through the gutter, which creates a positive air pressure
inside the printhead cover tube. This positive air pressure helps to keep the printhead free
of dust and other airborne particles.
FA48008
The pump has a rating of 2.7 watts and the supply voltage is +12 volts DC from connector
PL212 on the I/O PCB.
The air supply pipe (yellow stripe) is a standard fit on the Mk11 printhead. However, the
pump is not a standard part on the 8900 printer, but is available as a ‘factory fit’ option
(refer to the applicable Parts List or contact your Linx Distributor).
FA48008
3.8 Electronics and software
3.8.1 Summary
The main electronics system in the 8900 printer is contained on two printed circuit boards
(PCBs): the I/O PCB and the CPU PCB. The combination of these two PCBs is called the
IPM Assembly. The IPM Assembly is fitted horizontally to the electronics shelf in the upper
compartment of the cabinet.
A TFT LCD touch screen assembly is fitted in the front top panel of the printer, above the
IPM Assembly.
The RFID module, which reads the RFID tags for the ink and solvent cartridges and the
service module, is fitted in the cartridges receptacle between the ink and solvent cartridges.
The main functions of the two IPM Assembly PCBs are described in the following:
I/O PCB
 Battery back-up. During a power-down, the printer uses a rechargeable NiMH battery
to continue to supply power to the CPU. This action allows the software to continue to
write the settings and message data to the flash memory if the mains electrical supply is
turned off before shutdown. The battery is automatically charged while the printer is
turned on.
 Interface with the RFID module (also processed by the CPU PCB).
 Charge gain and modulation DACs, which provide drive signals for the printhead.
 Internal alarm buzzer to indicate the occurrence of faults and warnings.
 Ink pump control with current limits and stall detection.
 Pressure control, rpm control, and built-in test.
 Valve drives (24 V activation; 4 V hold-on voltage).
 Management of service module detection, spillage detection, and the fluid level sensors
(also processed by the CPU PCB).
 Pump PIC configuration switches.
 Interface for the input signals of photocell trigger devices and shaft encoder.
 External alarm control to activate an external alarm device when faults and warnings
occur.
 External signals connectors (photocells, shaft encoder, alarm, USB and Ethernet).
 Fault diagnosis links and configuration switches.
 Unique number identification chip (UNIC), which provides a unique number to
identify each printer. The system software detects the presence of the UNIC on
power-up and displays the 12-character serial number in the UNIC Code option (Main
Menu > System Information > Machine ID).
NOTE: If the IPM Assembly is replaced, the UNIC must be removed from the old I/O PCB
and fitted to the replacement board. If the UNIC is not transferred, the replacement
IPM Assembly will not acknowledge any configuration code.
 TFT touch screen connection from the CPU to the TFT cable.
 Printhead connections.
 VFC connections.
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CPU PCB
 Main central processing unit (CPU), which processes the ink system and printhead
control signals.
 SDRAM and flash memory. The system software is stored in flash memory.
 Field-programmable gate array (FPGA), which provides the timing and sequences for
the printer functions.
 FPGA interface, which processes the phase and time of flight signals from the printhead.
 Charge sequence SDRAM, which controls the drop charging during print.
 USB interface, which enables storage of printer information on a USB memory device.
 Touch screen and display interface, which provides control of the TFT LCD display.
 Ethernet connection.
3.8.2 System diagram

A system diagram of the standard 8900 printer is provided at the end of this chapter, which
shows the interconnecting cables for the different components.
3.8.3 IPM Assembly

WARNING IS IGNORED.
The IPM Assembly is shown in the following illustration.
89021
CPU PCB
I/O PCB
Figure 3-36. IPM Assembly
FA48008
CAUTION: Do not disconnect the CPU PCB from the I/O PCB. Separation of these two boards
can damage the components and cause contamination of the edge connector fingers of the
CPU PCB.
The CPU PCB is connected to an edge connector on the I/O PCB, and is supported by two
mounting brackets.
NOTE: The CPU PCB and I/O PCB are supplied as a single IPM Assembly spare part for
the 8900 printer and cannot be ordered separately.
The following illustration identifies all of the electrical connectors on the I/O PCB.
89025
SK202 PL214
PL208 PL100
PL101 PL213
PL207 SK204
SK200 SK206
PL212 PL216
PL204 SK209
PL220 PL221
PL215 SK207
PL203 PL210
PL211 SK208
PL200 PL201
PL222 PL225 PL217 PL219

PL223 PL226 PL218 PL224 PL205
PL100 CPU PCB MK1 PL212 POSITIVE AIR PUMP PL223 SERV MODULE SENSORS
PL101 CPU PCB MK2 PL213 USB PL224 GUTTER FLOW PURGE
PL200 INK SYSTEM PUMP PL214 ETHERNET PL225 DAMPER
PL201 DOOR/SPILL SENSORS PL215 OVERRIDE & TEST LINKS PL226 MANIFOLD VALVES
PL203 PRINTHEAD PL216 RED/GREEN POWER LEDS SK200 CHARGE
PL204 HVPM PL217 SOLVENT PRIME VALVE SK202 10 INCH DISPLAY
PL205 DOOR RFID PL218 TRANSFER PUMP SK204 SD CARD
PL207 PARALLEL I/O PL219 INK MIXING VALVE SK206 RS-232
PL208 UPS PL220 POWER SK207 PHOTOCELL/SHAFT ENC
PL210 VFC MODULE PL221 POWER ON SWITCH SK208 PHOTOCELL/SHAFT ENC
PL211 FAN PL222 SOLVENT TANK SK209 24 V ALARM
Figure 3-37. I/O PCB connectors
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Test points
Test points are provided on the I/O PCB to help fault diagnosis. The test points are
identified below with descriptions of their functions.
To make the test points easier to find, the I/O PCB edges are marked with grid square
identifiers—1 to 10 vertically, and A to G horizontally. A grid reference is provided in
brackets after each test point number in the following list, which identifies the location on
the I/O PCB. Further help to find test points is provided after the following list in an
illustration of a reference grid drawn on top of the I/O PCB.
TP7 (A8) 5V_PH. 5 volts supply voltage to the printhead that is controlled by the
CPU PCB. This voltage is either on or off.
TP9 (A3) CHARGE. Low voltage charge signal, before amplification, of between
0 volts and –2 volts, which equates to 0 volts to 300 volts on the charge
electrode plates.
TP10 (B4) MOD. Modulation. Low voltage modulation signal, before amplification,
of between 0 volts and –2 volts. A sine wave should be observed with a
frequency dependent on the type of printhead fitted: 80 kHz (Midi 62 µm).
TP11 (D3) PRI. Primary. (Next object input). This is the primary trigger input signal
(buffered output from IC25). It is a 0 volts to 3.3 volts digital signal, with
the falling or rising edge indicating the presence of the object.
TP12 (D3) SEC. Secondary. This is the secondary trigger input signal (buffered output
from IC27). It is a 0 volts to 3.3 volts digital signal, with the falling or rising
edge indicating the presence of the object.
TP13 (E3) MAIN. Single-ended shaft encoder input. This is the shaft encoder signal
(buffered output from IC31) that is a 0 volts to 3.3 volts digital signal.
TP14 (E3) QUAD. Quadrature. This is the quadrature shaft encoder input signal
(buffered output from IC32) that is a 0 volts to 3.3 volts digital signal.
TP15 (A9) PH GUT. Printhead Gutter valve. Low side driver (bank 2 valve).
Low = open; High (4.0 V) = closed.
TP16 (A9) PH SOL. Printhead Solvent valve. Low side driver (bank 2 valve).
TP17 (A8) VPWR2. Valve Power. High side supply voltage for the bank 2 valves.
24 volts to open the valve; 4 volts hold-on voltage.
TP18 (A8) PH FEED. Printhead Feed valve. Low side driver (bank 2 valve).
TP19 (A9) nCOVER. Printhead Cover tube detection.
Low = detected; High (3.3 V) = not detected.
TP20 (B9) SM 5V. Service Module 5 volts. Supply voltage for the front access door
Hall effect switch and all three Hall effect switches on the service module.
This voltage is always on.
TP21 (B9) SM 0V. Service Module 0 volts. Supply voltage return for the front access
door Hall effect switch and all three Hall effect switches on the service
module.
TP22 (B9) SM DET. Service Module Detection.
Low = detected; High (3.3 V) = not detected.
TP23 (C9) SM HIGH. Service Module High fluid detection.
Low = service module over full; High (3.3 V) = service module not over
full.
FA48008
TP24 (B9) SM LOW. Service Module Low fluid detection.
Low = service module fluid level low; High (3.3 V) = service module fluid
level not low.
TP25 (D9) IP 5V. Ink Pressure transducer 5 volts. Supply voltage from the PIC pump
5 volts supply. This voltage is always on.
TP26 (C9) IP 0V. Ink Pressure transducer 0 volts. Supply voltage return for the
pressure transducer.
TP27 (C9) IP. Ink Pressure. Pressure transducer signal of 0.5 volts to 4.5 volts, which
equates to 0 p.s.i. to 100 p.s.i.
TP28 (C9) ST LOW. Solvent Tank Low fluid detection.
Low = tank fluid level not low; High (3.3 V) = tank fluid level low.
TP29 (F10) VPWR1. Valve Power. High side supply voltage for the bank 1 valves.
TP31 (C10) VPWR3. Valve Power. High side supply voltage for the bank 3 valves.
TP32 (F9/F10) VPWR4. Valve Power. High side supply voltage for the bank 4 valves.
TP33 (D10) VP. Voltage Pump. Ink system pump and transfer pump 24 volts supply.
This voltage is always on.
TP34 (D10) VWSP. Voltage Webber Spare. Supply voltage for a spare Webber valve
(bank 4 valve). 24 volts to open the valve; 4 volts or 10 volts hold-on
voltage (configuration dependent).
TP35 (E9) VIM. Voltage Ink Mix. Supply voltage for the Ink Mix valve (bank 1 valve).
24 volts to open the valve; 4 volts or 10 volts hold-on voltage (configuration
dependent).
TP36 (F9) S TOP. Solvent Top-up valve. Low side driver (bank 3 valve).
TP37 (C9/C10) S ADD. Solvent Add valve. Low side driver (bank 3 valve).
TP38 (F9) S CART. Solvent Cartridge valve. Low side driver (bank 1 valve).
TP39 (F9) VENT. Vent valve. Low side driver (bank 3 valve).
TP40 (E9) PUG1. Purge 1 valve. Low side driver (bank 4 valve).
TP41 (F9/F10) PUG2. Purge 2 valve. Low side driver (bank 1 valve).
TP42 (F9) I CART. Ink Cartridge valve. Low side driver (bank 4 valve).
TP43 (D9) FEED. Ink system Feed valve. Low side driver (bank 3 valve).
TP44 (E9) S PRIME. Solvent Prime valve. Low side driver (bank 1 valve).
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TP45 (F9/F10) GUT F1. Gutter Flow 1 valve. Low side driver (bank 2 valve).
TP46 (F9/F10) GUT F2. Gutter Flow 2 valve. Low side driver (bank 4 valve).
TP47 (D10) WSP. Webber Spare valve. Low side driver (bank 4 valve).
Low = open; High (4.0 V or 10 V) = closed (configuration dependent).
TP48 (E9) I MIX. Ink Mix valve. Low side driver (bank 1 valve).
Low = open; High (4.0 V or 10 V) = closed (configuration dependent).
TP49 (D10) T PUMP. Transfer Pump. Low = On; High (24 V) = Off.
TP50 (G8) SPILL. Spillage detector. This is the spill logic signal after the detector
amplifier.
Low = spillage; High (3.3 V) = no spillage.
TP51 (B9) PDMD. Pump Demand. Control drive to the ink system pump of 0 volts
(Off) to 5 volts (full demand).
89029
3
10
A B C D E F G
Test point
Figure 3-38. I/O PCB test points
FA48008
LEDs
WARNING: LETHAL VOLTAGE HAZARD. WHEN THE RED LED (LED1) ON THE I/O PCB IS
ILLUMINATED, MAINS ELECTRICAL VOLTAGE EXISTS IN THE PRINTER.
MAXIMUM CAUTION MUST BE USED WHEN WORK IS DONE ON THE PRINTER WHEN THE
RED LED1 IS ILLUMINATED AND THE REAR ACCESS PANEL IS REMOVED. THE CORRECT,
STANDARD ELECTRICAL SAFETY PRECAUTIONS MUST BE TAKEN.
WARNING IS IGNORED.
A red LED (LED1) next to the 24 volts power connector PL220 on the I/O PCB indicates that
the 24 V DC supply is available to the board.
The green LED on the CPU PCB indicates that the board is either supplied by the 24 volts
supply or the battery.
Links
Links are provided on the I/O PCB, which are used to enable or disable different printer
functions to help fault diagnosis. The following illustration shows the location of header
PL215 links.
B T S CG
89022
SW201
Figure 3-39. Location of header PL215 links

The links on the I/O PCB are given below with descriptions of their functions.
Header PL215
Pins B Buzzer
When this link is fitted between the pair of pins B, the internal alarm
buzzer is disabled. The link can be fitted during fault diagnosis to prevent
personal irritation, but the link must not be fitted during normal operation.
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Pins T Built-In Self-Test (BIST)
When this link is fitted between the pair of pins T, the gate array is put in
self-test mode.
Pins S Safety Override
WARNING: LETHAL VOLTAGE HAZARD. IF THE ‘SAFETY OVERRIDE’ LINK

IS FITTED WHILE THE “PRINTHEAD OVER TEMPERATURE” OR “EHT TRIP”
FAULT CONDITIONS EXIST, 300 VOLTS DC CONTINUES TO BE SUPPLIED TO
THE PRINTHEAD.
THE CORRECT, STANDARD ELECTRICAL SAFETY PRECAUTIONS MUST BE
TAKEN WHEN WORK IS DONE ON THE PRINTHEAD WITH THE ‘SAFETY
OVERRIDE’ LINK FITTED. DO NOT FIT THE LINK PERMANENTLY AND DO
NOT LEAVE THE PRINTER UNATTENDED WHILE THE LINK IS FITTED.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF
THIS SAFETY WARNING IS IGNORED.
When this link is fitted between the pair of pins S, the Printhead Over
Temperature sense, fluid spillage detection and EHT Trip-sense software
do not disable the 300 volts, ink system pump, feed valves, and EHT. This
link can be fitted, with caution, to help the fault diagnosis. See also ‘“3.15
Safety Override Active”’ in Chapter 6: ‘System Events’.
Pins C Cover Off Override
WARNING: LETHAL VOLTAGE HAZARD. WHEN THE ‘COVER OFF

OVERRIDE’ LINK IS FITTED AND THE PRINTHEAD COVER TUBE IS
REMOVED, 300 VOLTS DC CONTINUES TO BE SUPPLIED TO THE CHARGE
ELECTRODE. THE EHT ALSO CONTINUES TO BE SUPPLIED TO THE
DEFLECTOR PLATES.
THE CORRECT, STANDARD ELECTRICAL SAFETY PRECAUTIONS MUST BE
TAKEN WHEN WORK IS DONE ON THE PRINTHEAD WITH THE ‘COVER OFF
OVERRIDE’ LINK FITTED AND WITH THE COVER TUBE REMOVED. DO NOT
FIT THE LINK PERMANENTLY AND DO NOT LEAVE THE PRINTER
UNATTENDED WHILE THE LINK IS FITTED.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF
THIS SAFETY WARNING IS IGNORED.
When this link is fitted between the pair of pins C, the EHT and charge
voltages remain on while the printhead cover tube is removed (that is, the
voltages are not automatically disabled). This condition allows the printing
to continue for fault diagnosis purposes. The red strobe LED also remains
illuminated. See also System Warnings ‘“3.12 Printhead Cover Off”’ and
‘“3.13 Cover Override Active”’ in Chapter 6: ‘System Events’.
After the printhead cover tube is removed, and then the link is fitted (or the
printhead cover tube is refitted), there is a delay of between 1 and 2
seconds before printing restarts.
FA48008
Printhead Cover Override option
The function of the Cover Off Override link can be enabled or disabled in
the Printhead Cover Override option on the Installation screen (Main
Menu > Printer Setup > Installation > Printhead Cover Override).
 If the Yes option is selected for the Printhead Cover Override option
and this link is fitted, the link is enabled and overrides the automatic
‘printhead cover off’ function. The printer does not disable the
printhead EHT and charge voltage when the removal of the printhead
cover tube has been detected.
 If the No option is selected for the Printhead Cover Override option
and this link is fitted, the link is ignored. The printer automatically
disables the printhead EHT and charge voltage when the removal of
the printhead cover tube has been detected. (The phase and TOF
operations continue because these voltages are safe.)
Pins G Gutter Sense Override
The gutter sense circuit detects the flow of ink in the gutter. If ink flow is
not detected in the gutter for any reason (for example, an incorrectly
aligned jet), the software shuts down the jet with a quick stop sequence and
reports Print Failure “2.09 Misaligned Ink Jet”.
Under normal operating conditions with the jet running, a loss of ink in the
gutter is detected after approximately 20 seconds. During a Normal Start, a
loss of ink in the gutter is detected after approximately 3 seconds. Gutter
sense operation is disabled when the Jet Test-Start function is used.
When a link is fitted between the pair of pins G, the software ignores the
gutter detection status, and the jet can be started and maintained normally.
When this link is fitted, the Print Failure “2.09 Misaligned Ink Jet” is
prevented from being reported. See also ‘“3.16 Gutter Override Active”’ in
Chapter 6: ‘System Events’.
FA48008
Safety interlocks
Hardware and software safety interlocks protect against electrical hazards that can occur as
a result of fault conditions.
Hardware interlock
This interlock operates when any of the following fault conditions occur:
 EHT trip
 300V trip
 Spillage detector has activated
 Printhead over temperature
The interlock disables the ink system pump, transfer pump, and all of the valves, until the
fault is cleared and the printer is The interlock disables the ink system pump, transfer
pump, and all of the valves, until the fault is cleared and the printer is turned off and then
turned on again.
Software interlock
This interlock operates when any of the following conditions are detected:
 Cover Sense (printhead cover tube off). The EHT is turned off and the charge voltage is
limited while the cover is removed.
 Service module not detected.
 Ink system pump not responding to commanded drive (suspected leak).
 Valve drive fault. If valves continue to have the activation (‘hit’) voltage applied for
more than 3 seconds, the valves are turned off.
 Printer over temperature. If the temperature of the electronics enclosure is more than
75 °C, the system is shut down.
NOTES:
1. The Safety Override link disables all safety interlocks.
2. The Cover Off Override link disables the Printhead Cover Off detector.
PCB replacement
If the IPM Assembly is replaced, the UNIC must be removed from the old I/O PCB and
fitted to the replacement board. The printer configuration code must then be re-entered on
the user interface to enable the printer to access the required configuration options (Main
Menu > Printer Setup > Installation > Printer Configuration Code).If the UNIC is not
transferred, the replacement IPM Assembly will not acknowledge any configuration code.
3.8.4 I2C-bus
There are three I2C communications buses. One I2C-bus is the 3V3 main system bus where
the main processor is the master. The main system bus runs around the IPM Assembly and
to the high voltage power module (HVPM).
The second bus communicates between the IPM master and the printhead PIC® (the slave).
The third 5V bus communicates between the IPM master and the PIC® pump.
3.8.5 Software
Downloading software
The 8900 printer system software is stored in flash memory on the CPU. The software is
downloaded to the printer from a USB memory device connected to the USB port on the left
side of the printer cabinet. The Ethernet connection, also on the left side of the printer
cabinet, can also be used to download the system software from a desktop or laptop PC.
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3.9 External signals
The following external signals information describes the external print trigger input, shaft
encoder input, external alarm output, serial interface, Ethernet interface, and USB interface.
All of the connectors are on the left side of the printer, and Figure 3-40 identifies these
connectors.
89023
A. VFC (optional) C. Photocell/shaft encoder E. USB

B. RS-232 (optional) D. External alarm F. Ethernet
Figure 3-40. Location of the external signal connectors
3.9.1 External print trigger

The external print trigger input can be from a photocell, a contact switch, a relay contact, a
signal from a PLC, or many other sources.
A photocell is normally used to detect the product on the production line as the product
moves towards the printhead, and to supply a ‘next object’ signal to the printer. This signal
starts a print delay, after which a message is printed. If the photocell is put in the correct
position and an applicable delay is set, the position of the message on the product (print
registration) can be accurately controlled.
The trigger device is connected to either SK207 or SK208 on the I/O PCB. These two
connectors are 9-way, D-type connectors, which are fitted through the left side of the
printer cabinet and are identified ‘PHOTOCELL SHAFT ENC’. The connectors are
internally connected in parallel, and so either can be used for a trigger device.
The print trigger source must be an open-collector device, of either NPN or PNP type, that
can use a 24 volts supply. A volt-free relay contact can also be used. The type of photocell is
selected with the Photocell Type option (Home screen > Line Settings > Advanced >
Photocell Type), either NPN or PNP.
Signal conditions for the print trigger are a sink/source (NPN/PNP) current of greater than
20 mA per printer input, and a signal duration of greater than 100 µs.
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3.9.2 Shaft encoder
A shaft encoder generates a number of pulses per revolution. When connected to a
production line (normally by a friction wheel), the encoder generates a pulse per distance
travelled by the production line. The printer uses these pulses to trigger the printed rasters,
which maintains equal distance between rasters irrespective of the speed of the production
line. This feature is used to compensate for variations in production line speed to give a
fixed width of print. Linx recommends that a shaft encoder that generates a minimum of
2500 pulses per revolution is used.
40391
Figure 3-41. Shaft encoder

Either a 5-volt or a 24-volt, single-ended or quadrature shaft encoder can be used. The input
circuit for the shaft encoder has a maximum frequency response of 80 kHz.
The shaft encoder is connected to either SK207 or SK208 on the I/O PCB. These two
connectors are 9-way, D-type connectors, which are fitted through the left side of the
printer cabinet and are identified ‘PHOTOCELL SHAFT ENC’. The connectors are
internally connected in parallel, and so either can be used for a shaft encoder.
The supply voltage for a shaft encoder is selected with the Encoder Voltage option (Home
screen > Line Settings > Advanced > Encoder Voltage), either 5 Volts or 24 Volts.
Regardless of the supply voltage setting, the sink current for the shaft encoder must not be
less than 10 mA per printer.
NOTE: If a quadrature shaft encoder is used, the printer counts two pulses per encoder
pulse. For example, a 2500 ppr encoder is seen as 5000 pulses per revolution.
Figure 3-42 shows the pinouts for the photocell and shaft encoder connectors SK207 and
SK208.
SK207
0VCH
5
S_ENC_CH2 9
89024 SEC_IN 4
S_ENC_CH1 8
5VD 3
nPRINT_BUSY 7
0VF 2
PRI_IN 6
24VD 1
SK208
0VCH
5
S_ENC_CH2 9
SEC_IN 4
S_ENC_CH1 8
5VD 3
nPRINT_BUSY 7
0VF 2
PRI_IN 6
24VD 1
Figure 3-42. Pinouts for the photocell and shaft encoder connectors
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3.9.3 Alarm output
The alarm internal switching signal can be used to operate either a 24 volts external alarm,
or a mains-powered external alarm through a volt-free contact (VFC) relay.
The printer is shipped in the 24 volts alarm operation configuration, but the mains-powered
external alarm capability (VFC) is available as an optional accessory.
24 volts external alarm

CAUTION: Printer Electrical Damage. Do not connect the ALARM output connector of the
printer to the mains electrical supply or any other power source. Damage to the printer can
occur if this caution is ignored.
The output current for the 24 volts external alarm is approximately 500 mA, and the output
circuit is protected by a self-resetting thermal fuse on the I/O PCB. The alarm output
connector, SK209 on the I/O PCB, is a 2-way Buccaneer connector, which is fitted through
the left side of the printer cabinet and is identified ‘ALARM’. Pin 1 = 24 V; pin 2 = ALARM.
Mains (VFC) external alarm

For a mains-powered external alarm, the alarm switching signal operates a volt-free contact
(VFC) relay in a VFC module, which is an optional accessory.
The internal module allows the end user to connect externally-powered beacons, sirens,
production line interlocks, or other error reporting equipment to the printer. The printer
can then control this equipment according to the operating state of the printer.
40390
Figure 3-43. VFC module

When the internal VFC module is connected to external equipment and to the printer, the
following warning is applicable.
WARNING: LETHAL VOLTAGE HAZARD. DANGEROUS VOLTAGES CAN EXIST IN THE

PRINTER WHEN IT IS DISCONNECTED FROM THE MAINS ELECTRICAL SUPPLY, AND A
MAINS-OPERATED EXTERNAL ALARM REMAINS CONNECTED TO THE VFC MODULE. THERE
CAN BE MAINS VOLTAGE WITHIN THE VFC MODULE UNDER THESE CONDITIONS.
DISCONNECT ALL MAINS ELECTRICAL POWER SOURCES BEFORE THE VFC MODULE
COVER IS REMOVED. DO NOT OPERATE THE VFC MODULE WITH THE COVER REMOVED.
WARNING IS IGNORED.
The VFC alarm output connector is PL210 on the I/O PCB. Included in the optional VFC
accessory is a cable that connects between PL210 and the 15-way, D-type connector on the
VFC module. The VFC module is mounted on an option plate that is fitted to the left side of
the printer cabinet. The control signals from the module to the external equipment are
connected (pre-wired) to a Buccaneer connector on the option plate.
Inside the module there are two terminal blocks (J1 and J2) that connect the control signals
to the external equipment. The standard 24 volts alarm terminal block (J2) has three
terminals which can be used to activate a beacon or siren. The 24 volts alarm relay (RLA2)
in the module is protected by a 250 V, 1 A, ceramic, slow-blow fuse (F2).
FA48008
The VFC terminal block (J1) has five terminals that control three switch-states from two
common connections. One of these outputs is driven through the normally open (NO)
contacts of a relay by the nALARM_24V signal (the same logic as the 24 volts standard
alarm output). The other two outputs are driven through the NO and normally closed (NC)
contacts of a relay by the nALARM_VFC signal, and are mutually exclusive. The VFC relay
(RLA1) in the module is protected by a 250 V, 1 A, ceramic, slow-blow fuse (F1).
The VFC relay is typically connected to an interlock where all equipment on the line is
connected through a single electrical connection. When this connection is made, the
production line runs. If the printer stops printing (Print Failure), or a software error occurs
(System Failure), or the printer is turned off, the equipment connection is broken and the
line stops.
This VFC relay can also be used to drive an externally-powered, three-stage beacon. The
nALARM_24V signal drives the amber light, and the nALARM_VFC output drives the red
(NC contact) and green (NO contact) lights. When the printer is turned off, the
nALARM_VFC signal is not asserted and the red light is not illuminated (unless the
external mains electrical supply for the beacon remains on).
IMPORTANT: The VFC module must not be used in a safety-critical production line
interlock.
VFC relay operation

The VFC relay provides two possible connections, normally closed (NC) and normally open
(NO). The operation of these connections depends on the state of the printer and the VFC
alarm settings in the printer. The alarm groups (if any) that activate the VFC relay can be
configured on the Alarm Setup VFC Alarm screen (Home screen > Line Settings > Alarms
> VFC Alarm). When the VFC alarm is activated, it operates continuously.
Normally closed (NC)

Before electrical power is applied to the printer, the NC relay contact is closed. When
electrical power is applied to the printer, the state of the relay depends on the printer state
and the VFC alarm settings. If an alarm group is set to On in the VFC alarm setup and an
event within that group occurs on the printer, the relay contact remains closed. If no events
within that group occur, or an event occurs but the related alarm group is not set to On in
the VFC alarm setup, the relay contact opens.
Normally open (NO)

Before electrical power is applied to the printer, the NO relay contact is open. When
electrical power is applied to the printer, the state of the relay depends on the printer state
and the VFC alarm settings. If an alarm group is set to On in the VFC alarm setup and an
event within that group occurs on the printer, the relay contact remains open. If no events
within that group occur, or an event occurs but the related alarm group is not set to On in
the VFC alarm setup, the relay contact closes.
VFC alarm output conditions

When an event occurs in an alarm group that has the VFC alarm option enabled, the alarm
is activated. When the VFC alarm is active, the relay is de-energized and pin 3 of the alarm
output connector is connected to pin 1. When the VFC alarm is not active, the relay is
energized and pin 3 is connected to pin 2. If electrical power is removed from the printer,
this condition is equivalent to the VFC alarm being active. A summary of these conditions is
shown in the following table.
Alarm state Alarm connector conditions

Active Pin 3 connected to pin 1 (NC)
Not active Pin 3 connected to pin 2 (NO)
Power off Pin 3 connected to pin 1 (NC)
Table 3-1. VFC alarm output conditions
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External equipment connections
Either a ‘normally open’ (NO) or ‘normally closed’ (NC) VFC relay contact operation is
available at the alarm output connector. The external alarm equipment connected to this
output must have its wiring connected according to the following table.
Alarm signal Alarm connector

RLA1 ‘VFC Alarm’ RLA2 ‘24V Alarm’ pin numbers
Common — 3
Normally open (NO) — 2
Normally closed (NC) — 1
— Normally open (NO) 4
— Common 3
Table 3-2. VFC alarm external connections
Refer to the ‘VFC Module Installation’ maintenance instruction in Chapter 5: ‘Maintenance’

for the installation procedure and important electrical safety information.
3.9.4 Dual alarm

The dual alarm facility for the 8900 printer allows a mains-powered (VFC) external alarm
and the standard 24 volts external alarm to be used at the same time. This capability is
available with the optional, internal VFC module accessory.
The operation of both alarms can be configured on the Alarm Setup screens (Home screen
> Line Settings > Alarms > 24V Alarm and VFC Alarm).
The printer software controls the two alarm outputs. When an alarm condition is detected
by the printer, the software selects which alarm output is triggered.
The following examples are a common arrangement:
 The 24 volts external alarm is activated when there is a System Warning, for example,
“Ink Cartridge Empty”, “Solvent Cartridge Empty”, or “Printhead Cover Off”.
 The VFC external alarm is activated when there is a Print Failure, for example, “Time
Of Flight Failure”, “Phase Failure”, or “Internal Spillage”.
For more information about alarms, see the section ‘Alarm output’ on page 3—63 of this
chapter.
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3.9.5 Multi-stage alarm
A multi-stage alarm capability is available with the optional, internal VFC module
accessory.
The multi-stage alarm provides more information on the printer status to operators who are
at a distance from the printer. An example of a multi-stage alarm is a three-stage alarm with
three different coloured beacons. These beacons can be configured for different alarm
groups, as shown in the following example:
 Green beacon for ‘Printing’ (the printer is in the ‘Printing’ state).
 Amber beacon for ‘Consumable Warning’ (for example, the ink or solvent cartridge is
empty).
 Red beacon for not ‘Printing’ (the printer is not in the ‘Printing’ state).
The alarm groups that illuminate each beacon can be configured on the Alarm Setup
screens (Home screen > Line Settings > Alarms > 24V Alarm and VFC Alarm).
Multi-stage alarm connections

Either a ‘normally open’ (NO) or ‘normally closed’ (NC) VFC relay contact operation is
available at the alarm output connector. The multi-stage alarm connected to this output
must have its wiring connected according to the following table.
Alarm signal Wiring for a

Alarm connector
common-neutral
RLA1 ‘VFC Alarm’ RLA2 ‘24V Alarm’ pin numbers
beacon
Common — 3 Mains supply (live)
Normally open (NO) — 2 Green beacon
Normally closed (NC) — 1 Red beacon
— Normally open (NO) 4 Amber beacon
— Common 3 Mains supply (live)
Table 3-3. VFC alarm external connections—multi-stage alarm
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3.9.6 Serial interface
The 8900 printer can be fitted with an optional RS-232 serial interface accessory. This facility
provides a method of controlling all the printer functions from a remote device, for example
a PC or PLC, through the serial port, instead of using the local keyboard and display. The
printer is a ‘slave’ that receives commands from a remote host, and returns requested status
information and data.
A configuration code is required to enable the RS-232 option.
The RS-232 interface is an Electronic Industries Association (EIA) approved standard for
connecting serial devices, and provides point-to-point communications. Refer to the Linx
Remote Communications Interface Reference Manual for more information.
The protocol used is defined by Linx and is called the simple communications protocol
(SCP). Refer to the Linx SCP Reference Manual for more information.
The RS-232 connector is a 9-way, D-type connector mounted on an option plate, which is
fitted to the left side of the printer cabinet above the alarm connector. A cable connects the
RS-232 connector to SK206 on the I/O PCB.
Pin connections for the RS-232 interface cable are shown in the following illustration.
COMPUTER 68047 PRINTER

"RS232 INTERFACE"
1 1 not connected
RxD RxD
2 2
TxD TxD
3 3
4 4 not connected
Gnd Gnd 5
5
6 6 not connected
7 7 not connected
8 8 not connected
9 9 not connected
Figure 3-44. Pin connections for the RS-232 interface cable
3.9.7 Ethernet interface

The Ethernet interface provides a high-speed data interface to the printer. The 8900 printer
uses the standard transmission control protocol/Internet protocol (TCP/IP-10/100Base-T).
These protocols allow the printer to be connected to a standard Ethernet network or directly
to a local PC.
The Ethernet connector, PL214 on the I/O PCB, is an RJ45 connector, which is fitted through
the left side of the printer cabinet and is identified ‘ETHERNET’.
3.9.8 USB interface

The USB interface allows a USB memory device to be connected to the printer for the
following purposes:
 To download system software to the printer, which can be done only at the Service
access level.
 To transfer message data to and from a USB memory device.
 To copy or back up the configuration of a printer and to restore a configuration to any
8900 printer.
The USB type A connector, PL213 on the I/O PCB, is fitted through the left side of the
printer cabinet and is identified ‘USB’.
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3.9.9 D-type connector assembly
Correct assembly of the D-type connectors that connect trigger devices and shaft encoders
to the printer is shown in the following general illustration.
Cable screen to be terminated by removing the

outer sheath and folding the braid back on itself
by approximately 10 mm. Braid to be secured
by the cable clamp over the exposed braid.
6321
F
E
D J (see NOTE 1)
C
K
B A
A. Cable F. Rubber gasket

B. Holding cap (x2) G. Main body of hood
C. Locking screw (x2) H. Cable clamp
D. Top part of hood J. D-type connector
E. Hood screw (x2) K. Contact plate—internal (only for shielded version)
NOTES: 1. For the photocell and shaft encoder cables, item J is a male connector.
2. Test all cable connections for continuity and short circuits before use.
3. The cable clamp over the screen braid is to be pulled into the connector
hood until it 'clicks' into place.
4. Pad out the cable outside diameter with heatshrink, if necessary, to
ensure a good seal at the rubber gasket.
Figure 3-45. Correct assembly of the IP67 D-type connector
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MK11 PRINTHEAD
NOTES
NA = Fitted but Not Available Printhead PCB AS20343
NF = Not Fitted
1. Pressure transducer is Sensor Technics RVAP100GU2 Modulation
(Alternative Honeywell PC40-100G)
2. The combination of MAIN I/O and CPU = IPM ASSEMBLY
INK SYSTEM
300VDC
Charge
Charge DAMPER
Amplifier -5V
inverter
+5V
TOF
Amplifiers FEED
VALVE
Vpress PRESSURE
TRANSDUCER
PH PIC µC NOTE 1
Strobe LED Strobe 0V
Driver inc.PH type
& version
22M
Thermistor
22M
INK SOL VENT PURGE SOL TOP SOL ADD
Deflection Plates CART CART VALVE VALVE VALVE VALVE
VALVE VALVE
Gutter Sense
I2C MANIFOLD VALVES
SAFETY INK PUMP

EARTH
PH FEED
VALVE
PH SOLVENT TRANSFER PUMP

FEED
VALVE
VPWRS
PH GUTTER
VALVE INK SPILL
DETECTOR
SPILL+
COVER
COVER SENSOR SENSE CCT
CONTACTS
SERV MOD SERV MOD SERV MOD SOLVENT TANK DOOR

DETECT HIGH SENSOR LOW SENSOR LEVEL SENSOR SOLVENT SENSOR RFID PCB
PRIME
VALVE AS11004
5VP nCOVER Modulation HALL EFFECT HALL EFFECT HALL EFFECT REED SWITCH HALL EFFECT
Interconnect PCB 0V (2) VPOWERS Charge
I2C DATA nPH FEED 300VDC
AS20344 I2C CLK
STROBE
nPHSOLVENT FEED
nPG GUTTER
SERVICE MODULE SENSORS
ELECTRICAL / INK SYSTEM

SAFETY BARRIER
CONDUIT
AS11017
AS11018
AS11080
AS11079
AS11019
AS11021
AS11020
AS11010
AS11008
2-6 METRES
5VPH
High Voltage Power Module 0V (2)
TOF I2C VPWRS 24V
MP11050 YELLOW
STROBE nSOL ADD DEMAND
MINIFIT JR
HIGHVOL EHT nCOVER 5V nSOL CART TACHO 5V
MICROFIT
MICROFIT
MICROFIT
MICROFIT
MICROFIT
MICROFIT
CONNECTOR SAFETY VPWRS PRESS SIG nINK CART FWD/REV nSER MOD DET 5V
8 WAY
12 WAY
12 WAY
10 WAY
C-GRID
C-GRID
nPH FEED nPURGE ERROR
2 WAY
4 WAY
0 - +4KV 0V nSER MOD LOW
5 WAY
4 WAY
2 WAY
RED EARTH DOOR
Trip nPH SOLVENT VPWRS nVENT CURRENT nSER MOD HIGH 0V
RADIALL nPH GUTTER 24V 0V VPWRS
30M nFEED nSOL TOP 0V 0V SPILL
EHTinverter MCX SERIES nT. PUMP LOW SIG SOL PRIME
0 - -4KV WHITE
Trip
30M
" !
300VDC
4 WAY SINGLE MICROCLASP
Trip 0VDC
300V inverter
300VDC
Trip
Fused 24V 14 WAY 0.1"
Power PH Control and 5V Ext Battery Charger " IDC LATCHED
Management Supplies 3 WAY RIBBON CABLE
x16)
& DDR3 128M
(Flash 8GB
Memory
peripherals
RS232, I2C etc
with built-in display,
iMX6 Processor
RADIALL SINGLE
MCX SERIES ! HIROSE 5V
BLUE 164W DUAL SPI CLK
Modulation ROW EDGE LED Green SPI MOSI
Battery backup. Charge & Mod DACs CONNECTOR 0V SPI MISO
Amplifier SPI CSN
600mAh for CPU USB 2.0 level & scale Buzzer 5V LED Red
24V Shutdown & RTC (2 chan. mux'd) 3V3 0V
nEHT-OVER GND
nEHT-EN- JTAG
10.1" WVGA TFT LCD, LED BACKLIGHT AND PCAP TOUCHSCREEN
10 WAY 10 WAY
LV MOD+ SINGLE MICROFIT 24V
FPGA
RAM linked to
Charge sequence
SDRAM 16M x16
Altera EP4CE10
FPGA
LV MOD-
PLATED TRACKS
MICROCLASP nEHT-OVER 3V3 I/O OUT OF CPU PCB:
0V nEHT-EN- RS232 debug 16-bit TFT LCD INTERFACE NA
I2C CLK Auxiliary PSU Programming & TOF and system BACKLIGHT LED
LV MOD+
SOCKET
generators XJTAG interface interface I2C interfaces SPI, USB, RS232 4 WAY
I2C DATA AS11022 LV MOD- I2C (Touchscreen & System)
(5V, 5V5, 10V, 4V6, MICROFIT
0V 4V4 & 3V3) MUX'D 10-bit DAC BUS 10.1" WVGA LCD
I2C CLK uP GPIO (Incl. LCD to 24-bit)
I2C DATA FPGA GPIO TOUCH SCREEN
Ethernet 0V PCAP EXC3000
UPS SDC I2C
Comms interface Print trigger & Alarm & Input Multiplexer 3V3 I/O INTO CPU PCB: UPS SDA
& driver chips shaft encoder Print Busy for low bandwidth MUX'D 16-bit FPGA INPUTS
regulation
management &
Local power
LOW VOLTAGE PSU (Ethernet and interface & interfaces FPGA signals uP GPIO (Incl. 6 PCB LINKS) FI-RE41
Customer RS232) filtering FPGA GPIO 41 WAY FFC
24VDC 150W Touch
2V5 I/O: BP549385
BP494011 FPGA GPIO 5V Screen
4 WAY 0.156 [Possible future Ethernet] 6 WAY 3V3 PCB
5WAY 0.156 MAC Address & Temperature Drivers for UNIC 10.1" TFT MINIFIT JR LVDS
Serial EEPROM Sensor chip, Strobe, & LVDS Filter TOUCH
BACKLIGHT
interface
& display
Touch Screen
24V 24V chip Peripheral Resets
0V 0V 24V, 0V POWER SW
4 FPGA 0V
L
N
0V TO CHASSIS AS15064 Service Micro SD Card Power Fail Detect
CONNECTION Links (x 5) Realtime Clock Socket NF & Shutdown Timer 36W DUAL
AS11059 Software Option (RTC) ROW EDGE
Switches (x 8) CONNECTOR
0.25"
PLATED TRACKS
SPADE 2 WAY
POSITIVE MINIFIT JR
SOCKET
10V PIC config. Valve Drives,
AIR PUMP 0V UNIC Spill Detect switches 24V/4V switch HDMI
(Optional) with timeout, LVDS
freewheel diodes
Install 8900 software
AS10126
CPU PCB
MEMBRANE SW
6 WAY
Ink Pump Driver Pressure control, Pressure, RPM, HDMI NF SHIELD DIN
2 WAY with current RPM control, diagnostics, Res Touch NF !
MINIFIT JR limits and stall built-in test reporting RGB TFT NF
FAN detection etc
24V TXD, RXD
IP55 0V RTS, DTR
0V
SAFETY EARTHS Pressure Input Sensor Transfer 4 WAY

FAN Transducer Filtering / RFID RS422 Pump Drive MINIFIT JR OPTION PLATE 3 VARIANTS
Printhead Gain/Offset Level shift
IP65 VFC Option RS232 Option ======================
Rear Panel AS64022 AS11012
AS11051 24V VFC ONLY
IP65 Option Fan. 24V ALARM RS232 ONLY
AS11049
CHASSIS Only 1 Fan fitted
MAIN I/O PCB VFC ALARM
0V VFC & RS233
CONNECTION ON AS11000
ELECTRONICS TRAY PRI (NPN or PNP) PRI (NPN or PNP)
TX+-S Vbus SEC (NPN or PNP) SEC (NPN or PNP)
TX--S D- S-ENC-CH1 24VF S-ENC-CH1 24VF
RX+-S D+ S-ENC-CH2 5VF S-ENC-CH2 5VF 24V
RX--S GND PRINT BUSY 0V PRINT BUSY 0V nALARM 24V 6 WAY 9W D Socket
IP65 IP65
IEC INTEGRATED
MAINS FILTER 8 WAY USB Type A PC/SE PC/SE ALARM
& FUSE (2 x 4A (T)) L N E RJ45 IP65 IP65 9W D Socket 9W D Socket 2W IP65
IP RATED AND EMC BARRIER

IP55 & IP65 VARIANTS OF 8900 PRINTER
THIS DRAWING IS FOR REFERENCE ONLY.

LINX PRINTING TECHNOLOGIES PLC
IT IS NOT AN ASSEMBLY DRAWING LINX HOUSE, 8 STOCKS BRIDGE WAY
COMPASS POINT BUS. PARK, ST IVES
CAMBS PE27 5JL
R:\01NPD\Engineering\Projects\Brambling\Electronics\System
THIS DRAWING IS CONFIDENTIAL AND MUST NOT BE COPIED
IN WHOLE OR PART WITHOUT THE PRIOR WRITTEN CONSENT Title
DRN DATE 24-06-2015 OF LINX PRINTING TECHNOLOGIES PLC. 8900 ELECTRONICS SYSTEM DIAGRAM
IT MUST ONLY BE USED FOR THE PURPOSES FOR WHICH IT
CHK DATE 24-06-2015 HAS BEEN SPECIFICALLY SUPPLIED. Size Document Number Rev
IT IS TO BE KEPT SECURELY AND MUST NOT BE DISCLOSED A1 CD11082 1
APPD DATE 24-06-2015 TO ANY THIRD PARTY.
Date: Wednesday, June 24, 2015 Sheet 1 of 1
CHAPTER 4: TROUBLESHOOTING
4.1 Introduction
Troubleshooting flow charts for the 8900 printer are available to download from the
'Customer Service > Documentation and Videos' section of ExtraLinx (http://
www.extralinx.com/).
These flow charts give logical step-by-step processes to quickly identify a fault on the
printer.
FA48008
FA48008
CHAPTER 5: MAINTENANCE
5.1 Introduction
This chapter is divided into two parts. The first part describes the available options on the
Maintenance screen. The second part contains Maintenance Instruction procedures, which
describe how to test and repair the 8900 printer, and how to install additional features.
The information shown in this chapter refers to 8900 printers with Version 1.0 System
Software installed, unless otherwise stated.
5.2 Access to Maintenance options

Access to different sets of options is by a user level and a related security PIN. To get full
access to all of the options, the Supervisor level is selected on the Select User screen (Main
Menu > User Login > Select User screen). Then the related PIN for the Service level is
entered on the Enter PIN Code screen.
These maintenance options are only for use by maintenance technicians and other
personnel who have been trained and authorized by Linx.
The default PIN for the Service level options is not printed in this manual for printer
security reasons. Some personnel who have access to this manual will not have received the
necessary training to correctly use the complete list of Maintenance options. The default
PIN for the Service level is supplied on an 8900 maintenance training course approved by
Linx.
5.2.1 Service level timeout

The 8900 printer has a security timeout for the Service access level. When the printer is at
the Service access level, the printer automatically changes to the default Operator level after
24 hours. This feature prevents printers being accidentally left in the Service access level
condition.
5.3 Total Maintenance options

When the Menu button on the Home screen is touched, and then the Maintenance button
on the Main Menu screen is touched, the following Maintenance (1 of 3) screen is
displayed.
89280
Figure 5-1. Maintenance (1 of 3) screen
FA48008
The More button displays further options on the Maintenance (2 of 3) and Maintenance
(3 of 3) screens.
89281

These two screens show all of the Maintenance options that are available at the Service
security level.
89282
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5.4 Option availability
The printer has three main states: ‘Idle’, ‘Jet Running’, and ‘Printing’ (printing or ready to
receive a ‘Print Go’ signal). These states can have an effect on the availability of some
Maintenance options, and also on the ability to select an option or change its parameters.
The Maintenance options are only displayed if the options are valid for the security level
used and the current printer state. For example, the Jet Sequences option (Main Menu >
Maintenance) is displayed only at the Service level, and when the printer is in the ‘Idle’ (jet
off) state. When the printer is in the ‘Jet Running’ or ‘Printing’ states, the Jet Sequences
option is displayed but is dimmed and cannot be selected. However, the Jet Sequences
option is not displayed at the Supervisor level.
Table 5-1 shows when each Maintenance option and the suboptions are available, related
to the printer state at the Service access level. The symbols used in the table indicate when
the options are available, and the symbols have the following descriptions:
 The options that are displayed and can be selected or changed are identified with a
solid circle (●).
 The options that are displayed, but cannot be selected or changed are identified with an
empty circle ().
 The options that are displayed, but cannot be selected or changed at the Service level in
any printer state are identified with ‘NS’ (not selectable). These buttons are
permanently dimmed at the Service Level.
Page number cross-references are provided next to each option in the table (where
applicable) to a description later in the section.
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Maintenance screen option 2nd level screen Idle Jet Printing
Running
Nozzle Flush (page 5—7) ●  
Nozzle Clear (page 5—8) ●  
Jet Monitor (page 5—9) ● ● ●
SET Pressure (page 5—9) ● ● ●
REF Pressure (page 5—11)   
ACT Pressure (page 5—11)   
REF Mod (page 5—11)   
ACT Mod (page 5—11)  ● ●
REF TOF (page 5—12) ● ● ●
ACT TOF (page 5—13)   
Phase On/Off (page 5—14) ● ● ●
ACT Phase position (page 5—14)  ● ●
Solvent Add Pressure (page 5—15)   
Solvent Add counts (page 5—15)   
Temp (°C) (page 5—16)   
Replace Service Module (page 5—16) ●  
Maintenance Times (page 5—18) ● ● ●
Power On Time (Total) (page 5—18)   
Power On Time (Present) (page 5—18)   
Jet Run Time (Total) (page 5—18)   
Jet Run Time (Present) (page 5—18)   
Maintenance Due Within (page 5—18)   
Maintenance Due By (page 5—19)   
Clean Touch Screen (page 5—20) ● ● ●
Calibrate Touch Screen (page 5—20) ● ● ●
Jet Functions (page 5—21) ● ● ●
Jet Test-Start (page 5—21) ●  
Jet Test-Stop (page 5—22)  ● 
Start Print (page 5—22)  ● 
Stop Print (page 5—22)   ●
Test Print (page 5—22)   ●
Table 5-1. Availability of the Maintenance options
FA48008
Running
Jet Sequences (page 5—23) ●  
From Storage (page 5—24) ●  
Gutter Valve Reset (page 5—24) ●  
Ink Prime (page 5—24) ●  
Ink Prime–Valve Unstick (page 5—24) ●  
Into Storage (page 5—24) ●  
Nozzle Flush (page 5—24) ●  
Reset All Valves (page 5—24) ●  
Reset Solvent Tank Valves (page 5—24) ●  
Safely Remove SM (page 5—25) ●  
Solvent Prime (page 5—25) ●  
Solvent Pump Auto Flush (page 5—25) ●  
Solvent Pump Flush (page 5—25) ●  
Valve Test (page 5—26) ● ● ●
PH Feed (page 5—26) ●  
PH Solvent (page 5—26) ●  
PH Gutter (page 5—26) ●  
Purge (page 5—26) ● ● ●
Feed (page 5—26) ●  
Solvent Add (page 5—26) ● ● ●
Solvent Top-Up (page 5—26) ● ● ●
Ink Cartridge (page 5—26) ● ● ●
Solvent Cartridge (page 5—26) ● ● ●
Vent (page 5—26) ● ● ●
Solvent Prime (page 5—26) ● ● ●
Pressure (page 5—27) ● ● ●
RPM (page 5—28) ● ● ●
Mod (page 5—29) ● ● ●
Power (page 5—29)   
TOF (page 5—30)   
Phase (page 5—30)   
Transfer Pump (page 5—30) ● ● ●
All Valves Off (page 5—26) ●  
Commissioning (page 5—30) ●  
Table 5-1. Availability of the Maintenance options (continued)
FA48008
Running
Calibration (page 5—33) ● ● ●
printhead serial number (page 5—36)   
PCB serial number (page 5—37) NS NS NS

conduit length (page 5—37) NS NS NS
IPM: Press. Trans. (mV) (page 5—37) ● ● ●
Service: Press. Trans. (mV) (page 5—37) NS NS NS

P’head: Charge Gain (%) (page 5—37) NS NS NS
IPM: Charge Gain (%) (page 5—37) NS NS NS
Service: Charge Gain (%) (page 5—37) NS NS NS
P’head: EHT Gain (%) (page 5—37) NS NS NS
IPM: EHT Gain (%) (page 5—37) NS NS NS
Service: EHT Gain (%) (page 5—37) ● ● ●
P’head: Ref Press (page 5—38) NS NS NS

Service: Ref Press (page 5—38) ● ● ●
P’head: Ref Mod (page 5—38) ● ● ●
Service: Ref Mod (page 5—38) ● ● ●
Service: Gutter (page 5—38) ● ● ●
Decommissioning (page 5—39) ●  
From Storage (page 5—42) ●  
Into Storage (page 5—42) ●  
Valve Reset (page 5—42) ●  
Printhead Characteristics (page 5—43) ● ● ●
Consumables History (page 5—43) ● ● ●
Ink Level (page 5—44)   
Solvent Level (page 5—44)   
Service Module Life (page 5—44)   
Ink Cartridges Used (page 5—44)   
Solvent Cartridges Used (page 5—44)   
Recent Ink Cartridges (page 5—45)   
Recent Solvent Cartridges (page 5—45)   
Current Ink Usage (page 5—45)   
Current Solvent Usage (page 5—45)   
Reset (page 5—45) ●  
Software Upgrade (page 5—46) ●  
Table 5-1. Availability of the Maintenance options (continued)
FA48008
5.5 Maintenance options
5.5.1 Nozzle Flush

THE EYES AND SKIN.
WEAR SAFETY EYEGLASSES AND SOLVENT-RESISTANT PROTECTIVE GLOVES WHEN
THERE IS DIRECT CONTACT WITH THE INKS AND SOLVENTS, WHEN WORK IS DONE ON THE
PRINTER, AND WHEN THE PRINTER IS CLEANED.
WARNING: HIGH-PRESSURE SOLVENT JET HAZARD. IT IS VERY IMPORTANT THAT THE

DIFFERENCE BETWEEN THE NOZZLE FLUSH SEQUENCE AND THE NOZZLE CLEAR
SEQUENCE IS UNDERSTOOD. DURING THE NOZZLE FLUSH SEQUENCE, SOLVENT IS
EJECTED FROM THE PRINTHEAD NOZZLE AT MAXIMUM PRESSURE.
WHEN THE NOZZLE FLUSH SEQUENCE IS IN OPERATION, ENCLOSE THE PRINTHEAD IN AN
ACCEPTABLE CONTAINER TO CONTAIN THE SOLVENT JET. WEAR SAFETY EYEGLASSES
AND SOLVENT-RESISTANT PROTECTIVE GLOVES.
The Nozzle Clear sequence described later in this section removes particles from the
printhead jewel and nozzle area. These particles can then remain distributed within the gun
chamber where they can collect on the jewel again. This effect can cause the problems of jet
alignment or nozzle blockage to occur again in the future, if not immediately. Therefore, the
Nozzle Flush sequence can be used instead of the Nozzle Clear sequence, or with the
Nozzle Clear sequence, when there is a known nozzle obstruction or blockage.
The Nozzle Flush sequence is different from the Nozzle Clear sequence, which draws
solvent into the nozzle. The Nozzle Flush sequence automatically fills the nozzle with the
solvent, and then ejects a jet of solvent from the nozzle and into the gutter to flush away any
deposits.
A Nozzle Flush sequence takes approximately 1 minute to complete. The pump is run at a
pressure of 200 LPB, and then the Gutter valve is opened. This action applies the vacuum to
the gutter for 20 seconds, which draws the solvent jet into the gutter. The Gutter valve is
then closed and the pump is stopped, which decreases the pressure to zero.
IMPORTANT: The Nozzle Flush sequence tries to create a solvent jet. If a jet is started, the
returned solvent goes into the service module, but too much solvent can
decrease the viscosity of the ink. If the Nozzle Flush sequence is used too
many times, the decreased ink viscosity causes the printer to fail. The
Nozzle Flush sequence must not be used more than three times to clear a
nozzle blockage.
When the Nozzle Flush button is touched, the Nozzle Flush screen is displayed, which
includes Start and Stop buttons, and a sequence progress bar. When the sequence is in
operation, the Stop button can be used to cancel the sequence. The Stop button is disabled
until the sequence is started. The Exit button returns the display to the Maintenance screen.
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5.5.2 Nozzle Clear

THE EYES AND SKIN.
The Nozzle Clear sequence can be used instead of the Nozzle Flush sequence or with the
Nozzle Flush sequence, when there is a known nozzle obstruction or blockage. (Refer to
‘Nozzle Flush’ earlier in this section.)
can fail if the wrong solvent is allowed to enter the ink or solvent tanks. Make sure that the
solvent used during the following procedure is the correct type for the ink and solvent used in
the printer. Use only Linx solvents.
The Nozzle Clear sequence applies a vacuum to the printhead nozzle to clear an obstruction
or blockage. While the printer is performing the Nozzle Clear sequence, the printhead must
be turned upside down and solvent applied in small drops to the nozzle assembly face.
Refer to the ‘Nozzle Clear sequence’ part of the ‘Jet Alignment and Nozzle Cleaning’
maintenance instruction later in this chapter on page 5—133.
A single Nozzle Clear sequence takes approximately 30 seconds to complete. The pump is
run at the maximum pressure of 255 LPB, and then the Purge valve is opened. This action
transfers the vacuum from the gutter to the nozzle assembly for 20 seconds, which draws
the applied solvent into the nozzle. The Purge valve is then closed and the pump is
stopped, which decreases the pressure to zero.
Linx recommends that a maximum of eight Nozzle Clear sequences are performed to try to
clear an obstruction or blockage. An attempt is made to start the jet after each sequence.
When the Nozzle Clear button is touched, the Nozzle Clear screen is displayed, which
includes Start and Stop buttons, and a sequence progress bar. When the sequence is in
until the sequence is started. The Exit button returns the display to the Maintenance screen.
If this procedure does not remove the nozzle blockage, perform the necessary ‘Nozzle soak’
and ‘Nozzle wash’ procedures described in the ‘Jet Alignment and Nozzle Cleaning’
maintenance instruction later in this chapter on page 5—133. If these procedures do not
clear the nozzle blockage, the nozzle assembly or complete printhead must be replaced.
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5.5.3 Jet Monitor
The Jet Monitor screen displays the jet control parameters. The values shown in the
following example screen are typical values for the Mk11 Midi printhead with the jet in
operation, and 3103 ink. Some parameters are for display only, while other parameters can
be changed.
89283
CJ400 numbers scaling for 8900:

H = 72%
V= 62%
Figure 5-4. Jet Monitor screen

The displayed values on the Jet Monitor screen are updated every 250 ms.
The following paragraphs describe each of the options and parameters on the Jet Monitor
screen.
Pressure
The Pressure area of the Jet Monitor screen displays three pressure values, in Linx pressure
bits (LPB): Set Pressure, Reference Pressure, and Actual Pressure.
SET (Set Pressure)

The value displayed on the SET button is the ink system pressure that is used by the
software for the following functions.
Set Pressure performs two separate functions. First, when the jet is in the ‘Jet Running’ or
‘Printing’ states, the Set Pressure is automatically adjusted by the software to maintain the
Time Of Flight (TOF) within the control parameters. The Set Pressure value also indicates
the different pressures required by the software to perform the different jet sequences, for
example, startup and shutdown. Therefore, the Set Pressure value can be used to monitor
the series of pressure changes during each jet sequence.
Second, when the jet is stopped, the Set Pressure function becomes a very useful diagnostic
tool. The following are diagnostic uses for setting a Set Pressure value:
 To find faults caused by pressure loss.
 To clean the printhead.
 The pressure can be increased and decreased to try to produce TOF measurements to
confirm high or low ink viscosity.
The Set Pressure function can be used to start and stop the pump. Also, if the pump is
operating and ink is flowing through the venturi, the pressure can help with fault diagnosis
of the ink system. Under these conditions, the pressure provides a vacuum in the gutter
line, which can be used to help clear blockages or to flush the printhead.
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Enter Pressure screen
During normal operation (Jet Running), the Set Pressure value is automatically adjusted by
the printer to maintain the correct TOF. Automatic pressure control is enabled during
startup, and disabled during shutdown.
For diagnostic purposes, the Set Pressure value can be changed while the jet is in operation.
When the blue SET button is touched, the Enter Pressure screen is displayed, which allows
the Set Pressure to be freely adjusted as required.
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Enter Pressure
179
0 .. 255
Press Cancel to return to automatic pressure management.
Figure 5-5. Enter Pressure screen

The up (+) and down (–) buttons increase or decrease the pressure by one pressure bit for
each touch of the button. A pressure value can also be entered by the numeric keypad, and
the screen allows values between 0 and 255 LPB to be set.
The left and right arrow buttons move the insertion point cursor in the value box by one
position for each touch of the button.
The left arrow button next to the numeric keypad deletes one digit to the left of the insertion
point cursor for each touch of the button.
When the Set Pressure value is changed and the Save button is touched, the automatic
pressure control is disabled and the printer uses the new pressure value. The display
returns to the Jet Monitor screen and the blue SET button changes to a yellow button,
which displays the new pressure value. A yellow Cancel button is also added at the bottom
of the screen.
To return the Set Pressure to automatic pressure control, the yellow SET button is touched,
which displays the Enter Pressure screen again. If the Cancel button on the Enter Pressure
screen is touched, the display returns to the Jet Monitor screen and automatic pressure
control is enabled again. The value then displayed on the blue SET button is the pressure
that the printer is using to automatically control the jet.
The yellow Cancel button at the bottom of the Jet Monitor screen returns all manual
changes made to any of the jet parameters to their original values.
If the jet is stopped and then restarted while the automatic pressure control is disabled, the
manually changed Set Pressure value is reset.
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REF (Reference Pressure)
The value displayed in the REF box is the Reference Pressure used by the printer during
normal operation. The value is for display only and cannot be changed.
The Reference Pressure value, which is different for each printhead, is stored in the
printhead and can be seen on the Calibration screen.
ACT (Actual Pressure)

The value displayed in the ACT box is the pressure measured by the ink system pressure
transducer. The value normally reflects the Set Pressure value (refer to ‘SET (Set Pressure)’
on page 5—9) with only a small difference of normally 4 to 5 LPB. During the pressure
check part of the Normal Start sequence, if the Actual Pressure is greater than 5 LPB below
the Set Pressure, the System Warning “3.18 Low Pressure” is reported.
Mod (Modulation)
The Modulation area of the Jet Monitor screen displays the Reference Modulation and the
Actual Modulation, in volts.
REF (Reference Modulation)

The value displayed in the REF box is the Reference Modulation used by the printer during
normal operation. The value is for display only and cannot be changed.
During normal operation, there is normally a small difference between the Reference
Modulation voltage and the Actual Modulation voltage (refer to ‘Actual Modulation’
below). The Reference Modulation voltage, which is different for each printhead, is stored
in the printhead and can be seen on the Calibration screen.
ACT (Actual Modulation)

The Actual Modulation value displayed on the ACT button is the current modulation
voltage used by the printer to control the jet break-up.
During normal operation, there is normally a small difference between this value and the
Reference Modulation value (refer to ‘Reference Modulation’ above).
Enter Modulation screen

The current Reference Modulation values are set as defaults of modulation and viscosity
slopes. During normal operation (Jet Running), the Actual Modulation is used by the
printer to control the drop break-off point of the jet. As the Set Pressure moves away from
the Reference Pressure, the modulation voltage is adjusted to follow the Set Pressure by an
offset value (in V/bit). This offset depends on the type of ink and the printhead.
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For diagnostic purposes, the Actual Modulation voltage can be changed while the jet is in
operation. When the blue ACT button is touched, the Enter Modulation screen is
displayed, which allows the Actual Modulation to be freely adjusted as required.
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Enter Modulation
90
0 .. 255
Press Cancel to return to automatic modulation tracking.
Figure 5-6. Enter Modulation screen

The up (+) and down (–) buttons increase or decrease the modulation by one volt for each
touch of the button. A modulation voltage can also be entered by the numeric keypad, and
the screen allows values between 0 and 255 volts to be set.
When the Actual Modulation voltage is changed and the Save button is touched, the printer
uses the new modulation voltage. The display returns to the Jet Monitor screen and the
blue ACT button changes to a yellow button, which displays the new modulation voltage.
Two additional items are displayed—an additional modulation box and a Cancel button.
The modulation box is an information box to the left of the REF box, which shows what the
modulation voltage would be if the value had not been adjusted. A yellow Cancel button is
also added at the bottom of the screen.
To return the Actual Modulation to automatic control, the yellow ACT button is touched,
which displays the Enter Modulation screen again. If the Cancel button on the Enter
Modulation screen is touched, the display returns to the Jet Monitor screen and automatic
modulation is enabled again. The value then displayed on the blue ACT button is the
modulation voltage that the printer uses to automatically maintain the correct point of drop
break-off.
By default, automatic modulation control is enabled during a power-up, and disabled
during a power-down.
If the jet is stopped and then restarted while the automatic modulation control is disabled,
the modulation is reset to the Reference Modulation.
TOF (Time of Flight)

The TOF area of the Jet Monitor screen displays the Reference TOF and the Actual TOF, in
10ths of microseconds (µs).
REF (Reference TOF)

The value displayed on the REF button is the Reference TOF, which is the jet velocity
reference. The software uses this value with the Actual TOF value to maintain the correct TOF.
FA48008
ACT (Actual TOF)
The Actual TOF value displayed in the ACT box is the measured TOF displayed as an
average reading. The value is related to the jet speed—the higher the reading, the slower
the jet; the lower the reading, the faster the jet. The value is for display only and cannot be
changed.
The time taken for a special ‘packet’ of low-charged drops to pass between two fixed points
(the phase and TOF sensors) is measured to get TOF readings. These sensors are in the
Charge Electrode and Time of Flight (CETOF) assembly in the printhead. The software
makes a number TOF measurements, all of which must be within ±40% of the Reference
TOF. An average of these TOF measurements is the displayed TOF value. Three average
readings, one after the other, must be within a given tolerance of the Reference TOF before
the readings can be used to control the system pressure.
The software uses the average value to increase or decrease the pressure, as necessary, to
maintain the TOF at the Reference TOF.
The Print Failure “2.03 Time Of Flight Failure” is displayed if there are no valid TOF
readings for a period of 40 minutes.
Enter TOF screen

For diagnostic purposes, the Reference TOF value can be changed while the jet is in
operation. When the blue REF button is touched, the Enter TOF screen is displayed, which
allows the Reference TOF to be freely adjusted as required.
89285
Enter TOF
2025
1800 .. 2500
Press Cancel to return to Reference TOF.
Figure 5-7. Enter TOF screen

The up (+) and down (–) buttons increase or decrease the TOF value by one for each touch
of the button. A TOF value can also be entered by the numeric keypad, and the screen
allows values between 0 and 2500 to be set.
When the Reference TOF is changed and the Save button is touched, the printer uses the
new TOF value. The display returns to the Jet Monitor screen and the blue REF button
changes to a yellow button, which displays the new TOF value. Two additional items are
displayed—an additional TOF box and a Cancel button. The TOF box is an information box
to the left of the REF button, which shows what the TOF value would be if the value had
not been adjusted. A yellow Cancel button is also added at the bottom of the screen.
FA48008
To return the Reference TOF value to automatic control, the yellow REF button is touched,
which displays the Enter TOF screen again. If the Cancel button on the Enter TOF screen is
touched, the display returns to the Jet Monitor screen and the original Reference TOF is
enabled again. The value then displayed on the blue REF button is the Reference TOF that is
used by the printer to maintain the correct TOF.
If the jet is stopped and then restarted while the automatic TOF control is disabled, the
manually changed Reference TOF is reset to the original Reference TOF.
Phase
The Phase area of the Jet Monitor screen displays the Phase On and Off button and the
Actual Phase position.
Phase On and Off

The Phase button turns automatic phase control on or off. When the phase control process
is turned off, phase measurements are not performed, but a manual phase position can be
set. When this mode is selected, a TOF can be found for a jet that has bad break-up.
When phase control is turned off, a yellow Cancel button is displayed at the bottom of the
Jet Monitor screen. This Cancel button returns all manual changes made to any of the jet
parameters to their original values and turns on phase control.
ACT (Actual Phase)

When the phase control process is set to On, the Actual Phase value displayed on the ACT
button reflects the drop break-off point (phase position) of the jet. This value is the phase
position used by the printer for printing. The phase position makes sure that the drop
break-off and the drop charge occur at the best offset or ‘phase’ to give consistent charge.
The printer checks the phase position at regular intervals during jet startup, jet running, or
printing. The period between checks depends on the printer state.
Enter Phase screen

For diagnostic purposes, the Actual Phase position can be changed while the jet is in
operation. This function can be used to find the size of the phase window, so that the best
phase position can be manually set. When the blue ACT button is touched, the Enter Phase
screen is displayed, which allows the Actual Phase position to be freely adjusted as
required.
89286
Enter Phase
0 .. 15
Press Cancel to return to automatic phase tracking.
Figure 5-8. Enter Phase screen
FA48008
The up (+) and down (–) buttons increase or decrease the phase position by one for each
touch of the button. A phase position value can also be entered by the numeric keypad, and
the screen allows phase positions in the range 0 to 15 to be set.
When the Actual Phase position is changed and the Save button is touched, the printer uses
the new phase position. The display returns to the Jet Monitor screen and the blue ACT
button changes to a yellow button, which displays the new phase position for printing. Two
additional items are displayed—an additional phase box and a Cancel button. The phase
box is an information box to the left of the ACT button, which shows what the phase
position would be if the value had not been adjusted. A yellow Cancel button is also added
at the bottom of the screen.
To return the Actual Phase to automatic control, the yellow ACT button is touched, which
displays the Enter Phase screen again. If the Cancel button on the Enter Phase screen is
touched, the display returns to the Jet Monitor screen and automatic phase measurements
are performed again. The value then displayed on the blue ACT button is the phase
position that is used by the printer for printing. (If automatic phase control was turned Off,
the operation is reset to On.)
If the jet is stopped and then restarted while the automatic phase control is disabled, the
manually changed phase position is ignored and automatic phase measurements are used.
Solvent Add
The Solvent Add area of the Jet Monitor screen displays the Solvent Add Pressure and the
Solvent Add count.
Solvent Add Pressure

The value displayed in the left box is the Solvent Add Pressure, which is the pressure that
the printer uses as a trigger to add solvent to the service module.
The Solvent Add Pressure, which is different for each printhead, is the Reference Pressure
value with an offset added. This offset is a small pressure value, which is normally 4 LPB
for most inks.
The Solvent Add Pressure value is for display only and cannot be changed.
Refer to ‘Viscosity control’ on page 3—19 and ‘Solvent addition’ on page 3—39 for more
information.
Solvent Add counts

The value displayed in the right box is the Solvent Add count, which is the number of times
that solvent has been added to the service module, counted from the time the jet was last
started. The value is reset to 0 (zero) when the jet is started.
The Solvent Add count is for display only and cannot be changed.
FA48008
Temp (°C)
The value displayed in the Temp (°C) box is the internal printhead temperature. If the
internal temperature of the printhead is greater than 63 °C, the Print Failure message “2.00
Printhead Over Temperature” is displayed.
WARNING: HIGH TEMPERATURE HAZARD. WHEN THIS FAULT IS REPORTED, THE

PRINTHEAD AND COVER TUBE CAN BE VERY HOT.
MAXIMUM CAUTION MUST BE USED TO PREVENT SKIN BURNS AND TO DECREASE THE
RISK OF A FIRE. DO NOT TOUCH THE PRINTHEAD, OR TRY TO REMOVE THE PRINTHEAD
COVER TUBE UNTIL THE PARTS BECOME SAFELY COOL NATURALLY.
THERE IS A DANGER OF SEVERE BURNS TO THE HANDS IF THE PRINTHEAD COVER TUBE
IS REMOVED BEFORE IT HAS BECOME SAFELY COOL. THERE IS ALSO AN INCREASED RISK
OF FIRE CAUSED BY THE SUDDEN INCREASE OF AIR AROUND THE OPEN PRINTHEAD.
Refer to ‘Printhead temperature sensor’ on page 3—11 for more information.
5.5.4 Replace Service Module

The Replace Service Module button is only enabled when both cartridges that contain the
correct ink and solvent types are fitted, and the ink and solvent levels in the cartridges are
acceptable. The Replace Service Module button accesses the following screen, which
provides on-screen step-by-step instructions for this procedure.
89287
8900
Figure 5-9. Replace Service Module screen

A service module Easi-Change® Service Key is required, which is an RFID (radio frequency
identification) tag that identifies the service module as a true Linx part and acceptable for
use in the 8900 printer. Each service module is shipped with a unique and separate
Easi-Change® Service Key.
When a service module is replaced, the Easi-Change® Service Key must be inserted
between the ink and solvent cartridges, so that the Easi-Change® Service Key can be read
by the RFID module. If the service module identification is correct, the Easi-Change®
Service Key is removed from the printer when requested by the on-screen instructions. The
Easi-Change® Service Key is a one-time use item—it cannot be used again on the printer,
and it cannot be used on any other printer.
If a valid Easi-Change® Service Key is not detected, the service module will not fill with ink
during the commissioning process, and the maintenance times cannot be reset.
FA48008
Replacement process
After the screen shown in Figure 5-9 above, the next step of the procedure advises that the
Easi-Change® Service Key for the new service module must be available to use.
The Easi-Change® Service Key is inserted at the next step. If the Easi-Change® Service Key
is not inserted, the following advisory message is displayed:
“Valid Easi-Change Service Key not detected”
If an Easi-Change® Service Key that is not associated with the new service module is
inserted, the following advisory message is displayed:
“This Easi-Change Service Key was already used”
If a valid Easi-Change® Service Key is inserted, the Maintenance Due Within Time screen
is displayed. This screen allows the maintenance technician to change the maximum jet
running time for the replacement service module.
At the next step of the procedure, the ink system pump is run backwards at 2000 rpm for 30
seconds. This action clears ink from the pipes in the primary ink circuit back into the service
module. An ‘in progress’ bar is displayed during this sequence. When the sequence is
completed, the Next button is enabled, and the service module can then be removed in the
following step.
NOTE: Port sealing plugs are fitted to a new service module. This combined set of three
plugs must be removed, and then fitted to the three ports on the old removed
service module to prevent any ink spillage. The module must then be discarded
correctly, according to local regulations.
A new service module is fitted at the next step of the procedure, which enables the Next
button again. The following screen displays an instruction to remove the Easi-Change®
Service Key and close the front access door. When the Next button is touched, the new
service module is filled with ink from the ink cartridge. An ‘in progress’ bar is displayed
during this sequence, which can take 30 minutes to complete.
When the service module has been filled, the Maintenance Times are automatically reset to
12 months or 18 months (ink type dependent) and the jet running time that was set by the
maintenance technician during the commissioning process.
The final step tells the maintenance technician to discard the old service module correctly.
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5.5.5 Maintenance Times
The Maintenance Times screen displays the operating times of the printer in three
categories. All the parameters are for display only.
89288
Figure 5-10. Maintenance Times screen
Power On Time (Total)

The Power On Time (Total) parameter is the total time (from manufacturing), in hours and
minutes, that the printer has been turned on. The time is updated while the printer is turned
on.
Power On Time (Present)

The Power On Time (Present) parameter is the time, in hours and minutes, that the printer
has currently been turned on. The time is reset to zero when the printer is turned on, and
updated while the printer is turned on.
Jet Run Time (Total)

The Jet Run Time (Total) parameter is the total time (from manufacturing), in hours and
minutes, that the jet has been operating in the ‘Jet Running’ or ‘Printing’ states. The time is
updated while the jet is in operation.
Jet Run Time (Present)

The Jet Run Time (Present) parameter is the time, in hours and minutes, that the jet has
currently been in the ‘Jet Running’ or ‘Printing’ states. The time is reset to zero when the
printer is turned on, and updated while the jet is in operation.
Maintenance Due Within

The Maintenance Due Within parameter is the jet running time that remains, in whole
hours, until the next replacement of the service module is required. The time decreases
(when the jet is in operation) from a value set by the maintenance technician when the
service module was commissioned.
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When the Maintenance Due Within time is less than 1 month of calculated jet operation,
the System Warning “3.45 Service Module Replacement Due Within One Month” is
reported. This warning is displayed each time the printer is turned on, and the jet can be
started normally.
When the Maintenance Due Within time reaches zero, the System Warning “3.40 Service
Module Requires Replacement” is reported. This warning is displayed each time the printer
is turned on, until the service module is replaced and the Maintenance Due Within time is
reset.
If the warning is ignored, the Maintenance Due Within time continues to decrease and the
time is displayed as a negative value. This negative time indicates how long ago the service
module should have been replaced.
When the Maintenance Due Within time is more than 3 months of calculated jet operation
past the replacement time (zero hours), the Print Failure “2.27 Service Module Requires
Replacement” is reported. Printing is prevented until the service module is replaced and
the Maintenance Due Within time is reset.
How to select the service module replacement hours

Normally, the service module replacement interval is a maximum of 2000 jet running hours
(the default time), but for some inks a higher number of jet running hours can be set, up to a
maximum of 13000 hours. However, the maximum service interval is 18 months regardless
of running hours. The maximum number of hours depends on the environmental
conditions of temperature, humidity and dust. Refer to the 8900 How To Select the Service
Module Replacement Hours Maintenance Level document for more information.
When the printer is commissioned, the maintenance technician can set the Maintenance
Due Within time according to the information in this document.
Maintenance Due By
The Maintenance Due By parameter is the date that the next replacement of the service
module is required. The time interval is automatically set to 12 months or 18 months (ink
type dependent) when the service module is commissioned.
When the current date is less than 30 days before the Maintenance Due By date, the System
Warning “3.45 Service Module Replacement Due Within One Month” is reported. This
warning is displayed each time the printer is turned on, and the jet can be started normally.
When the Maintenance Due By date is reached, the System Warning “3.40 Service Module
Requires Replacement” is reported. This warning is displayed each time the printer is
turned on, until the service module is replaced and the Maintenance Due By date is reset.
When the current date is more than 3 months past the Maintenance Due By date, the Print
Failure “2.27 Service Module Requires Replacement” is reported. Printing is prevented
until the service module is replaced and the Maintenance Due By date is reset.
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5.5.6 Clean Touch Screen
After a period of use, the LCD touch screen can become dirty with finger marks and dust. If
an attempt is made to clean the touch screen while the printer is turned on, options and
icons can be accidentally activated when the screen is touched. The Clean Touch Screen
button deactivates the touch screen to allow the screen to be cleaned.
When this option is selected, the touch screen is deactivated for 30 seconds. A counter is
displayed, which immediately begins to count from 30 to 0, and then the display returns to
the Maintenance screen.
89289
Figure 5-11. Clean Touch Screen counter

Linx recommends that a soft cloth and an approved LCD screen cleaner are used to clean
the screen. Linx does not recommend the use of solvent on the LCD screen.
5.5.7 Calibrate Touch Screen

CAUTION: Touch Screen Damage. The surface of the user interface touch screen can be easily
damaged if items like pens and other tools are used to activate the on-screen functions. To
prevent damage, use only a finger to activate the functions. The use of incorrect items can
cause scratches on the touch screen, which can make the screen less sensitive to touch.
This calibration process makes sure that when an area of the screen is touched, the correct
option or icon is activated. The process resets the X and Y coordinates of the touch screen to
the reference values in the software.
The Calibrate Touch Screen button accesses the first of five screens, which provide
on-screen step-by-step instructions for the calibration.
89290
Figure 5-12. Calibrate Touch Screen
FA48008
If the calibration process is not successful, the following advisory message is displayed:
“Touch screen calibration failed”
“Invalid calibration data. Try again?”
Yes and No buttons are available at the bottom of the screen. The Yes button repeats the
calibration process, and the No button returns the display to the Maintenance screen.
A confirmation screen is displayed when the calibration is completed.
5.5.8 Jet Functions

The Jet Functions screen contains buttons to start and stop the jet and printing, which can
help with fault diagnosis. The following screen is shown for a printer state of ‘Idle’.
89275
Figure 5-13. Jet Functions screen
Jet Test-Start
The Jet Test-Start button starts the jet but with a shorter method than a Normal Start
sequence to help with fault diagnosis. The total jet start time is approximately 30 seconds
compared to a Normal Start of approximately 3 minutes. The main difference is that the Jet
Test-Start sequence does not use a solvent jet before the ink jet is started. Therefore,
frequent starts do not put additional solvent into the service module.
When the Jet Test-Start button is touched, the printer enters the ‘Jet Running’ state before
the phase and TOF checks are started. The Normal Start checks and adjustments of phase
and TOF are ignored, and the printer uses the printhead Reference Pressure and Reference
Modulation values to start the jet. The printer enters the ‘Jet Running’ state, and then
adjusts the pressure to get the correct TOF.
When Jet Test-Start is used, the gutter sense function is disabled and the following Print
Failure reports are also disabled:
 2.02 Phase Failure
 2.03 Time Of Flight Failure
 2.09 Misaligned Ink Jet
 2.11 Pressure Limit Reached
 2.12 Viscosity Out of Range
After 45 minutes, the Print Failures are enabled again and reported as they occur.
The system can only use TOF correction if all the feedback signals are present. If the
feedback signals are not present, the printer operates at the printhead Reference Pressure
and Reference Modulation values.
FA48008
If Jet Test-Start is used and the fault is corrected or repaired, the jet must be restarted
normally to confirm that the fault has cleared. Use the Start Printing button on the Home
screen to start the jet again. This action is necessary because the fault or Print Failure
message can continue to be present after a Normal Start sequence.
CAUTION: Pump Damage. The Jet Test-Start option starts the jet even if the service module
level is low. Do not allow the ink system pump to run in a dry condition. The pump must not be
run for longer than 30 seconds after the change in the sound of the pump indicates that
cavitation (no ink in the pump) has occurred. Damage to the pump can occur if the pump is
allowed to run continuously in a dry condition.
While the jet is starting, the following message is displayed in the title bar of the Jet
Functions screen:
“Jet Starting”
Jet Test-Stop
When the Jet Test-Stop button is touched, the total jet stop time is approximately
10 seconds compared to a Normal Stop of approximately 2 minutes. The Jet Test-Stop
sequence does not use solvent to clean the printhead during the shutdown process.
Therefore, frequent stops do not put additional solvent into the service module.
During a Jet Test-Stop sequence, the EHT, 300 volts and modulation are turned off. A
printhead purge pressure is set followed by a short delay, and then the jet is stopped. The
nozzle is purged, the gutter is cleared, and then all the valves and the pump are turned off.
IMPORTANT: The nozzle is not flushed with solvent during the Jet Test-Stop sequence.
The use of this stop method is for fault diagnosis ONLY. Do NOT use the
Jet Test-Stop button to shut down the printer before a period during which
the printer will not be used. This method does not prepare the printer
enough for a restart.
While the Jet Test-Stop sequence is being performed, the following message is displayed in
the title bar of the Jet Functions screen:
“Jet Stopping”
Start Print
The Start Print button changes the printer state from ‘Jet Running’ to ‘Printing’ only, that is,
the button does not start the jet. The change of printer state only occurs if a message is
currently selected and displayed in the message area of the Home screen. Refer to the Linx
8900 Quick Start Guide for descriptions of how to select and edit messages.
An advisory message is displayed if the Start Printing button is touched and no print
message is selected.
If the jet was started with the Jet Test-Start button, when the Start Printing button is used
the disabled Print Failures are enabled again and reported as they occur.
Stop Print
The Stop Print button changes the printer state from ‘Printing’ to ‘Jet Running’ only, that is,
the button disables printing but maintains the jet. The change of printer state allows some
other diagnostic options to be displayed and selected, which are not available in the
‘Printing’ state.
Test Print
The Test Print button is only enabled in the ‘Printing’ state. Test Print generates a
simulation of a single print trigger to print one message manually, instead of printing from
an automatically generated signal from a trigger device. The current message displayed in
the message area of the Home screen is printed. The Print Delay setting (Home screen >
Message Settings > Advanced > Print Delay button) applies like a normal trigger device.
The Test Print function also updates sequential numbers and print counters.
FA48008
If the line speed option is set to Shaft Encoder (Home screen > Line Settings > Shaft
Encoder), printing will only start when shaft encoder pulses are received. This arrangement
is the normal condition when a production line is in operation. The shaft encoder is
disabled when Fixed Speed is selected on the Line Settings screen. The printer then prints
at a speed calculated by the Print Delay setting.
The printer operates normally for all of the other functions. For example, checks for the
printhead cover not fitted and overspeed are made, and any related event messages are
displayed.
Jet Monitor
The Jet Monitor button provides a shortcut to the Jet Monitor screen, where the jet
parameters can be monitored for correct operation.
The Exit button returns the display to the Jet Monitor screen.
Nozzle Clear
This button accesses the same sequence as the Nozzle Clear button on the Maintenance
screen, and the operation is described in ‘Nozzle Clear’ on page 5—8.
During fault diagnosis of an incorrect jet alignment, the standard procedure is to use the Jet
Test-Start sequence to try to start the jet. If the jet does not start or the jet is incorrectly
aligned, a Nozzle Clear sequence is used in an attempt to clear a nozzle obstruction or
blockage. The Jet Test-Start sequence is then used again to try to start the jet.
The Nozzle Clear button is included on the Jet Functions screen to make the sequence
quicker to access than with the Nozzle Clear button on the Maintenance screen.
This Nozzle Clear button can also be used before every Jet Test-Start sequence to make sure
that the operation of the start sequence is clean and reliable. The use by the maintenance
technician of this Nozzle Clear sequence before every Jet Test-Start sequence is optional.
5.5.9 Jet Sequences

The Jet Sequences screen provides a range of operating sequences and allows these
sequences to be selected and started individually. Each sequence in the list shows the
duration of the sequence in brackets after the name.
89291
Figure 5-14. Jet Sequences screen

When an operating sequence button is touched, the related screen is displayed, which
includes Start and Stop buttons, and a sequence progress bar. When a sequence is in
until a sequence is started. The Exit button returns the display to the Jet Sequences screen.
NOTE: The printer must be in the ‘Idle’ state (jet off) before any of the sequences can be
started.
FA48008
The following paragraphs describe the operating sequences that are available in the Jet
Sequences list.
From Storage
This option accesses the same sequence as the From Storage button on the Maintenance
screen, and the operation is described in ‘From Storage’ on page 5—42.
Gutter Valve Reset

The Gutter Valve Reset option can be used if the printer does not start after a shutdown
period of two days or more. The sequence tries to operate the Gutter valve six times and
then the Purge valve 10 times to ‘unseat’ a valve that may have become stuck. This process
is audible in a quiet environment.
If necessary, the sequence can be repeated. However, Linx recommends that the sequence is
not run more than four times, because the sequence discharges approximately half the
contents of the solvent priming unit into the service module. This quantity of solvent is
equivalent to approximately one startup and shutdown operation and can make the ink
thinner, which can cause printer failure. The service module can also overflow, which puts
ink into the solvent tank.
The Gutter Valve Reset option must only be used if the printer has a startup fault.
Ink Prime
This sequence fills the ink lines with ink in preparation for a normal jet startup, and the
sequence is part of the printer commissioning process. The sequence can be used separately
after the printhead has been replaced, the 6-way connector assembly has been
disconnected, or the ink lines have been deprimed. This priming action is recommended for
a reliable jet start after these events.
Ink Prime–Valve Unstick

This sequence operates all of the ink system valves a number of times to minimize the
possibility of a valve sticking closed. The Gutter valve, in particular, is operated more times
than the other valves to prevent this condition.
Into Storage
This option accesses the same sequence as the Into Storage button on the Maintenance
screen, and the operation is described in ‘Into Storage’ on page 5—42.
Nozzle Clear
This option accesses the same sequence as the Nozzle Clear button on the Maintenance
screen, and the operation is described in ‘Nozzle Clear’ on page 5—8.
Nozzle Flush
This option accesses the same sequence as the Nozzle Flush button on the Maintenance
screen, and the operation is described in ‘Nozzle Flush’ on page 5—7.
Reset All Valves

This option accesses the same sequence as the Valve Reset button on the Maintenance
screen, and the operation is described in ‘Valve Reset’ on page 5—42.
Reset Solvent Tank Valves

This sequence operates the Solvent Top-up valve and the Vent valve a number of times to
maintain successful top-ups of the solvent tank.
FA48008
Safely Remove SM
The Safely Remove SM option is available only when the printer state is ‘Idle’ (jet off).
The Safely Remove SM sequence is primarily for use by Linx development personnel.
However, the sequence can also be used by maintenance technicians under the direction
of the Linx International Technical Support department.
The Safely Remove SM sequence allows the service module to be quickly removed for
diagnostic purposes, with little or no ink spillage.
The sequence runs the ink system pump backwards for approximately 30 seconds to clear
ink from the pipes in the primary ink circuit. This action removes most of the ink from the
three ink system ports that connect to the service module. There is then little or no ink
spillage from the ports when the service module is removed.
The sequence can draw air into the primary ink circuit. If the service module is removed
and immediately refitted, the pump must be run for approximately 5 minutes to purge the
primary circuit of air. Print quality problems can occur if this action is not taken.
Solvent Prime
This sequence fills the solvent lines with solvent in preparation for a normal jet startup, and
the sequence is part of the printer commissioning process. The sequence can be used
separately after the printhead has been replaced, the 6-way connector assembly has been
disconnected, if the solvent tank becomes empty, or the solvent lines have been deprimed.
This priming action is recommended for a reliable jet start after these events.
Solvent Pump Auto Flush

The Solvent Pump Auto Flush option is available only when the printer state is ‘Idle’ (jet
off).
The Solvent Pump Auto Flush sequence is primarily for use by Linx development
personnel. However, the sequence can also be used by maintenance technicians under
the direction of the Linx International Technical Support department.
The Solvent Pump Auto Flush sequence uses a large amount of solvent to clean any
contamination from the solvent flow side of the solvent priming unit, and reprimes the unit.
The sequence discharges the full contents of the solvent priming unit along the solvent line
to the printhead. Unlike the Solvent Pump Flush sequence, where the solvent is fed out of
the printhead nozzle, the solvent is returned along the purge line. The transfer pump draws
the solvent through the Purge valve into the service module.
Linx recommends that the sequence is not run more than twice, because the sequence
discharges the full contents of the solvent priming unit into the service module. This
quantity of solvent is equivalent to approximately two startup and shutdown operations
and makes the ink thinner, which can cause printer failure. The service module can also
overflow, which puts ink into the solvent tank. For the same reasons, the sequence must not
be used if the printer is running below Reference Pressure.
Solvent Pump Flush

The Solvent Pump Flush option is available only when the printer state is ‘Idle’ (jet off).
The Solvent Pump Flush sequence is primarily for use by Linx development personnel.
However, the sequence can also be used by maintenance technicians under the direction
of the Linx International Technical Support department.
The Solvent Pump Flush sequence cleans any contamination from the solvent flow side of
the solvent priming unit, and reprimes the unit.
FA48008
The sequence discharges the full contents of the solvent priming unit along the solvent line
and out of the printhead nozzle. Further solvent is drawn from the solvent tank, through
the solvent priming unit, and along the solvent line to the printhead. The solvent is then
returned along the purge line, through the Purge valve and the transfer pump and then into
the service module. The solvent priming unit is then completely reprimed and ready for
operation.
Linx recommends that the sequence is not run more than twice, because the sequence
discharges the full contents of the solvent priming unit into the service module. This
quantity of solvent is equivalent to approximately two startup and shutdown operations
and makes the ink thinner, which can cause printer failure. The service module can also
overflow, which puts ink into the solvent tank. For the same reasons, the sequence must not
be used if the printer is running below Reference Pressure.
5.5.10 Valve Test

The Valve Test screen allows each of the ink system and printhead valves to be opened and
closed manually for fault diagnosis purposes. The state of each valve can also be monitored
as the valve opens and closes during any of the operating sequences.
The area on the right of the screen allows some ink system parameters to be changed, and
displays other parameter values to help with fault diagnosis.
89293
Figure 5-15. Valve Test screen—Feed valve turned on
Valve states
When a valve button is touched and released, the selected valve changes state momentarily.
If a valve button is touched and held, the selected valve changes state, and then turns off
and on continuously until the button is released. The valve then returns to its original state.
When the On radio button to the right of a valve button is touched, the valve turns on and
remains in the On state. The valve remains on until the Off radio button to the right of a
valve button is touched, or the All Valves Off button is touched. If the jet is running, the
All Valves Off button is dimmed and cannot be selected.
If more than one valve is manually turned on, the All Valves Off button can be used to turn
off all the valves at the same time. If a valve is turned on and the Exit button is touched, the
valve remains in the On state. The Valve Test screen must be accessed again to turn off the
valve.
The On and Off radio buttons show the state of the valves during normal jet operation and
during other operating sequences. During an operating sequence, the valve states change as
the sequence continues. Also, the valve buttons and the On and Off buttons for the valves
that are being used by the printer during a sequence are disabled. These ‘in use’ valves
cannot be manually operated. Valve buttons that are not disabled can be used to turn those
valves on and off.
FA48008
IMPORTANT: If the printhead Gutter valve is manually left open, with suction on the
gutter and no ink or solvent jet running, the flow of air can dry the ink
within the valve and prevent valve operation.
The printhead Gutter valve must not remain in the open state under
these conditions for periods greater than 2 minutes.
Pressure
For diagnostic purposes, the Set Pressure value can be changed while the jet is in operation.
When the blue Pressure button is touched, the Enter Pressure screen is displayed, which
allows the Set Pressure to be freely adjusted as required.
89284
Enter Pressure
179
0 .. 255
Press Cancel to return to automatic pressure management.
Figure 5-16. Enter Pressure screen

The up (+) and down (–) buttons increase or decrease the pressure by one pressure bit for
each touch of the button. A pressure value can also be entered by the numeric keypad, and
the screen allows values between 0 and 255 LPB to be set.
When the Set Pressure value is changed and the Save button is touched, the automatic
pressure control is disabled and the printer uses the new pressure value. The display
returns to the Valve Test screen and the blue Pressure button changes to a yellow button,
which displays the new pressure value. A yellow Cancel button is also added to the screen.
The Pressure radio button is also selected to show that the new Set Pressure displayed on
the yellow Pressure button is currently applied to the ink system.
If the RPM button indicates a manually set pump speed (yellow button) and the RPM radio
button is touched, the pump speed displayed on the yellow RPM button is applied to the
ink system pump. The Set Pressure no longer has priority over the pump speed.
The value to the left of the Pressure radio button is the Actual Pressure, which is also
displayed in the ACT box on the Jet Monitor screen. The value on the Pressure button is
also displayed on the SET button on the Jet Monitor screen.
To return the Set Pressure to automatic pressure control, the yellow Pressure button is
touched, which displays the Enter Pressure screen again. If the Cancel button on the Enter
Pressure screen is touched, the display returns to the Valve Test screen and automatic
pressure control is enabled again. The value then displayed on the blue Pressure button is
the pressure that the printer is using to automatically control the jet.
The yellow CANCEL button on the Valve Test screen returns all manual changes made to
any of the jet parameters to their original values.
If the jet is stopped and then restarted while the automatic pressure control is disabled, the
manually changed Set Pressure value is reset.
FA48008
RPM
For diagnostic purposes, an ink system pump speed can be set and applied while the jet is
in operation. When the blue RPM button is touched, the Enter RPM screen is displayed,
which allows a pump speed to be set from the default setting of zero.
89294
Enter RPM
-1000 .. 4000
Press Cancel to return to pressure control.
Figure 5-17. Enter RPM screen

The up (+) and down (–) buttons increase or decrease the pump speed by one revolution
per minute (rpm) for each touch of the button. A pump speed can also be entered by the
numeric keypad, and the screen allows values between –1000 and +4000 rpm to be set.
When a pump speed value is set and the Save button is touched, automatic pressure control
is disabled and the printer uses the set pump speed. The display returns to the Valve Test
screen and the blue RPM button changes to a yellow button, which displays the set pump
speed. A yellow Cancel button is also added to the screen. The RPM radio button is also
selected to show that the pump speed displayed on the yellow RPM button is currently
applied to the ink system pump.
If the Pressure radio button is touched, the Set Pressure displayed on the (blue or yellow)
Pressure button is applied to the ink system instead of the pump speed displayed on the
RPM button.
The value to the left of the RPM radio button is the true speed of the ink system pump.
Under some fault conditions this indication can confirm that, although there is zero
pressure displayed on the Pressure button, the pump is rotating. If the system is operating
correctly, the Actual Pressure value displayed on the Jet Monitor screen is the equivalent
pressure for the set pump speed on the yellow RPM button.
To return to automatic pressure control, the yellow RPM button is touched, which displays
the Enter RPM screen again. If the Cancel button on the Enter RPM screen is touched, the
display returns to the Valve Test screen and automatic pressure control is enabled again.
The value displayed on the blue RPM button is returned to zero.
The yellow Cancel button on the Valve Test screen returns all manual changes made to any
of the jet parameters to their original values.
FA48008
Mod (Modulation)
For diagnostic purposes, the Actual Modulation voltage can be changed while the jet is in
operation. When the blue Mod button is touched, the Enter Modulation screen is
displayed, which allows the Actual Modulation to be freely adjusted as required.
89278
Enter Modulation
90
0 .. 255
Figure 5-18. Enter Modulation screen

The up (+) and down (–) buttons increase or decrease the modulation by one volt for each
touch of the button. A modulation voltage can also be entered by the numeric keypad, and
the screen allows values between 0 and 255 volts to be set.
When the Actual Modulation voltage is changed and the Save button is touched, the printer
uses the new modulation voltage. The display returns to the Valve Test screen and the blue
Mod button changes to a yellow button, which displays the new modulation voltage. A
yellow Cancel button is also added to the screen.
To return the Actual Modulation to automatic control, the yellow Mod button is touched,
which displays the Enter Modulation screen again. If the Cancel button on the Enter
Modulation screen is touched, the display returns to the Valve Test screen and automatic
modulation is enabled again. The value then displayed on the blue Mod button is the
modulation voltage that the printer uses to automatically maintain the correct point of drop
break-off.
The yellow Cancel button on the Valve Test screen returns all manual changes made to any
of the jet parameters to their original values.
By default, automatic modulation control is enabled during a power-up, and disabled
during a power-down.
If the jet is stopped and then restarted while the automatic modulation control is disabled,
the modulation is reset to the Reference Modulation.
Power
This parameter is the pump motor power, measured in milliwatts, for a known Actual
Pressure. When the pump is stationary, the value does not decrease to zero due to
tolerances in the electronics.
A potential use for this parameter can be to make an analysis of possible pump wear. The
power value can be monitored over a period of time for a known pressure. If the power
value increases, the pump motor is drawing more current to maintain the same pressure,
which can indicate that the pump motor is becoming worn.
FA48008
TOF
The TOF value is the same value that is displayed in the ACT TOF box on the Jet Monitor
screen. This parameter is provided on the Valve Test screen so that the value can be
monitored as required, instead of accessing the Jet Monitor screen to read the value.
Phase
The Phase value is the same value that is displayed on the blue ACT Phase button on the
Jet Monitor screen. This parameter is provided on the Valve Test screen so that the value
can be monitored as required, instead of accessing the Jet Monitor screen to read the value.
Transfer Pump
The On and Off radio buttons to the right of the Transfer Pump option simply allow the
transfer pump to be turned on and off manually for diagnostic purposes.
Jet Monitor button

This button provides quick access to the Jet Monitor screen. If this button is used, the Exit
button on the Jet Monitor screen returns the display to the Valve Test screen.
5.5.11 Commissioning
The Commissioning button is only enabled when the following conditions apply:
 A service module is correctly fitted and has a low ink condition.
 The correct ink and solvent cartridges are fitted that are not empty.
NOTE: Every new 8900 printer has a new, empty service module fitted.
The Valve Test screen is the first screen that is displayed when the Commissioning button
is touched.
89306
Figure 5-19. Commissioning Valve Test screen

This preliminary stage is optional and can be used as a precaution before the main
commissioning process is started. The sequence operates all of the ink system valves a
number of times to release any that may have become stuck during shipping. The valves are
operated in turn for approximately 3 minutes.
The Start button starts the sequence, and the Stop button can be used at any time to stop the
sequence.
FA48008
When the Exit button is touched, the next screen is a safety warning and commissioning
confirmation screen. This screen is the start of the on-screen step-by-step instructions for the
commissioning procedure.
89307
Figure 5-20. Commissioning confirmation screen

When the Yes button is touched, the next screen asks if a new service module is being
installed. After the Yes button is touched, the following screen displays an instruction to
open the front access door and insert the Easi-Change® Service Key.
Every service module requires an Easi-Change® Service Key, which is an RFID (radio
frequency identification) tag that identifies the service module as a true Linx part and
acceptable for use in the 8900 printer. Each service module is shipped with a unique and
separate Easi-Change® Service Key.
When a new service module is fitted, the Easi-Change® Service Key must be inserted
between the ink and solvent cartridges, so that the Easi-Change® Service Key can be read
by the RFID module. If the service module identification is correct, the Easi-Change®
Service Key is removed from the printer when requested by the on-screen instructions. The
Easi-Change® Service Key is a one-time use item—it cannot be used again on the printer,
and it cannot be used on any other printer.
If a valid Easi-Change® Service Key is not inserted or detected, the service module will not
fill with ink during the commissioning process, and the maintenance times cannot be reset.
The following advisory message is displayed:
“Valid Easi-Change Service Key not detected”
If an Easi-Change® Service Key that is not associated with the new service module is
inserted, the following advisory message is displayed:
“This Easi-Change Service Key was already used”
FA48008
When a valid Easi-Change® Service Key is inserted, the Maintenance Due Within Time
screen is displayed. This screen allows the maintenance technician to set the maximum jet
running time until replacement of the new service module is required. The default
maximum time is 2000 hours, but for some inks a higher number of jet running hours can be
set, up to a maximum of 13000 hours. The maximum number of hours depends on the
environmental conditions of temperature, humidity and dust. Refer to the 8900 How To
Select the Service Module Replacement Hours Maintenance Level document for more
information.
89298
Maintenance Due Within Time
2000
Enter Maintenance Time (hours)
Figure 5-21. Maintenance Due Within Time screen

The up (+) and down (–) buttons increase or decrease the jet running time by one hour for
each touch of the button. A number of hours can also be entered by the numeric keypad,
and the screen allows a maximum time of 13000 hours to be set, but only for some inks.
When the jet running time is changed and the Save button is touched, the following
instruction screen is displayed:
“Remove the Easi-Change Service Key and close the front access panel”
When these actions have been performed, the new service module is then filled with ink
from the ink cartridge. While the service module is being filled, the screen title bar is purple
and contains the message “Filling Up”.
When the service module has been filled to an acceptable level, the screen title bar changes
to white and contains the message “Filling Complete”.
The final stages of the commissioning procedure are a Solvent Prime sequence followed by
an Ink Prime sequence. When the service module filling is complete, the Solvent Prime
screen is automatically displayed and the printer provides on-screen step-by-step
instructions for the sequences.
NOTE: When the service module has been commissioned, the Maintenance Due By time is
automatically set to 12 months or 18 months (ink type dependent).
For the complete commissioning process, refer to the 8900 Commissioning Procedure
document.
FA48008
5.5.12 Calibration
The Calibration screen displays the calibration parameters of the printer.
89299
XX000
00123
Figure 5-22. Calibration screen

When the printer is turned on, all valid calibration values stored in the printhead and on the
IPM Assembly are read. These production calibration values are then displayed on the blue
button and light yellow buttons below the Printhead and IPM buttons on the Calibration
screen.
NOTE: If a printhead is not fitted to the printer, or the printer cannot communicate with
the printhead, the buttons in the Printhead column will be red. The conduit length
buttons will also be red. Buttons can be red if their related value is corrupt.
All of these parameter buttons are disabled at the Service access level, except for the IPM:
Pressure Transducer (mV) and Printhead: Ref Mod buttons (see later in this section), and
so the values cannot be changed. The production calibration values can be changed only at
the Factory User level. Any calibration value that has been changed from its default value
during manufacturing is displayed on a light yellow button.
Although the stored calibration values cannot be changed at the Service level, a
maintenance technician can add or subtract an offset value to adjust some of the calibration
values. The parameters that can be adjusted are indicated by dark blue buttons below the
Service button. This facility allows fine adjustments to be made to the calibration values to
improve print quality and for printer environmental requirements.
When a maintenance technician adjusts a value, the difference between the stored value
and the adjusted value is recorded in the printer. These adjusted values are not affected by
printer power-downs, printhead changes, or software updates.
FA48008
When any of the dark blue parameter buttons are touched, the related offset-entry
keyboard is displayed. The operation of the offset-entry keyboards is the same for all the
calibration parameters, and Figure 5-23 shows the keyboard on the Ref Pressure Offset
(Printer) screen as an example.
89300
Ref Pressure Offset (Printer)
-30 .. 30LPB
Press Cancel to clear value
Figure 5-23. Ref Pressure Offset (Printer) keyboard
Enter parameter offset

An offset can be entered either through the keyboard screen or with the Nudge button.
The keyboard screen allows values to be entered and adjusted, but the change only has an
effect when the Save or the Cancel button is touched. The nudge method allows a value to
be adjusted immediately with each touch or hold of the button.
Keyboard method
The up (+) and down (–) buttons increase or decrease the value by one digit for each touch
of the button. A value can also be entered by the numeric keypad.
When the calibration offset value has been entered and the Save button is touched, the
display returns to the Calibration screen. The dark blue button changes to a bright yellow
button, which displays the entered offset value (5 LPB in the example shown in Figure 5-24).
89301
XX000
00123
Figure 5-24. Reference Pressure offset of ‘5’ entered
FA48008
To remove a calibration offset, the applicable bright yellow offset button is touched, which
displays the offset-entry keyboard again. The Cancel button is then touched, the display
returns to the Calibration screen, and the offset value is removed from the button, which
becomes a dark blue button again.
Nudge button method

When the Nudge button is touched, the nudge panel replaces the button, and all values that
can be adjusted are shown in italics, as shown in Figure 5-25.
89302
XX000
00123
1784
150
Figure 5-25. Nudge panel displayed

To adjust a calibration value, the applicable dark blue button or bright yellow button is
touched, which puts a line under the value on the button. The nudge panel now displays
the value that is underlined and its unit of measurement (Figure 5-26).
89303
XX000
00123
1784
150
Figure 5-26. Reference Pressure offset value displayed in the nudge panel
FA48008
The up (+) and down (–) buttons on the nudge panel increase or decrease the value by one
digit for each touch of the button.
89304
XX000
00123
1784
150
Figure 5-27. Reference Pressure offset adjusted to ‘7’

When the calibration offset value has been adjusted and the ‘X’ button above the nudge
panel is touched, the Nudge button is displayed again. The italics are also removed from
the adjustable values (Figure 5-28).
89305
XX000
00123
Figure 5-28. Reference Pressure offset now set to ‘7’

The Default button above the nudge panel can be used to return the adjusted value displayed
on the applicable button to its original value. When the Default button is touched, the original
value is displayed on the button, which changes to dark blue again, but the value remains in
italics and underlined. If the ‘X’ button above the nudge panel is now touched, the italics and
underline are removed from the value, and the Nudge button is displayed again.
NOTE: When the Default button is touched, the previously adjusted value remains
displayed on the nudge panel, so that further adjustments to this value can be
made, as required.
Printhead serial number

The first button on the top row displays the printhead serial number, which is stored in and
read from the printhead.
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Printhead PCB serial number
The printhead PCB serial number is displayed below the printhead serial number button
(see above).
NOTE: In the System Information screen (Main Menu > System Information > Machine
ID), the first number next to the Printhead item is the printhead PCB serial number.
The second number is the printhead serial number.
Conduit length
The second button on the top row displays the printhead conduit length. This calibration
value is stored in and read from the printhead.
Printhead, IPM, Service

These three buttons on the top row are only column headings for the different parameter
buttons displayed below; they cannot be selected.
Pressure Transducer (mV)

Every pressure transducer has a calibration value that is stored in and read from the
non-volatile memory on the IPM Assembly. When a pressure transducer is replaced, the
calibration value for the new unit must be entered into the printer with the IPM: Pressure
Transducer (mV) button on the Calibration screen. This calibration value is written on the
pressure transducer. The Pressure Transducer Calibration screen allows values between
1500 mV and 2000 mV, and the factory default value is 1784 mV.
The Service: Pressure Transducer (mV) offset button is disabled at the Service access level,
and so an offset value cannot be applied to the Pressure Transducer parameter.
Charge Gain (%)

The calibration value displayed on the Printhead: Charge Gain (%) button is stored in and
read from the printhead. This value is set when the printhead PCB is manufactured and
cannot be changed.
The calibration value displayed on the IPM: Charge Gain (%) button is stored on and read
from the IPM Assembly. This value is set when the IPM Assembly is manufactured and
cannot be changed.
The Service: Charge Gain (%) adjustment button is disabled at the Service access level, and
so an adjustment value cannot be applied to the Charge Gain parameter.
EHT Gain (%)

The calibration value displayed on the Printhead: EHT Gain (%) button is stored in and
read from the printhead. This value is set by Linx during manufacturing.
The calibration value displayed on the IPM: EHT Gain (%) button is stored in and read
from the EHT power supply. This value is set when the EHT power supply is manufactured
and is only for reference.
The software uses a combination of the Service: EHT Gain (%) adjustment (if any) and the
Printhead: EHT Gain (%) value to set the required output from the EHT power supply.
When the Service: EHT Gain (%) button is touched, the EHT Voltage Adjustment (Printer)
screen allows adjustments between –10.0% and +10.0% to be entered. This adjustment value
is then applied with the Printhead: EHT Gain (%) value to set the EHT output.
The Service EHT Gain adjustment is primarily for use by Linx development personnel.
This facility is not normally for use by maintenance technicians, but can be used under
the direction of the Linx International Technical Support department.
FA48008
Ref Press
The Reference Pressure calibration value displayed on the Printhead: Ref Press button is
stored in and read from the printhead. The value is for display only and cannot be changed.
When the Service: Ref Press offset button is touched, the Reference Pressure Offset
(Printer) screen allows offset values between –30 LPB and +30 LPB to be entered.
Ref Mod
The Reference Modulation calibration value displayed on the Printhead: Ref Mod button is
stored in and read from the printhead.
When the Service: Ref Mod offset button is touched, the Reference Modulation Offset
(Printer) screen allows offset values between –100 V and +100 V to be entered.
Gutter
The gutter sense circuit detects the flow of ink in the gutter. If ink flow is not detected in the
gutter for any reason (for example, an incorrectly aligned jet), the software shuts down the
jet with a quick stop sequence and reports Print Failure “2.09 Misaligned Ink Jet”.Under
normal operating conditions with the jet running, a loss of ink in the gutter is detected after
approximately 20 seconds. During a Normal Start, a loss of ink in the gutter is detected after
approximately 3 seconds. Gutter sense operation is disabled when the Jet Test-Start
function is used.
The Wet and Dry indicators on the Calibration screen show the almost immediate change
of state of the gutter detector. Wet indicates that the ink jet is detected in the gutter, and Dry
indicates that the ink jet is not detected in the gutter.
The smaller Gutter button in the Service column allows temporary adjustment of the gutter
detection threshold. This offset value is then applied to the gutter threshold default value of
150 that is stored in the printhead. The entered offset value is not remembered by the
software when the printer is turned off and then turned on again.
When the Service: Gutter offset button is touched, the Gutter Threshold Trial Value screen
allows offset values between 0 and 255 to be entered.
This feature allows the maintenance technician to monitor the Wet and Dry buttons to
confirm operation of the gutter detection. Different gutter detect threshold values can be
entered to test for correct operation of the gutter detection.
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5.5.13 Decommissioning
The decommissioning feature provides a method for the removal of the ink and solvent
from the 8900 printer.
A decommissioning kit is required to drain and flush ink and solvent from the printer. The
kit includes a customized service module attached to an external flushing device. Empty
solvent bottles are used to collect the waste fluid from the flushing process. Figure 5-29
identifies the main parts of the decommissioning kit.
40264 A
C
A. Decommissioning service B. Drain bottle D. Feed tap
module C. Feed bottle E. Drain tap
Figure 5-29. Decommissioning kit
The decommissioning kit is used in the following circumstances:
 To drain and flush a printer in preparation for storage.
 To drain and flush a printer in preparation for shipping.
 To drain and flush a printer to allow a change of ink type.
 To remove contaminated ink or solvent from a printer.
FA48008
When the Decommissioning button is touched on the Maintenance (2 of 3) screen, the first
screen that is displayed is a safety warning and decommissioning confirmation screen.
When the Yes button is touched, this screen is replaced by the first decommissioning
procedure screen (Removing the Service Module).
NOTE: The Decommissioning button is available only at the Service access level and only
when the printer state is ‘Idle’ (jet off).
89295
89296
Figure 5-30. Removing the Service Module screen

This screen includes the Prepare for SM removal button that is used to start the printer
decommissioning procedure.
The printer provides on-screen step-by-step instructions for the decommissioning
procedure.
Decommissioning procedure
IMPORTANT: Before the decommissioning procedure is started, the printhead must be

put into a beaker to contain any ink and solvent that is ejected from the
nozzle during the procedure.
Prepare for SM removal

IMPORTANT: When the decommissioning has started, the process must not be
interrupted. The system cannot detect the stage in the process at which an
interruption occurred.
When the Prepare for SM removal button is touched, the printer performs a sequence to
clear the gutter, and then runs the pump backwards to clear ink from the pipes in the
primary ink circuit. This preparation takes approximately 2 minutes and 30 seconds to
complete.
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The next two screens request that the service module is removed and replaced with the
service module of the decommissioning kit.
When the service module of the decommissioning kit has been fitted, the Flush the Ink
Circuit screen is displayed, which contains the Flush Ink Circuit button.
Flush the ink system

This screen requests that the ink cartridge is removed and a special solvent flushing
cartridge is fitted in its place. There also must be a full solvent cartridge fitted to the printer,
and empty feed and drain bottles fitted to the decommissioning kit. When all of the
on-screen preparation instructions have been completed, the Flush Ink Circuit button can
be touched to start the ink circuit flush sequence.
When the sequence is finished, the Ink Circuit Flushed screen is displayed, which contains
the Drain Ink Circuit button. The on-screen instructions advise that this button can be
touched to drain the fluid from the ink system.
Drain the ink system

The sequence drains the fluid from the ink system through the service module to the
decommissioning kit. When the sequence is finished, the pump is stopped and the Solvent
Cycle 1 screen is displayed.
Flush the ink system

The on-screen instructions request that the feed and drain bottles are removed from the
decommissioning kit, emptied, and then refitted. When the on-screen instructions have
been completed, the Solvent Cycle 1 button can be touched to start the first solvent cycle.
During this sequence, solvent is circulated around the ink system. When the sequence is
finished, the Solvent Cycle 1 Complete screen is displayed, which contains the Drain Ink
Circuit button. The on-screen instructions advise that this button can now be touched to
drain the solvent from the ink system.
Drain the ink system

When the drain sequence is finished, the pump is stopped and the Solvent Cycle 2 screen is
displayed. The on-screen instructions request that the feed and drain bottles are removed
from the decommissioning kit, emptied, and then refitted. When the on-screen instructions
have been completed, the Solvent Cycle 2 button can be touched to start the second solvent
cycle.
This flush and drain routine is repeated two more times (Solvent Cycles 3 and 4), which
completes the decommissioning process.
The Abort button can be used to stop the sequences in an emergency at any time, for
example, a fluid leak.
IMPORTANT: When the decommissioning procedure is completed, the printhead and
cover tube must be cleaned with the correct solvent to remove any
remaining ink deposits.
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5.5.14 From Storage
The From Storage option is available only when the printer state is ‘Idle’ (jet off).
The From Storage option prepares the printer for operation after an extended shutdown of
more than four weeks (that is, after a printer has been put into storage, or after an extended
production line shutdown).
When the printer is first used after the extended shutdown period, the From Storage option
must be selected before the jet is started for the first time.
When the From Storage button is touched, on-screen step-by-step instructions are provided
for the procedure.
The sequence flushes the printhead and attempts to operate all the printer valves in turn.
The valves are then ‘buzzed’ (turned on and off continuously) to check operation. This
process is audible but depends on the background noise:
 The first valves to be buzzed are the Ink Add, Ink System Feed, Solvent Add, Solvent
Prime, Printhead Solvent Feed, and Printhead Feed valves.
 The Purge valve is then buzzed later in the sequence.
 Finally, the Printhead Gutter valve is buzzed at the end of the sequence.
If the printer does not start correctly after the From Storage sequence has finished, the
sequence can be repeated. However, Linx recommends that the sequence is not run more
than three times, because the sequence discharges the full contents of the solvent priming
unit into the service module. This quantity of solvent is equivalent to approximately two
startup and shutdown operations and makes the ink thinner, which can cause printer
failure. The service module can also overflow, which puts ink into the solvent tank. For the
same reasons, the sequence must not be used after only overnight shutdowns.
5.5.15 Into Storage

The Into Storage option is available only when the printer state is ‘Idle’ (jet off).
The Into Storage option prepares the printer for an extended shutdown of more than four
weeks (that is, before a printer is put into storage, or before an extended production line
shutdown).
The printer must be shut down with a full normal shutdown before the Into Storage option
is used.
When the Into Storage button is touched, on-screen step-by-step instructions are provided
for the procedure.
The sequence flushes the printhead with an increased amount of solvent compared to a
normal shutdown sequence. Therefore, Linx recommends that the sequence is not run more
than twice, because the sequence discharges double the full contents of the solvent priming
unit into the service module. This quantity of solvent is equivalent to approximately four
startup and shutdown operations and makes the ink thinner, which can cause printer
failure. The service module can also overflow, which puts ink into the solvent tank. For the
same reasons, the sequence must not be used before only overnight shutdowns.
5.5.16 Valve Reset

The Valve Reset option is available only when the printer state is ‘Idle’ (jet off).
The Valve Reset option operates all the printer and printhead valves alternately to ‘unseat’
a valve that may have become stuck.
When the Valve Reset button is touched, on-screen step-by-step instructions are provided
for the procedure. If necessary, the Valve Reset sequence can be repeated.
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5.5.17 Printhead Characteristics
The Printhead Characteristics option displays a real-time status graph that is used for
advanced diagnostics. This feature is for Linx internal use only.
During a call to Linx International Technical Support, a description or a photograph of the
Printhead Characteristics screen can be requested by Linx to help to identify the cause of
unusual faults.
5.5.18 Consumables History

The Consumables History screen provides the Distributor and the customer with an
indication of the rate at which the printer has used ink and solvent.
89297
Figure 5-31. Consumables History screen

All the information buttons are for display only at Supervisor and Service access levels, and
cannot be selected or changed. However, some of the values can be reset to zero at the
Service level (refer to ‘Reset’ later in this section).
The information can be used for the following purposes:
 To allow more flexible commercial arrangements between the supplier and the
customer.
 To provide customers with a greater knowledge of ink and solvent use from day to day.
 To provide maintenance technicians with information about the past performance of
the printer.
The information provided on the Consumables History screen can help Distributors to
demonstrate true ink and solvent usage during customer trials. Because Distributors can
monitor ink and solvent usage over time, the information can also help to provide ‘cost per
print’ data.
Linx recommends that the consumables history values are reset when a new printer is
commissioned.
NOTE: A note must be made of the Consumables History values before the IPM Assembly
is replaced. Linx recommends that the USB facility is used to save this data before
the IPM Assembly is replaced. When the maintenance is completed, the USB
facility can then be used to restore the data.
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Ink Level
The ink level status of the printer. If the ink cartridge contains fluid, ‘Ink OK’ is displayed
on this button. When the cartridge is empty, ‘Cartridge Empty, REPLACE CARTRIDGE’ is
displayed. Also, when the jet is running, this message is displayed alternately every
10 seconds with the remaining printing time.
If the ink system is empty ‘Ink System Empty, REPLACE CARTRIDGE’ is displayed.
When the ink cartridge is removed, ‘Cartridge Removed’ is displayed.
The percentage of ink that remains in the ink cartridge is displayed on the printer
consumables status panel on the Home screen. When the status panel is touched, this
Consumables History screen is displayed.
Solvent Level
The solvent level status of the printer. If the solvent cartridge contains fluid, ‘Solvent OK’ is
displayed on this button. When the cartridge is empty, ‘Cartridge Empty, REPLACE
CARTRIDGE’ is displayed. Also, when the jet is running, this message is displayed
alternately every 10 seconds with the remaining printing time.
If the solvent tank is empty ‘Solvent Tank Empty, REPLACE CARTRIDGE’ is displayed.
When the solvent cartridge is removed, ‘Cartridge Removed’ is displayed.
The percentage of solvent that remains in the solvent cartridge is displayed on the printer
consumables status panel on the Home screen. When the status panel is touched, this
Consumables History screen is displayed.
Service Module Life

The life status of the service module. If there is valid life remaining on the service module,
'Service Module OK' is displayed on this button. This message is displayed alternately
every 10 seconds with the remaining life of the service module in months and printing
hours.
When the service module replacement is due, ‘Replacement due within 1 month’ is
displayed. This message is displayed alternately every 10 seconds with ‘To order a
replacement Service Module contact your local Linx Distributor’.
If the service module replacement is overdue by less than 3 months, ‘Service Module
expired’ is displayed. This message is followed by two more messages: ‘Replacement
overdue by …’ (time shown in hours, days or months) and ‘To maintain printer reliability
replace the Service Module’.
If the service module replacement is overdue by more than 3 months, ‘To continue printing
replace the Service Module’ is displayed.
Ink Cartridges Used

The number of ink cartridges used from the time that the printer was manufactured. This
value cannot be reset. Therefore, the Recent Ink Cartridges value (see below) should be
used to monitor ink usage over a set period of time, for example, during a customer trial.
The Recent Ink Cartridges value must be reset to zero before measurement of ink usage is
started.
Solvent Cartridges Used

The number of solvent cartridges used from the time that the printer was manufactured.
This value cannot be reset. Therefore, the Recent Solvent Cartridges value (see below)
should be used to monitor solvent usage over a set period of time, for example, during a
customer trial. The Recent Solvent Cartridges value must be reset to zero before
measurement of solvent usage is started.
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Recent Ink Cartridges
The volume of ink used (shown as the number of 500 ml cartridges per 28-day period) from
the time that the consumables history values were last reset to zero. To allow an accurate
calculation of usage, the value is not displayed during the first seven days (a hyphen is
displayed instead). This option allows ink usage to be tracked over a set period of time as a
‘usage per month’ figure.
Recent Solvent Cartridges

The volume of solvent used (shown as the number of 1000 ml cartridges per 28-day period)
from the time that the consumables history values were last reset to zero. To allow an
accurate calculation of usage, the value is not displayed during the first seven days (a
hyphen is displayed instead). This option allows solvent usage to be tracked over a set
period of time as a ‘usage per month’ figure.
Current Ink Usage

The calculated ink usage in ml per hour. The usage is measured when a message is being
printed. A value is displayed when ink consumption is stable and an accurate calculation is
possible, which normally occurs soon after printing starts. This time can vary according to
the application, ambient temperature, ink type, and the period of time that the printer is in
the ‘Jet Running’ or ‘Printing’ states. A hyphen is displayed until a true value is available.
This value provides an indication of ink usage and printer efficiency.
Current Solvent Usage

The calculated solvent usage in ml per hour. The usage is measured when a message is
being printed. A value is displayed when solvent consumption is stable and an accurate
calculation is possible, which normally occurs following the first solvent addition after the
value was last reset to zero. This time can vary according to the application, ambient
temperature, solvent type, and the period of time that the printer is in the ‘Jet Running’ or
‘Printing’ states. A hyphen is displayed until a true value is available. This value provides
an indication of solvent usage and printer efficiency.
Reset
The Reset button is only available at the Service access level and when the printer is in the
‘Idle’ state. The button resets the following consumables history values to zero:
 Recent Ink Cartridges
 Recent Solvent Cartridges
 Current Ink Usage
 Current Solvent Usage
The Reset button displays the date of, and the number of days since, the last reset.
FA48008
5.5.19 Software Upgrade
The Software Upgrade option is available only at the Service access level and only when
the printer state is ‘Idle’ (jet off). The printer provides on-screen step-by-step instructions
for the upgrade procedure.
A USB memory device must be inserted in the USB connector on the left side of the printer
cabinet before the software upgrade process is started.
To start the software upgrade process, the Software Upgrade button is touched on the
Maintenance (3 of3) screen. The system examines the contents of the USB memory device
and displays a list of valid software package files.
If no valid files are found or the USB memory device is not inserted, the system requests
that a memory device that contains valid software is inserted.
89308
Figure 5-32. Software Upgrade: insert a valid memory device instruction

A check box must then be selected for one item only from the list of files. If there is not
enough free space on the USB memory device, an advisory message screen is displayed.
When the Upgrade button is touched, a prompt screen is displayed that requests
confirmation to continue:
“Are you sure you want to upgrade the printer? Do not remove the USB stick
during the upgrade process.”
When the Yes confirmation button is touched, the printer restarts and the software upgrade
begins. On completion, the system advises whether the upgrade is successful or not.
Sometimes, the printer restarts again automatically after a successful upgrade, but this
action depends on the type of software upgrade and the files that are downloaded.
FA48008
5.6 Maintenance instructions
5.6.1 Double pole/neutral fusing

WARNING IS IGNORED.
5.6.2 Introduction
The following Maintenance Instructions are provided for use by maintenance technicians
who are trained and authorized by Linx. These instructions describe how to perform a
range of maintenance tasks on the Linx 8900 Continuous Ink Jet Printer. For example, how
to drain and flush the ink system, replace parts in the ink system, test the valves, and align
the jet.
5.6.3 Maintenance terminology

Some maintenance actions used in this section have special meanings, which are defined in
the following:
Check Make a comparison of a measurement of time, pressure, temperature,
resistance, dimension or other quantity, with a known figure for that
measurement.
Test Confirm, with the use of the correct test equipment, that a component or
system correctly functions.
Examine Inspect the condition of an item. For example, any of the following can
have an effect on the condition of an item:
 Loose connection or installation.
 Cracks.
 Corrosion or contamination.
 Distortion.
 Loose or missing rivets.
 Cuts or wear.
 Damaged or broken locks or fasteners.
 Loose pipeline clips or protective material. Obstruction of pipelines or
leaks from pipelines.
 Change of colour due to high temperature or fluid leaks.
Operate Make sure that an item or system functions correctly, without the use of
test equipment or reference to measurements.
FA48008
Refill Add a material to a tank, bottle or other container to a known level or
quantity, and as necessary:
 Remove caps or covers from filler apertures.
 Clear filler apertures.
 Make sure that gaskets and caps or covers are not damaged.
 Refit caps or covers.
 Fit locks or fasteners as necessary.
Fit Correctly attach one item to another item.
Refit Fit an item that was previously removed.
Replace Remove an item and fit a serviced or new item.
Connect Join or attach electrical cables, pipelines or controls.
Disconnect Separate or remove electrical cables, pipelines or controls.
Reconnect Join or attach electrical cables, pipelines or controls that were previously
disconnected.
5.6.4 Antistatic precautions
The PCBs in Linx printers use some electrostatic-sensitive components that can be severely
damaged if these components are submitted to static discharge. Static electricity, which is
generated on a person through friction and movement, is discharged through the first route
to earth that is contacted.
Damage caused by a static discharge is not always immediately detected after the static
discharge has occurred, and can cause component failure in the future. When PCBs are
touched, it is very important that maintenance technicians use the following antistatic
precautions:
 Wear an antistatic wrist strap that is approved by industry and includes a resistive
component (greater than 2 M) in the lead. The antistatic wrist strap must be connected
to a good electrical earth. The continuity of the antistatic wrist strap and the electrical
earth must be checked at regular intervals.
 Always hold a PCB by its edges and do not touch the components or printed circuit
tracks. After a PCB is removed from a printer or its packaging, the PCB must be put on
a static-dissipative mat.
 Always use antistatic packaging when PCBs and software components are shipped or
moved between locations. All Linx PCBs are shipped in special antistatic boxes and
these boxes must be used again for any further transportation.
FA48008
5.6.5 CE approval checklist for the 8900 printer
CE approval for the Linx 8900 Continuous Ink Jet Printer depends on the conditions given
below. If the printer is not left in the correct condition, the CE approval for the printer can
be invalidated. All maintenance technicians must make sure that the printer meets the
following conditions after any maintenance task is completed, so that the CE approval and
general safety are maintained.
Electronics
 All of the IPM Assembly securing screws must be fitted and correctly tightened.
 The cooling fan must be connected to PL211 on the IPM Assembly and must be
operating.
 The links on header PL215 on the I/O PCB must NOT be fitted unless authorized by
Linx.
 The grommet seals for the electrical cables must be undamaged and fitted correctly to
the cut-outs on the edge of the electronics shelf.
Ink system
 The spillage detector cable must be connected to the floor of the spillage tray.
Printhead
 The printhead to chassis earth wire must be securely connected to the protective earth
(PE) blade terminals on the HVPM mounting plate.
 The printhead cover tube must be fitted and the thumb screw must be completely
tightened.
Cabinet
 EMC gaskets must be undamaged and correctly fitted. The access panels must be
correctly fitted to make a good EMC seal.
 There must not be any interruption to the ventilation of the printer, for example, a
blockage or obstruction of the air filter.
 All earth cables must be securely connected to the protective earth (PE) blade terminals
on the HVPM mounting plate. These earth terminals are identified by an adjacent PE
label.
5.6.6 Maintenance instruction documents

The Maintenance Instructions that describe how to correctly perform different maintenance
tasks on the 8900 printer are contained in the following section. Each maintenance
instruction is created as a single document, which can be removed from the manual and
copied for separate use.
FA48008
FA48008
8900 Maintenance Instruction
Printer Installation
Equipment required
FA48008 Linx 8900 Maintenance Manual
MP65978 8900 Commissioning Procedure (supplied with printer)
TP1A001 Linx 8900 Quick Start Guide
TP1A002 Linx 8900 Operating Manual
FA999056 Gloves Nitrile Small 6–6.5 )
FA999057 Gloves Nitrile Medium 7–7.5 ) as required
FA999058 Gloves Nitrile Large 8–8.5 )
FA999076 Safety Spectacles Blue
Installation Service Report Form
Procedure

THE EYES AND SKIN.
1 Printer configuration
Log in to the printer at the Service security level. Enter the supplied configuration
code on the Printer Configuration Code screen (Main Menu > Printer Setup >
Installation > Printer Configuration Code).
2 Installation parameters
Enter the required parameters on the Printer Setup screens (Locale, Date & Time,
and Installation > Ink/Solvent).
Refer to the Linx 8900 Operating Manual.
3 Commissioning
Commission the printer according to the Commissioning Procedure checklist.
4 Installation on the production line
Install the printer on the production line and install the applicable accessories (for
example, cabinet, gantry, product sensor, and line speed detector).
Also refer to the ‘Correct Installation of Mk11 Printheads’ maintenance instruction.
If the customer has more than one production line, set up the printer for each line.
FA48008
Printer Installation
5 Line parameters
Enter the required parameters on the Advanced Line Setting screens (Line, Speed
Mode, Line Speed or Encoder Pitch, Print Trigger, Photocell Type, Line
Direction, and Printhead Height).
6 Message creation
Set the message defaults. Create a template and adjust the print parameters as
necessary.
Refer to the Linx 8900 Quick Start Guide.
7 Operator/Supervisor training
Give operator training that includes how to set operator and supervisor access
levels. Use the Linx 8900 Operating Manual as a reference for the training.
8 Security password
Configure the User Management options (Main Menu > Printer Setup > User
Management) and set the required user level.
9 Documentation
Complete the Installation Service Report Form and make sure that the customer
puts their signature on the form.
10 The ‘Printer Installation’ maintenance instruction is now completed.
FA48008
Correct Installation of Mk11 Printheads
Introduction
Correct installation and conduit route have an important effect on the life and reliability of
the conduit. If the basic installation guidelines contained in this maintenance instruction are
followed, the life of the conduit will be significantly increased.
The most important factor that restricts the life of a conduit is the minimum bend radius
that is used in an application. Linx recommends that the method used to install the
printhead maximizes this radius, and that the bend radius is never less than the minimum.
This maintenance instruction describes the two important elements of printhead and
printer installation:
1. Conduit route (for static and dynamic applications):

 Static applications. The printhead is fixed in position relative to the printer or product
line, and the product is moved relative to the printhead. A conveyor line is a typical
example.
 Dynamic applications. The printhead is moved relative to a stationary product. A
printhead mounted on a traversing system to cross a multi-lane indexing line is a
typical example.
2. Printer position
1 Conduit route
 Do not make a sharp bend in the conduit of less than 60 mm (the minimum bend
radius, measured to the inside of the conduit). Make sure that the orientation of the
conduit is correct before it is bent (see Figure 1).
 Use a support to stop movement of loose conduit and to make sure that the conduit
does not touch other machinery to minimize transmission of vibration (see Figure 2 on
page 5—54). Remember to allow access to clean the printhead.
 Make sure that there are cut-outs in guards, so that the conduit is not compressed when
the guards are closed (see Figure 3 on page 5—54).
 Always select a route that gives the most gradual curves on the conduit and use
supports as necessary, so that the minimum bend radius is never less than 60 mm (see
Figure 4 on page 5—54 and Figure 5 on page 5—55).
40234
>60 mm
The conduit will be damaged if it is There is no strain on the conduit if it is

forced to bend along the widest section bent along the narrowest section
Figure 1. Direction of conduit bend and minimum bend radius
FA48008
1.1 Conduit route for static applications

89270
The conduit is left to hang down The conduit is supported out of the
towards the production line way of the production line
Figure 2. Support for the conduit
AS174
The conduit will be crushed when the The conduit lies in a cut-out to prevent it
machine guard is closed being crushed when the guard is closed
Figure 3. Cut-outs in guards for the conduit
40236
The conduit is forced into a tight bend A conduit support prevents the conduit
over a sharp edge being bent over a sharp edge
Figure 4. Conduit support and minimum bend radius—1
FA48008
AS176
The conduit is forced into a tight bend A conduit support prevents the conduit
round a sharp edge being bent round a sharp edge
Figure 5. Conduit support and minimum bend radius—2
1.2 Conduit route for dynamic applications

89271
The conduit is bent tighter than necessary Use a loop of conduit to take up the motion
when the printhead moves. This reduces over the greatest length of conduit. This
reliability improves reliability
Figure 6. Loop of conduit to take up the motion
89272
The conduit is pulled tight to prevent it hitting The conduit is supported on rollers to prevent
the web below as the printhead moves it hitting the web below as the printhead moves
Figure 7. Conduit supported on rollers
FA48008
89273
The conduit is twisted as the printhead The conduit is only bent as the printhead
moves. This reduces reliability moves. This improves reliability
Figure 8. Conduit only bent not twisted when printhead moves
2 Printer position
The printer must be installed so that the conduit is not bent tightly at the side of the printer.
Always allow 150 mm clearance for the conduit to bend (see Figure 9).
89026
<150 mm >150 mm
The conduit will be unreliable if it is The conduit will be more reliable if

bent tight because there is less than there is more than 150 mm to the left
150 mm to the left side of the printer side of the printer for it to bend
Figure 9. Minimum space to the left side of the printer
FA48008
Rear Access Panel Removal & Access Preparation
Introduction
This maintenance instruction describes the removal of the rear access panel assembly of the
printer. The panel allows access to the electronics system in the upper compartment of the
cabinet and the ink system in the lower compartment of the cabinet. Also included are
instructions for the preparation of the ink and electronics systems for maintenance access.
Procedure

WARNING IS IGNORED.
Rear access panel removal

1 Shut down and turn off the printer.
2 Turn off the mains electrical supply and disconnect the electrical supply cable of
the printer.
3 Remove the two knurled thumbscrews from the air filter access panel, and remove
the panel.
4 Remove the air filter.
5 Remove the two M4 x 8 screws in the top left and right corners of the rear access
panel.
6 Carefully pull the top of the panel away from the printer enough to allow hand
access to the I/O PCB.
7 Disconnect the earth wire from the blade terminal on the electronics tray, and the
fan 2-way connector from PL211 on the I/O PCB.
8 Lift the panel to disengage the two tabs at the bottom of the panel that fit into the
two slots in the cabinet, and then remove the panel from the cabinet.
FA48008
Ink system removal

9 Remove the ink system securing thumbscrew (refer to Figure 1).
89027
Electronics system
securing thumbscrew
Locating pin
Ink system
securing thumbscrew
Figure 1. Securing thumbscrews for the ink and electronics systems

10 Carefully slide the ink system out of the cabinet onto the workbench.
11 To refit the ink system, slide the ink system into the cabinet. Make sure that the
locating pin engages in the slot on the ink system tray (refer to Figure 1).
12 Refit the ink system securing thumbscrew.
FA48008
Electronics system access
CAUTION: Static-Sensitive Devices. The PCBs contain static-sensitive devices. Take the
following antistatic precautions when PCBs are touched. Wear an antistatic wrist strap and
connect the lead to a good electrical earth. Always hold PCBs by their edges and do not touch
the components, printed circuit tracks or connector pins.
9 Refer to Figure 2 and remove the locking rings from the external alarm, USB, and
Ethernet connectors.
89028
Alarm, USB,
and Ethernet
connectors
locking rings
D-type
connectors
screwlocks
Figure 2. I/O PCB external connectors

10 Remove the four screwlocks from the two photocell/shaft encoder D-type
connectors.
11 Loosen, but do not remove, the electronics system securing thumbscrew (refer to
Figure 1).
12 Slide the electronics system to the left to disengage the external connectors from the
side panel of the cabinet.
13 Carefully slide the electronics system out of the cabinet until the end of the guide
slot reaches the securing thumbscrew.
FA48008
Electronics system removal

14 Disconnect the printhead cable assembly as follows:
 Disconnect the blue modulation coaxial cable from connector J2 on the
modulation amplifier (HVPM).
 Disconnect the 4-way connector from J1 on the modulation amplifier (HVPM).
 Disconnect the printhead 12-way connector from PL203 on the I/O PCB.
 Disconnect the green and yellow earth wire from the blade terminal on the
electronics tray.
 Disconnect the positive and negative EHT connectors from the EHT power
supply.
 Disconnect the yellow charge coaxial cable from connector SK200 on the I/O
PCB.
15 Disconnect the live, neutral and earth wires from the blade terminals on the mains
electrical supply filter.
16 Remove the printhead cables from the two wire saddles on the LVPSU mounting
plate.
17 Disconnect all of the remaining cable connectors from the I/O PCB, except PL204
(HVPM) and PL220 (POWER).
18 Carefully remove the electrical cables and grommet seals from the cut-outs on the
edge of the electronics shelf.
19 Remove the securing thumbscrew, and then carefully remove the electronics
system from the cabinet onto the workbench.
Electronics system refitting

20 Carefully slide the electronics system into the cabinet, and then refit but do not
tighten the securing thumbscrew.
21 Reconnect the printhead cable assembly as follows:
 Reconnect the yellow charge coaxial cable to connector SK200 on the I/O PCB.
 Reconnect the positive and negative EHT connectors to the EHT power supply.
Make sure that the EHT cable that has a white identification sleeve is connected
to the negative (right) EHT socket. Refer to Figure 3-32 on page 3—47 of
Chapter 3: ‘Technical Description’ for the correct connection of the printhead
EHT connectors.
 Reconnect the green and yellow earth wire to the blade terminal on the
electronics tray.
 Reconnect the printhead 12-way connector to PL203 on the I/O PCB.
 Reconnect the 4-way connector to J1 on the modulation amplifier (HVPM).
 Reconnect the blue modulation coaxial cable to connector J2 on the modulation
amplifier (HVPM).
22 Refit the printhead cables to the two wire saddles on the LVPSU mounting plate.
23 Refer to Figure 3-37 on page 3—53 of Chapter 3: ‘Technical Description’and
reconnect all of the remaining cable connectors to the I/O PCB.
24 Reconnect the live, neutral and earth wires to the blade terminals on the mains
electrical supply filter.
FA48008
25 Refit the electrical cables and grommet seals to the cut-outs on the edge of the
electronics shelf.
26 Slide the electronics system completely into the cabinet, and then slide it to the
right in the guide slot to insert the external connectors through the side panel of the
cabinet.
27 Refit the four screwlocks to the two photocell/shaft encoder D-type connectors.
28 Refit the locking rings to the external alarm, USB, and Ethernet connectors.
29 Tighten the electronics system securing thumbscrew.
Rear access panel refitting

30 Make sure that all of the grommet seals for the electrical cables are refitted to the
cut-outs on the edge of the electronics shelf.
IMPORTANT: The grommet seals are very important safety barriers that prevent solvent
vapour entering the electronics system from the ink system. These seals can
be easily damaged and must be fitted carefully.
31 Insert the two tabs at the bottom of the panel into the two slots in the cabinet, and
then hold the top of the panel away from the printer enough to allow hand access to
the I/O PCB.
32 Reconnect the earth wire to the blade terminal on the electronics tray, and the fan
2-way connector to PL211 on the I/O PCB.
33 Close the access panel and refit the two M4 x 8 screws in the top left and right
corners of the panel.
34 Refit the air filter. Make sure that the filter is fitted with the foam side facing up
(metal mesh side facing down).
35 Refit the air filter access panel with the two knurled thumbscrews.
36 The ‘Rear Access Panel Removal & Access Preparation’ maintenance instruction is
now completed.
FA48008
FA48008
Venturi Replacement
Introduction
The Mk5 venturi is fitted in one end of the venturi manifold. An illustration of the venturi is
shown in Figure 1.
89034
Figure 1. Mk5 venturi
Parts required
FA16103 Mk5 Venturi Replacement Kit (includes a venturi removal tool)
Equipment required
Absorbent, lint-free paper towel
Procedure

THE EYES AND SKIN.

WARNING IS IGNORED.
FA48008
Venturi Replacement
Removal
the printer.
3 Remove the rear access panel (refer to the ‘Rear Access Panel Removal & Access
Preparation’ maintenance instruction on page 5–57), but do not remove the ink
system.
4 Put absorbent, lint-free paper towel under the venturi manifold to contain any ink
spillage.
5 Refer to Figure 2 and loosen the compression nut on the venturi manifold, and then
remove the fluid pipe from the Festo fitting (the venturi manifold is fitted to the left
side of the service module housing).
89033
Festo fitting
Compression nut
Figure 2. Venturi manifold

6 Remove the Festo fitting from the manifold.
7 Screw the venturi removal tool onto the threaded end of the venturi, and then pull
to remove the venturi from the manifold.
Installation
8 Insert the replacement venturi into the manifold.
9 Refit the Festo fitting to the manifold.
10 Refit the fluid pipe to the Festo fitting (a piece of abrasive paper can help to grip the
pipe), and then tighten the compression nut.
11 Remove any absorbent material from the ink system compartment.
12 Refit the rear access panel (refer to the ‘Rear Access Panel Removal & Access
Preparation’ maintenance instruction on page 5–57).
13 The ‘Venturi Replacement’ maintenance instruction is now completed.
FA48008
Main Ink Pump and Motor Assembly Replacement
Parts required
FA11047 Ink Pump and Motor
Equipment required
Abrasive paper
Procedure

THE EYES AND SKIN.


WARNING IS IGNORED.
Removal
the printer.
3 Remove the rear access panel and the ink system (refer to the ‘Rear Access Panel
Removal & Access Preparation’ maintenance instruction on page 5–57).
4 Put absorbent, lint-free paper towel under the pump and motor assembly and the
pipe connections to contain any ink spillage.
FA48008
5 Disconnect the pump motor 6-way connector from PL200 on the I/O PCB, and then
remove the cable and grommet seal from the cut-out on the edge of the electronics
shelf.
6 Use a 7 mm nut spinner to remove the four M4 nuts that hold the pump and motor
assembly to the mounting plate on the rear wall of the ink system (refer to
Figure 1).
89030
Pump
securing
nut x4
Figure 1. Securing nuts for the main ink pump and motor assembly
7 Lift the pump and motor assembly off the four threaded studs.
8 Carefully rotate the pump and motor assembly to allow access to the two
compression nuts (see Figure 2).
Motor 89010
Inlet from the

valves manifold
Outlet to the
venturi manifold
Pump
Compression
nuts
Figure 2. Ink pump and compression nuts

9 Loosen the two compression nuts and slide them back along the pipes.
10 Disconnect the two pipes from the barbs on the pump, and remove the pump and
motor assembly from the ink system.
Installation
11 Push the two pipes onto the barbs on the replacement pump (a piece of abrasive
paper can help to grip the pipe). Refer to Figure 2 and make sure that the inlet and
outlet pipes are connected to the correct barbs.
12 Slide the two compression nuts along the pipes to the barb connections, and then fit
and tighten the nuts.
FA48008
13 Fit the pump and motor assembly onto the four threaded studs on the mounting
plate.
14 Use a 7 mm nut spinner to fit the four M4 nuts to the threaded studs.
15 Connect the pump motor 6-way connector to PL200 on the I/O PCB.
16 Carefully refit the electrical cable and grommet seal to the cut-out on the edge of the
electronics shelf.
17 Remove any absorbent material from the ink system.

17 Refit the ink system and the rear access panel (refer to the ‘Rear Access Panel
18 Reconnect the mains electrical supply cable of the printer and turn on the printer.
19 Access the Jet Sequences screen (Main Menu > Maintenance > Jet Sequences) and
select the Ink Prime option to fill the primary circuit ink lines in preparation for a
normal jet startup.
20 The ‘Main Ink Pump and Motor Assembly Replacement’ maintenance instruction is
now completed.
FA48008
FA48008
Solvent Tank Pick-up Tube Replacement
Introduction
The solvent tank pick-up tube has an integral 20 µm, stainless steel, in-line filter fitted inside
the tube. The pick-up tube and filter, together with two O-rings are supplied as an
assembled part in the spare parts pack. A compression nut is also included.
Compression nut
89031
O-rings
Pick-up tube
including filter
Figure 1. Solvent tank pick-up tube and filter assembly
Parts required
FA13005 Solvent Tank Pick-up Tube
Equipment required
Procedure

THE EYES AND SKIN.


WARNING IS IGNORED.
FA48008
Solvent Tank Pick-up Tube Replacement
Removal
the printer.
4 Put absorbent, lint-free paper towel on top of the solvent tank around the top of the
pick-up tube to contain any solvent spillage.
5 Refer to Figure 2 and loosen the compression nut, and slide it back along the pipe.
89032
Compression nut
Solvent
pick-up tube
Figure 2. Pick-up tube assembly fitted to the solvent tank

6 Remove the pipe from the pick-up tube, and then remove and discard the
compression nut from the pipe.
7 Carefully twist and pull to remove the pick-up tube from the solvent tank. (The
pick-up tube is not threaded but is a push fit.)
Installation
8 Push the replacement pick-up tube firmly into the solvent tank.
9 Slide the new compression nut that is supplied in the kit onto the solvent pipe.
10 Push the solvent pipe completely into the top of the pick-up tube.
11 Fit and tighten the compression nut onto the pick-up tube.
14 The ‘Solvent Tank Pick-up Tube Replacement’ maintenance instruction is now
completed.
FA48008
Solvent Tank Level Sensor Replacement
Introduction
The solvent level sensor is a float switch device that is fitted through the top of the solvent
tank. An illustration of the solvent level sensor is shown in Figure 1.
89035
Float
Figure 1. Solvent level sensor
Parts required
FA11021 Solvent Level Sensor and Cable
Equipment required
Procedure

THE EYES AND SKIN.

FA48008

WARNING IS IGNORED.
Removal
the printer.
4 Put absorbent, lint-free paper towel on top of the solvent tank to contain any
solvent spillage from the level sensor.
5 Disconnect the level sensor 2-way connector from PL222 on the I/O PCB, and then
remove the cable and grommet seal from the cut-out on the edge of the electronics
shelf.
6 Refer to Figure 2 and remove the small self-tapping securing screw that holds the
level sensor to the tank.
89036
Electrical
cable
Securing
screw
Solvent level
sensor
Figure 2. Level sensor assembly fitted to the solvent tank

7 Carefully pull the level sensor out of the tank. A small flat-bladed screwdriver can
be inserted under the top rim of the sensor and used as a lever to help remove the
sensor.
FA48008
Installation
8 Push the replacement level sensor firmly into the solvent tank. Make sure that the
cut-out in the top rim of the sensor is aligned with the securing hole in the solvent
tank.
9 Refit the small self-tapping securing screw to the tank.
10 Connect the level sensor 2-way connector to PL222 on the I/O PCB.
electronics shelf.
14 The ‘Solvent Tank Level Sensor Replacement’ maintenance instruction is now
completed.
FA48008
FA48008
Solvent Tank Replacement
Parts required
FA11036 Solvent Tank Assembly
Equipment required
FA940052 Tube Cutter Plastic 4 mm–14 mm
Procedure

THE EYES AND SKIN.


WARNING IS IGNORED.
Removal
the printer.
4 Remove the solvent tank pick-up tube (refer to the ‘Solvent Tank Pick-up Tube
Replacement’ maintenance instruction on page 5–69).
5 Remove the solvent tank level sensor (refer to the ‘Solvent Tank Level Sensor
FA48008
Solvent Tank Replacement
6 Refer to Figure 1 and remove the three M4 x 8 securing screws for the ink system
support arm and remove the arm (two screws at the bottom and one screw at the
top). (The solvent priming unit is attached to the support arm.)
89037
ink system
To Solvent support arm
Top-up valve
To Solvent
Cartridge valve
To Vent valve
Two bottom
screws for the
support arm
Figure 1. Solvent tank connections and ink system support arm

7 Cut the three pipes from the barb connections on the solvent tank. Use the tube
cutter to cut the pipes accurately and as close as possible to the barbs.
8 Slide the solvent tank out of the ink system tray.
9 Empty the contents of the solvent tank into the correct waste container, and discard
the solvent and the tank according to local safety regulations.
Installation
10 Slide the replacement solvent tank into the ink system tray.
11 Refer to Figure 1 and reconnect the three pipes to the solvent tank barbs.
12 Refit the ink system support arm and the three M4 x 8 securing screws. Make sure
that the bottom end of the support arm is fitted to the inside face of the mounting
tab.
13 Refit the solvent tank pick-up tube (refer to the ‘Solvent Tank Pick-up Tube
14 Refit the solvent tank level sensor (refer to the ‘Solvent Tank Level Sensor
16 The ‘Solvent Tank Replacement’ maintenance instruction is now completed.
FA48008
Solvent Priming Unit and Valve Replacement
Introduction
The Solvent Priming Unit spare part includes the Solvent Prime valve, which can also be
replaced as a separate item. This maintenance instruction describes the replacement of the
solvent priming unit or only the Solvent Prime valve.
Parts required
FA11065 Solvent Priming Unit and Valve
Equipment required
Procedure

THE EYES AND SKIN.


WARNING IS IGNORED.
the printer.
FA48008
4 Disconnect the Solvent Prime valve 2-way connector from PL217 on the I/O PCB,
and then remove the cable and grommet seal from the cut-out on the edge of the
electronics shelf.
top). The solvent priming unit is attached to the support arm.
89042
Securing
screw hole for
the solvent
priming unit
Solvent
priming unit
locating pin
Ink system
support arm
Two bottom
screws for the
support arm
Figure 1. Ink system support arm and securing screws

6 Remove the screw that holds the solvent priming unit to the support arm, and then
remove the unit from the locating pin (see Figure 1).
7 To replace only the Solvent Prime valve, go to step 17.
Solvent priming unit replacement

8 Put absorbent, lint-free paper towel under the solvent priming unit to contain any
ink or solvent spillage.
In the next steps, use the tube cutter to cut the pipes accurately and as close as
possible to the barbs.
FA48008
9 Refer to Figure 2 and cut the pipe from the barb connection on port A of the solvent
priming unit. (This pipe is connected to the venturi manifold and has a red stripe.)
89038 B
Figure 2. Solvent priming unit ports

10 Cut the pipe from the barb connection on port B of the solvent priming unit. (This
pipe is connected to the 6-way fluid connector and has a green stripe.)
11 Cut the pipe from the barb connection on port C of the solvent priming unit. (This
pipe is connected to the Solvent Add valve on the valves manifold and has a green
stripe.)
12 Discard the solvent priming unit.
13 Connect the Solvent Add valve pipe (green stripe) to port C of the replacement
solvent priming unit.
14 Connect the 6-way fluid connector pipe (green stripe) to port B of the replacement
solvent priming unit.
15 Connect the venturi manifold pipe (red stripe) to port A of the replacement solvent
priming unit.
16 Go to step 22.
Solvent Prime valve replacement

17 Refer to Figure 2 and cut the pipe from the barb connection on port C of the solvent
priming unit. (This pipe is connected to the Solvent Add valve on the valves
manifold and has a green stripe.)
18 Refer to Figure 2 and remove the two securing screws ‘D’ for the valve retainer, and
then carefully remove the retainer.
19 Have the replacement Solvent Prime valve ready. Carefully remove the valve from
the solvent priming unit, and then immediately fit the replacement valve to the
solvent priming unit. Make sure that the orientation is correct—the shorter spigot
of the valve fits into the solvent priming unit.
20 Refit the valve retainer and the two securing screws.
21 Reconnect the Solvent Add valve pipe (green stripe) to port C of the solvent
priming unit.
FA48008
Refitting
22 Fit the solvent priming unit to the locating pin on the support arm, and then refit
the securing screw that was removed in step 6.
tab.
24 Connect the Solvent Prime valve 2-way connector to PL217 on the I/O PCB.
electronics shelf.
28 If the solvent priming unit is replaced, reconnect the mains electrical supply cable
of the printer and turn on the printer.
select the Solvent Prime option to fill the solvent priming unit and solvent lines in
preparation for a normal jet startup.
30 The ‘Solvent Priming Unit and Valve Replacement’ maintenance instruction is now
completed.
FA48008
Pressure Transducer and Damper Replacement
Introduction
The pressure transducer and damper assembly includes the pressure transducer, damper,
and the Ink System Feed valve. These three parts are replaced as a single unit.
Parts required
FA11064 Pressure Transducer, Damper and Feed Valve
Equipment required
Procedure

THE EYES AND SKIN.


WARNING IS IGNORED.
Removal
the printer.
FA48008
4 Disconnect the damper assembly 5-way connector from PL225 on the I/O PCB, and
then remove the cable and grommet seal from the cut-out on the edge of the
electronics shelf.
6 Use a 5.5 mm nut spinner to remove the two M3 Nyloc nuts that hold the pressure
transducer and damper assembly to the rear wall of the ink system (refer to
Figure 1).
89039
Securing
nuts
ink system
support arm
Two bottom
screws for the
support arm
Figure 1. Securing nuts for the pressure transducer and damper assembly
7 Put absorbent, lint-free paper towel under the pressure transducer and damper
assembly to contain any ink spillage.
In the next steps, use the tube cutter to cut the pipes accurately and as close as
8 Refer to Figure 2 and cut the pipe from the barb connection on port A of the
damper. (This pipe is connected to the venturi manifold and has a red stripe.)
89040
A
B
Figure 2. Damper ports
FA48008
9 Cut the pipe from the barb connection on port B of the damper. (This pipe is
connected to the 6-way fluid connector and has a red stripe.)
10 Discard the pressure transducer and damper assembly.
Installation
11 Connect the 6-way fluid connector pipe to port B of the replacement pressure
transducer and damper assembly.
12 Connect the venturi manifold pipe (that has a restrictor fitted) to port A of the
replacement pressure transducer and damper assembly.
13 Fit the pressure transducer and damper assembly and the two M3 Nyloc nuts to the
rear wall of the ink system.
tab.
15 Connect the damper assembly 5-way connector to PL225 on the I/O PCB.
electronics shelf.
20 Access the Calibration screen (Main Menu > Maintenance > Calibration), and then
enter the calibration value for the new pressure transducer with the IPM: Pressure
Transducer (mV) button. The calibration value is written on the pressure
transducer.
select the Ink Prime option to fill the primary circuit ink lines in preparation for a
normal jet startup.
22 The ‘Pressure Transducer and Damper Replacement’ maintenance instruction is
now completed.
FA48008
FA48008
Solvent Recovery Unit Replacement
Introduction
The solvent recovery unit is fitted to the bottom of the ink system tray between the solvent
tank and the service module housing.
Parts required
FA11037 Solvent Recovery Unit
Equipment required
Procedure

THE EYES AND SKIN.


WARNING IS IGNORED.
Removal
the printer.
FA48008
Solvent Recovery Unit Replacement
89044
ink system
support arm
Solvent
recovery unit
Two bottom
screws for the
support arm

5 Refer to Figure 2 and cut the three pipes from the barb connections on the solvent
recovery unit. Use the tube cutter to cut the pipes accurately and as close as
Outlet to the
ink system tray
Inlet from the
Inlet from the Vent valve
service module
89043
Figure 2. Solvent recovery unit pipe connections

6 Lift and remove the solvent recovery unit from the mounting slide.
7 Discard the solvent recovery unit.
Installation
8 Push the replacement solvent recovery unit onto the mounting slide.
9 Refer to Figure 2 and connect the three pipes to the barb connections on the solvent
recovery unit.
that the bottom end of the support arm is fitted to the inside face of the mounting tab.
12 The ‘Solvent Recovery Unit Replacement’ maintenance instruction is now
completed.
FA48008
Transfer Pump Replacement
Introduction
The transfer pump is fitted vertically to the rear wall of the ink system, next to the ink
system pump.
Parts required
FA11057 Transfer Pump
Equipment required
Procedure

THE EYES AND SKIN.


WARNING IS IGNORED.
FA48008
Removal
the printer.
4 Disconnect the transfer pump 4-way connector from PL218 on the I/O PCB, and
electronics tray.
top).
89106
Transfer
pump
Ink system
support arm
Two bottom
screws for the
support arm
FA48008
6 Refer to Figure 2 and loosen the two M4 screws that hold the transfer pump to the
rear wall of the ink system, and then lift the pump from the screws.
89107
Electrical supply
cable (to PL218)
Outlet to the
ink system tray Securing
screws
Inlet from the

valves manifold Outlet to the
valves manifold
Figure 2. Transfer pump pipe connections

7 Put absorbent, lint-free paper towel under the transfer pump to contain any ink or
solvent spillage.
8 Refer to Figure 2 and cut the three pipes from the barb connections on the transfer
pump.Use the tube cutter to cut the pipes accurately and as close as possible to the
barbs.
9 Discard the transfer pump.
Installation
10 Refer to Figure 2 and connect the three pipes to the barb connections on the transfer
pump. Make sure that the inlet and outlet pipes are connected to the correct
barbs—refer to the flow direction arrows on the pump body.
11 Fit the pump onto the two M4 securing screws on the rear wall of the ink system,
and then tighten the screws.
tab.
13 Connect the transfer pump 4-way connector to PL218 on the I/O PCB.
electronics shelf.
17 The ‘Transfer Pump Replacement’ maintenance instruction is now completed.
FA48008
FA48008
Manifold Valves Replacement
Introduction
This maintenance instruction describes the replacement procedure for all six of the
manifold valves together. The electrical cables for the six valves are combined into one cable
assembly, therefore, the valves must be replaced as one spare part.
The valves manifold assembly is fitted to the rear of the service module housing.
The following are the manifold valves and their position numbers in the manifold:
1. Solvent Add
2. Ink Cartridge
3. Purge
4. Solvent Top-up
5. Vent
6. Solvent Cartridge
Parts required
FA11018 Manifold Valves Assembly
Equipment required
Procedure

THE EYES AND SKIN.

FA48008

WARNING IS IGNORED.
Removal
the printer.
4 Disconnect the manifold valves 12-way connector from PL226 on the I/O PCB, and
electronics tray.
top).
89121
ink system
support arm
Two bottom
screws for the
support arm

6 Put absorbent, lint-free paper towel under the valves manifold to contain any ink or
solvent spillage.
7 Refer to Figure 2 and remove the two securing screws for the valves retainers.
FA48008
8 Carefully remove the two retainers from the valves.
Valves retainer B
89122
Securing screw
Valves retainer A
Solvent Cartridge valve (6) Securing screw
Vent valve (5)

Solvent Top-up valve (4)
Purge valve (3)
Ink Cartridge valve (2)
Solvent Add valve (1)
Figure 2. Valves and valves retainers
9 Remove all six valves from the manifold.
Installation
10 Fit the six replacement valves to the manifold. Refer to Figure 2 and make sure that
the valves are fitted to the correct numbered position on the manifold. Also make
sure that the valve orientation is correct—the longer spigot of the valve is inserted
into the manifold.
11 Refit the valves retainers to the valves. Make sure that the two retainer parts are
fitted in the correct orientation. The number of notches on each valve retainer
corresponds to the valve number. For example, the valve retainer that has six
notches must be fitted over valve number 6 (the Solvent Cartridge valve).
12 Refit the two securing screws for the valves retainers.
tab.
14 Connect the manifold valves 12-way connector to PL226 on the I/O PCB.
electronics tray.
19 Access the Valve Test screen (Main Menu > Maintenance > Valve Test).
20 Touch and hold each of the buttons for the manifold valves in turn, and check that
each valve turns on and off continuously until the button is released.
21 The ‘Manifold Valves Replacement’ maintenance instruction is now completed.
FA48008
FA48008
Front Access Door Removal and Installation
Equipment required
Procedure

THE EYES AND SKIN.


WARNING IS IGNORED.
Removal
the printer.
4 Open the front access door and remove the ink and solvent cartridges.
5 Close the access door.
FA48008
6 Refer to Figure 1 and loosen the two screws that hold the right striker plate, and
then remove the striker plate. (The right striker plate is on the right when looked at
through the rear of the printer, but by convention this is the left side of the printer
as seen from the front.)
89131
Left striker
plate Right striker
plate
Spring
Striker plate
securing Striker plate
screws securing
screws
Earth strap
connection
Figure 1. Access door right and left striker plates
7 Loosen the two screws that hold the left striker plate. Remove the striker plate, and
then disconnect the spring from the striker plate.
8 Use a cross-head screwdriver to push the hinge rod out of the door assembly, in the
direction of the arrow shown in Figure 2.
89132
Door hinge
rod
Figure 2. Door hinge rod

9 Open the access door and carefully remove the door from the ejector tracks, and
then lower the door onto the workbench.
FA48008
10 Remove the M5 nut that holds the braided earth strap to the door assembly and
disconnect the strap (refer to Figure 1).
Installation
11 Reconnect the braided earth strap and the M5 securing nut to the door assembly.
12 Engage both ends of the ejector rod for the cartridges receptacle into the ejector
tracks on the cabinet.
13 Align the holes for the hinge rod in the door assembly and the cabinet, and then
insert the hinge rod into the right side of the door assembly (refer to Figure 2). Push
the rod completely into the door.
15 Refer to Figure 1 and refit the left striker plate and tighten the two securing screws.
Reconnect the spring to the striker plate.
16 Refit the right striker plate and tighten the two securing screws.
17 Open the front access door and refit the ink and solvent cartridges.
20 The ‘Front Access Door Removal and Installation’ maintenance instruction is now
completed.
FA48008
FA48008
RFID Module and Cable Replacement
Parts required
FA11072 RFID Module and Cable
Equipment required
Procedure

THE EYES AND SKIN.


WARNING IS IGNORED.
Removal
the printer.
4 Remove the front access door from the cabinet (refer to the ‘Front Access Door
Removal and Installation’ maintenance instruction on page 5–95).
FA48008
RFID Module and Cable Replacement
5 Refer to Figure 1 and disconnect the cartridges receptacle spring.
89162
Door cage
Cartridges
receptacle spring Cartridges
receptacle
Cartridges receptacle
spring bracket
RFID module
RFID module
securing screws Cable ties x2
Ribbon cable
Figure 1. Access door assembly

6 Disconnect the RFID module ribbon cable connector from PL205 on the I/O PCB.
7 Remove the three M3 securing screws for the RFID module and the receptacle
spring bracket, and remove the bracket.
8 Cut the cable ties that hold the ribbon cable to the door cage, and then remove the
RFID module (with the ribbon cable attached) from the cartridges receptacle.
Installation
9 Insert the replacement RFID module (which includes a new ribbon cable) into the
cartridges receptacle.
10 Connect the RFID module ribbon cable connector to PL205 on the I/O PCB.
11 Refit the receptacle spring bracket and the three M3 securing screws for the RFID
module.
12 Fit new cable ties to hold the ribbon cable of the RFID module to the door cage.
13 Reconnect the cartridges receptacle spring.
14 Refit the front access door to the cabinet (refer to the ‘Front Access Door Removal
and Installation’ maintenance instruction on page 5–95).
16 The ‘RFID Module and Cable Replacement’ maintenance instruction is now
completed.
FA48008
Front Access Door Latch Replacement
Introduction
This maintenance instruction describes the front access door disassembly procedure for
access to the door latch mechanism. The mechanism has three parts: a latch spring, latch,
and latch slider plate, each of which can be replaced when the mechanism is disassembled
in this procedure.
Parts required
FA11068 Front Access Door Latch
Equipment required
Procedure

THE EYES AND SKIN.


WARNING IS IGNORED.
Removal
the printer.
FA48008
89181
Door latch Door cage
Cartridges
Ejector rod
receptacle spring
Cartridges receptacle Cartridges

spring bracket receptacle
RFID module RFID module

securing screws
Ribbon cable
Pipe
routing clips x3

7 Remove the RFID module (with the ribbon cable attached) from the cartridges
receptacle.
8 Remove the two cartridge pipes from the routing clips.
9 Remove the ejector rod for the cartridges receptacle.
10 Remove the cartridges receptacle from the door cage.
11 Refer to Figure 2 and disconnect and remove the latch spring from the door latch
(replace as necessary).
89191
Latch mounting plate
(welded to the door)
Latch slider plate

Door latch
Securing screws x6
Latch spring
Figure 2. Access door latch mechanism

12 Slide and lift the door latch from the latch slider plate (replace as necessary).
FA48008
13 Remove the six cross-head securing screws for the latch slider plate, and then
remove the slider plate from the latch mounting plate (replace as necessary).
Installation
14 Refit the latch slider plate and the six cross-head securing screws to the latch
mounting plate (as necessary).
15 Refit the door latch to the latch slider plate (as necessary).
16 Reconnect the latch spring to the door latch (as necessary).
17 Feed the two cartridge pipes through the bottom of the door cage and insert the
cartridges receptacle into the door cage. Make sure that the guide pins on each side
of the cartridges receptacle engage in the guide tracks in the door cage.
18 Refit the ejector rod to the cartridges receptacle.
19 Refit the two cartridge pipes under the routing clips. Make sure that the pipes are
not under tension when the cartridges receptacle is in the raised position.
20 Insert the RFID module into the cartridges receptacle.
module.
25 The ‘Front Access Door Latch Replacement’ maintenance instruction is now
completed.
FA48008
FA48008
Front Access Door Damper Replacement
Introduction
The front access door damper is fitted to the right side of the cabinet, at the front of the door
aperture, as shown in Figure 1. The ink system and the front access door must be removed
to allow access to the door damper assembly.
89224
Door
damper
Figure 1. Access door damper location
Parts required
FA11208 Front Access Door Damper
Equipment required
Procedure

THE EYES AND SKIN.

FA48008
Front Access Door Damper Replacement

WARNING IS IGNORED.
Removal
the printer.
5 Refer to Figure 2 and remove the three M3 x 16 securing screws for the door
damper assembly, and remove the assembly.
89225 Damper
Securing
screws x3
Damper carrier
Figure 2. Access door damper assembly
Installation
5 Fit the replacement door damper assembly and the three M3 x 16 securing screws
to the cabinet.
8 The ‘Front Access Door Damper Replacement’ maintenance instruction is now
completed.
FA48008
Front Access Door Sensor Replacement
Introduction
The front access door sensor is fitted to the left ejector track for the door, as shown in
Figure 1. The sensor cable assembly includes the ink spillage detector, therefore, both the
door sensor and the spillage detector must be replaced as one spare part.
The ink system must be removed and the front access door opened to allow access to the
door sensor.
89245
Ejector track
Door sensor
Ink spillage
detector
Figure 1. Access door sensor location
Parts required
FA11010 Front Access Door Sensor
Equipment required
Procedure

THE EYES AND SKIN.

FA48008

WARNING IS IGNORED.
Removal
the printer.
4 Open the front access door, which allows access to the door sensor through the rear
of the cabinet.
5 Refer to Figure 1 and remove the securing screw for the spillage detector from the
ink system slide, and disconnect the ring terminal.
6 Refer to Figure 2 and remove the two self-tapping securing screws for the door
sensor, and remove the sensor from the ejector track.
89246
Spillage
detector cable
Ejector
Door sensor track
cable
Door Securing
sensor screws
Figure 2. Access door sensor

7 Disconnect the door/spill sensors 4-way connector from PL201 on the I/O PCB,
and then remove the cable and grommet seal from the cut-out on the edge of the
electronics tray.
FA48008
Installation
8 Fit the replacement door sensor and the two self-tapping securing screws to the
ejector track. Make sure that the flat side of the sensor is fitted to the ejector track, so
that the white text on the sensor is visible.
9 Fit the spillage detector ring terminal and securing screw to the ink system slide.
10 Connect the door/spill sensors 4-way connector to PL201 on the I/O PCB.
electronics tray.
12 Route the cable assembly below the access panel for the service module.
13 Close the front access door.
15 The ‘Front Access Door Sensor Replacement’ maintenance instruction is now
completed.
FA48008
FA48008
Cartridges Receptacle Replacement
Introduction
The cartridges receptacle is part of the cartridges receptacle assembly, which also contains
the ink and solvent needle stem assemblies (refer to Figure 1). This maintenance instruction
describes the replacement procedure for the cartridges receptacle, but the needle stem
assemblies can also be replaced when they are removed during this procedure.
89252
Cartridges
receptacle
Ink needle
stem assembly
Solvent needle
stem assembly
Figure 1. Cartridges receptacle assembly
Parts required
FA11066 Cartridges Receptacle Assembly and Needle Assemblies
FA11069 Cartridges Receptacle
FA11070 Cartridge Needle Assembly
Equipment required
FA48008
Procedure

THE EYES AND SKIN.


WARNING IS IGNORED.
Removal
the printer.
FA48008
89181
Door latch Door cage
Cartridges
Ejector rod
receptacle spring
Cartridges receptacle Cartridges

spring bracket receptacle
RFID module RFID module

securing screws
Ribbon cable
Pipe
routing clips x3

7 Remove the RFID module (with the ribbon cable attached) from the cartridges
receptacle.
8 Remove the two cartridge pipes from the routing clips.
9 Remove the ejector rod for the cartridges receptacle.
10 Remove the cartridges receptacle from the door cage.
11 Refer to Figure 3 and remove the two screws that hold the ink needle stem
assembly to the bottom of the cartridges receptacle.
Ink 89253
pipe
Cartridges
receptacle
Solvent
pipe
Ink
needle stem
assembly
Solvent needle
stem assembly
Figure 3. Needle stem assemblies removed
FA48008
12 Remove the two screws that hold the solvent needle stem assembly to the bottom of
the cartridges receptacle.
13 Lift the ink and solvent needle stem assemblies out of the top of the cartridges
receptacle.
14 Put absorbent, lint-free paper towel under the needle stem assemblies to contain
any ink or solvent spillage.
15 Cut the two pipes from the barb connections on the needle stem assemblies. Use the
tube cutter to cut the pipes accurately and as close as possible to the barbs. The ink
or solvent needle stem assemblies can now be replaced, as required.
Installation
16 Make sure that the ink and solvent pipes are inserted through the correct openings
in the bottom of the door cage. The pipe for the ink cartridge has a red stripe, and
the pipe for the solvent cartridge has a green stripe.
17 Feed the ink and solvent pipes through the correct openings in the bottom of the
replacement cartridges receptacle.
18 Connect the pipes to the barb connections on the needle stem assemblies.
19 Insert the ink needle stem assembly into the bottom of the cartridges receptacle,
and then fit the two securing screws.
20 Insert the solvent needle stem assembly into the bottom of the cartridges receptacle,
and then fit the two securing screws.
21 Feed the two cartridge pipes through the bottom of the door cage and insert the
cartridges receptacle into the door cage. Make sure that the guide pins on each side
of the cartridges receptacle engage in the guide tracks in the door cage.
22 Refit the ejector rod to the cartridges receptacle.
23 Refit the two cartridge pipes under the routing clips. Make sure that the pipes are
not under tension when the cartridges receptacle is in the raised position.
24 Insert the RFID module into the cartridges receptacle.
module.
29 The ‘Cartridges Receptacle Replacement’ maintenance instruction is now
completed.
FA48008
High Voltage Power Module Replacement
Introduction
The high voltage power module (HVPM) includes the low voltage power supply unit
(LVPSU), 300 volts power supply, modulation amplifier, and the EHT power supply. This
module is replaced as a single unit.
Parts required
FA11051 High Voltage Power Module
Procedure

WARNING IS IGNORED.
Static-Sensitive Devices. The PCBs contain static-sensitive devices. Take the following
antistatic precautions when PCBs are touched. Wear an antistatic wrist strap and connect the
lead to a good electrical earth. Always hold PCBs by their edges and do not touch the
components, printed circuit tracks or connector pins.
Removal
the printer.
3 Remove the rear access panel and the electronics system (refer to the ‘Rear Access
Panel Removal & Access Preparation’ maintenance instruction on page 5–57).
4 Disconnect the HVPM 10-way connector from PL204 on the I/O PCB.
5 Disconnect the power 5-way connector from PL220 on the I/O PCB, and then
disconnect its green and yellow earth wire from the blade terminal on the
electronics tray.
6 Disconnect the green and yellow earth wire for the LVPSU from the blade terminal
on the electronics tray.
FA48008
High Voltage Power Module Replacement
7 Refer to Figure 1 and disconnect the mains electrical supply 2-way connector from
J1 on the LVPSU.
89254
Mains electrical supply LVPSU

connector J1
One of two
mounting plate
locating slots
(hidden)
HVPM
securing screw
Figure 1. HVPM
8 Remove the securing screw for the HVPM (fitted at the front of the unit).
9 Pull the HVPM to disengage the two tabs on the electronics tray from the two
locating slots in the HVPM mounting plate, and then remove the HVPM.
Installation
10 Fit the replacement HVPM to the electronics tray. Engage the two tabs on the
electronics tray with the two locating slots in the HVPM mounting plate.
11 Refit the securing screw for the HVPM.
12 Connect the mains electrical supply 2-way connector to J1 on the LVPSU.
13 Connect the green and yellow earth wire for the LVPSU to the blade terminal on the
electronics tray.
14 Connect the power 5-way connector to PL220 on the I/O PCB, and then connect its
green and yellow earth wire to the blade terminal on the electronics tray.
15 Connect the HVPM 10-way connector to PL204 on the I/O PCB.
16 Refit the electronics system and the rear access panel (refer to the ‘Rear Access
17 The ‘High Voltage Power Module Replacement’ maintenance instruction is now
completed.
FA48008
IPM Assembly Replacement
Introduction
UNIC
The unique number identification chip (UNIC), which provides a unique number to
identify each printer, is installed on the IPM Assembly. If the IPM Assembly is replaced, the
UNIC must be removed from the old I/O PCB and fitted to the replacement board. The
printer configuration code must then be re-entered on the user interface to enable the
printer to access the required configuration options (Main Menu > Printer Setup >
Installation > Printer Configuration Code). If the UNIC is not transferred, the replacement
IPM Assembly will not acknowledge any configuration code.
IPM Assembly battery

When the IPM Assembly is replaced, the battery on the replacement PCB must be
completely charged. The battery is used to save data during the power-down process, and
to supply the real-time clock while the printer is turned off. If the battery is not completely
charged, the printer must remain turned on for at least 90 minutes to charge the battery
correctly.
Printer backup
Make a backup copy to a USB memory device of the printer settings and any created
messages and logos before the IPM Assembly is removed. This backup data can then be
restored to the printer after the new IPM Assembly is fitted. The ability to make a backup is
not always possible, and depends on the type of fault and the available functionality of the
IPM Assembly.
Parts required
FA11000 IPM Assembly
Procedure

WARNING IS IGNORED.
FA48008
Removal
the printer.
4 Disconnect the HVPM 10-way connector from PL204 on the I/O PCB.
5 Disconnect the power 5-way connector from PL220 on the I/O PCB.
6 Refer to Figure 1 and remove the seven securing nuts, indicated by the arrows, for
the IPM Assembly (four Nyloc nuts and three plastic nuts).
89255
Figure 1. IPM Assembly securing nuts

7 Remove the IPM Assembly from the electronics tray.
Installation
8 Put the replacement IPM Assembly in position on the electronics tray, and then
refit the seven securing nuts. Make sure that the four Nyloc nuts and three plastic
nuts are fitted in the correct positions (refer to Figure 1).
9 Reconnect the power 5-way connector to PL220 on the I/O PCB.
10 Reconnect the HVPM 10-way connector to PL204 on the I/O PCB.
FA48008
13 Log in at the Service level.

14 Access the Calibration screen (Main Menu > Maintenance > Calibration), and then
use the IPM: Pressure Transducer (mV) button to enter the calibration value that is
written on the pressure transducer.
15 Perform the following steps to restore the printer configuration parameters.
16 Enter the configuration code that was supplied with the UNIC (Main Menu >
Printer Setup > Installation > Printer Configuration Code). If there is no record kept
of the code, contact the local Distributor, or the Sales Order Administration
department of Linx Printing Technologies Ltd, who will supply the configuration
code.
17 If a back-up file of the printer settings is available on a USB memory device, use the
‘Restore a printer from a memory stick’ instructions in the ‘How To Use the USB
Connection’ guide.
18 If a back-up file of the printer settings is not available on a USB memory device,
manually enter the following data:
 Language (Main Menu > Printer Setup > Locale > Language)
 Date and Time (Main Menu > Printer Setup > Date & Time)
 Ink and Solvent type (Main Menu > Printer Setup > Installation > Ink/Solvent)
 Line Settings and Message Settings
19 The ‘IPM Assembly Replacement’ maintenance instruction is now completed.
FA48008
FA48008
Touch Screen Assembly Replacement
Parts required
FA11045 Touch Screen Assembly
Procedure

WARNING IS IGNORED.
Removal
the printer.
4 Refer to Figure 1 and disconnect the miniature ribbon cable connector for the
power on switch from the touch screen assembly.
89256
Touch screen
assembly
securing nuts
Angled supports
Power on
switch connector
Figure 1. Touch screen assembly—power on switch connector and securing nuts
FA48008
Touch Screen Assembly Replacement
5 Remove the two M3 nuts that hold the touch screen assembly to the securing studs
on the cabinet.
6 Carefully lift the touch screen assembly upwards and out of the angled supports,
and remove the assembly from the cabinet.
Installation
7 Carefully fit the replacement touch screen assembly into the angled supports in the
cabinet. Make sure that the touch screen is completely inserted into the angled
supports before the assembly is pushed onto the two securing studs.
8 Hold the touch screen assembly in position on the securing studs and refit the two
M3 nuts.
9 Connect the miniature ribbon cable connector for the power on switch to the touch
screen assembly.
11 The ‘Touch Screen Assembly Replacement’ maintenance instruction is now
completed.
FA48008
Modulation Range Checks
Introduction
This maintenance instruction checks the quality of the printed message. The procedure
makes sure that the Reference Modulation value is set, so that the best print quality is
maintained with changes in ink viscosity. This instruction can also be used to make an
analysis of the relative viscosity of the ink.
Procedure
1 Turn on the printer.
2 Select the largest test message from the Message Store (Home screen > Message
Store > Message List).
89274
Figure 1. List of test messages in the Message Store

NOTE: If the test messages are not available in the Message Store, touch the Create
Test Messages button to create them (Message Store > Store > Create Test
Messages).
3 Access the Jet Functions screen (Main Menu > Maintenance > Jet Functions) and
touch the Nozzle Clear button.
89275
Figure 2. Nozzle Clear option on the Jet Functions screen
FA48008
4 When the Nozzle Clear sequence has completed, touch the Jet Test-Start button to
start the jet, and then touch the Start Print button.
89275
89276
Figure 3. Start Print option on the Jet Functions screen

5 Touch the Jet Monitor button to access the Jet Monitor screen and record the
Reference Modulation value (highlighted with an ellipse in Figure 4). The Actual
Modulation value is displayed on the button to the right of the Reference
Modulation.
89277

H = 72%
V= 62%
Figure 4. Reference Modulation value on the Jet Monitor screen
FA48008
6 Touch the Actual Modulation button to display the Enter Modulation screen.
89278
Enter Modulation
90
0 .. 255
Figure 5. Enter Modulation screen

7 Use the following method to perform a modulation range analysis. Make a series of
print samples. Start at the original Reference Modulation value, and then decrease
the Actual Modulation value in steps of 10 volts on the Enter Modulation screen.
Touch the Save button after each value change.
NOTE: The colour of the Actual Modulation button on the Jet Monitor screen
changes to yellow to indicate that the value has been manually adjusted
(see Figure 6).
89279

H = 72%
V= 62%
Figure 6. Actual Modulation decreased by 10 volts from Reference Modulation

8 Continue to decrease the Actual Modulation until the print quality begins to
deteriorate (see Figure 7), and record the value (Vm1). Then increase the Actual
Modulation from the original Reference Modulation value in steps of 10 volts.
Continue to increase the Actual Modulation until the print quality begins to
deteriorate (see Figure 8), or until the maximum of 235 is reached, and record the
value (Vm2).
FA48008
NOTES:
1. The maximum of 235 volts is the recommended maximum Actual
Modulation for the 8900 printer.
2. The recommended maximum setting for Vm2 can be reached without there
being any indication of over modulation. If this condition occurs, record
the maximum value as Vm2. The same applies to under modulation.
48168
Figure 7. Under modulation—expected deterioration when Reference Mod is < Vm1
48169
Figure 8. Over modulation—expected deterioration when Reference Mod is > Vm2

9 Use the following formula to confirm that the original Reference Modulation value
is approximately equal to the calculated modulation.
Vmc = Vm1 + (Vm2 – Vm1)
3
10 Record the calculated value (Vmc) on the applicable Service Report Form
(Installation/Scheduled Maintenance/Breakdown).
11 On the Jet Monitor screen, touch the yellow Cancel button to reset the Actual
Modulation to the original value and to restart automatic modulation tracking.
Relative viscosity analysis

12 Compare the Reference Modulation with the calculated modulation (Vmc):
(Vmc) = Ref. Modulation: viscosity is correct.
(Vmc) < Ref. Modulation: viscosity is low but no action is required.
(Vmc) << Ref. Modulation: viscosity is too low. Find the primary cause for the
low viscosity ink.
(Vmc) > Ref. Modulation: viscosity is high but no action is required.
(Vmc) >> Ref. Modulation: viscosity is too high. Find the primary cause for
the high viscosity ink.
13 If the printer has been failing because the ink viscosity is too low or too high,
necessary action must be taken to find the primary cause of the viscosity problem.
14 The ‘Modulation Range Checks’ maintenance instruction is now completed.
FA48008
VFC Module Installation
Parts required
FA11011 VFC Module
FA79500 Replacement Fuses: TR5 1A Fast Acting Fuse—Pack of 5
Introduction
The 8900 printer is fitted with a single 24 V alarm output as standard. The volt-free contact
(VFC) module is an optional accessory that allows an additional VFC alarm to be connected
to the printer. Therefore, the printer can control two alarm outputs (24 V and VFC).
The VFC module connects directly to the 4-way connector PL210 on the I/O PCB.
89268
Internal cable
connector
VFC module
VFC option plate
VFC external connector
External
alarm-equipment
connector
To PL210
on the I/O PCB
Figure 1. VFC alarm accessory

IMPORTANT: The VFC module must not be used in a safety-critical production line
interlock.
Refer to ‘Alarm output’ in Chapter 3: ‘Technical Description’ for more information.
Procedure


WARNING IS IGNORED.
FA48008

the printer.
4 Remove the six Nyloc nuts that fasten the options blanking plate to the left side of
the printer cabinet.
5 Withdraw and remove the blanking plate and gasket from inside the printer.
6 Make sure that the new gasket is fitted to the outside face of the VFC module
option plate.
7 Orientate the VFC option plate assembly inside the printer cabinet, with the VFC
external connector uppermost. Insert the option plate studs through the holes in the
left side of the cabinet.
8 Use the six Nyloc nuts that are supplied in the kit to fasten the option plate
assembly to the left side of the cabinet.
9 Connect the VFC module cable to connector PL210 on the I/O PCB.
10 Attach the ‘ALARM (VFC)’ label that is supplied in the kit to the cabinet below the
VFC option plate.
DVM test
12 Access the Alarm Setup screen (Home screen > Line Settings > Alarms).
13 Touch the VFC Alarm button, set the Warnings option to On, and then touch Exit.
14 Touch the Test Mode button on the Alarm Setup screen to make the test buttons
available.
15 Set the DVM to the resistance range and connect the meter between pins L and N
(‘normally closed’ contacts) on the VFC external connector (see Figure 3 on
page 5—131). The DVM should indicate a short circuit.
16 Touch the Test VFC Alarm button to set the function to On, and make sure that the
DVM indicates an open circuit.
17 Touch the Test VFC Alarm button to set the function to Off, and make sure that the
DVM indicates a short circuit again.
NOTE: If it is required that the alarm output operates in the opposite sense (that is,
‘normally open’ contacts), the two wires on the external alarm device must be
connected to the pins corresponding to L and E on the VFC external connector.
Perform the following three steps to test the alarm output.
18 Connect the DVM between pins L and N (‘normally closed’ contacts) on the VFC
external connector (see Figure 3 on page 5—131). The DVM should indicate an
open circuit.
19 Touch the Test VFC Alarm button to set the function to On, and make sure that the
DVM indicates a short circuit.
20 Touch the Test VFC Alarm button to set the function to Off, and make sure that the
DVM indicates an open circuit again.
21 Disconnect the DVM from the VFC external connector.
FA48008
22 Turn off the printer.

24 The ‘VFC Module Installation’ maintenance instruction is now completed.
Assembly and wiring of the external 3-way socket connector

IMPORTANT:
1. Assembly and wiring of the VFC external alarm-equipment connector and any
maintenance work on the connector must be performed only by Linx
maintenance technicians, personnel trained by Linx, or a qualified and
authorized electrician.
2. The VFC module is a Class II double-insulated device; no earth connection is
required.
3. The upstream electrical supply for the external equipment must have a method
of isolation that is easily accessible for use during maintenance or in an
emergency. The external equipment must not be wired directly into the mains
electrical supply. The isolation device must have a clearance of ≥ 3 mm between
its contacts when open.
4. If one or both of the fuses (F1 and F2) fails in the VFC module, the terminals in
the module and parts of the printer I/O PCB can remain at a hazardous voltage.
The following table provides a ratings specification for the VFC module external alarm
installation.
Item Specification
Maximum voltage 240 VAC
Internal fuses (x2) 1 A, 250 V, TR5 fast acting miniature, push fit
Recommended maximum load 1 A per relay connection
Upstream fuse The customer electrical supply must be limited by an upstream
fuse of 5 A (maximum) that has an IEC 60127-approved 1500 A
breaking capacity.
Table 1. VFC module external alarm ratings specification
FA48008
A cable specification for the external equipment connections to the VFC module is provided
in Table 2.
Item Specification
Cable type The cable must have flexible (multi-strand) conductors and
have insulation of the correct type for the voltage and
application environment.
Overall cable diameter Minimum 6.0 mm diameter
Maximum 8.0 mm diameter
Conductors Maximum size 2.5 mm2 (14 AWG)
Insulation removal Cut and remove the insulation from the end of 2 mm max
the cable, so that no more than 2 mm of bare
conductor is exposed when the cable is
clamped in the terminal.
Conductor clamping Clamp the conductor in the terminal so that a minimum of
0.5 x the conductor diameter is on the far side of the clamping
screw.
Table 2. Cable specification for the external alarm-equipment connector

The following additional tools are required for this part of the procedure:
 Small flat-blade screwdriver
 11/16-inch spanner or a suitable adjustable spanner
 Connector sealing cap/assembly tool
Figure 2 identifies the parts of the external alarm-equipment connector, shows the order of
assembly, and gives wire preparation information.
G
F
E 79078
D
C
H
B
A
m
m
m
m
20
6
A. Locking ring E. Gland

B. Socket insert F. Gland cage
C. Locking cap G. Gland nut
D. Main body H. Sealing cap/assembly tool
Figure 2. Assembly of the VFC external alarm-equipment connector

IMPORTANT: Do not connect primary signals (> 42 VAC peak or 60 VDC) and low
voltage signals (< 42 VAC peak or 60 VDC) to the same external
connector.
FA48008
1 Use the sealing cap/assembly tool (H) to remove the connector locking ring (A).
2 Remove the socket insert (B) from the connector.
3 Feed the cable through the connector components in the order shown in Figure 2.
4 Cut and remove 20 mm of outer insulation from the cable, as shown in Figure 2.
5 Cut and remove 6 mm of insulation from each of the conductors, as shown in
Figure 2.
6 Insert the bare conductor ends into the terminals on the socket insert (B) according
to the pin-out information for the printer plug connector in the following
illustration. The conductors must be inserted into the terminals so that no more
than 2 mm of bare conductor is exposed when the cables are clamped in the
terminals (see Table 2 on page 5–130). Completely tighten the terminal screws.
79079
MAINS (VFC) EXTERNAL ALARM CONNECTOR
Signal Pin
Common L
L
Normally closed (NC) N
E
N
Normally open (NO) E
3-way plug connector

on the printer
Figure 3. VFC external alarm-equipment connector details

7 Carefully pull the cable back until the socket insert (B) is correctly fitted in the
D-shaped location in the main body (D).
8 Insert the locking ring (A) into the main body (D), and use the sealing cap/
assembly tool (H) to tighten the locking ring (A).
9 Slide the gland cage (F) and the gland (E) down the cable and into the main body
(D), and then tighten the gland nut (G). The gland nut must be completely
tightened so that the cable is correctly sealed and tightly gripped.
FA48008
Fuse replacement
When the VFC module is connected to external alarm equipment and to the printer, the
following warning is applicable.
WARNING: LETHAL VOLTAGE HAZARD. DANGEROUS VOLTAGES CAN EXIST IN THE

PRINTER WHEN IT IS DISCONNECTED FROM THE MAINS ELECTRICAL SUPPLY, AND A
MAINS-OPERATED EXTERNAL ALARM REMAINS CONNECTED TO THE VFC MODULE. THERE
CAN BE MAINS VOLTAGE WITHIN THE VFC MODULE UNDER THESE CONDITIONS.
DISCONNECT ALL MAINS ELECTRICAL POWER SOURCES BEFORE THE VFC MODULE
COVER IS REMOVED. DO NOT OPERATE THE VFC MODULE WITH THE COVER REMOVED.
WARNING IS IGNORED.
Relay RLA2
Relay RLA1 89269
Fuse F2 for relay RLA2
Fuse F1 for relay RLA1
Figure 4. VFC module fuses

the printer.
3 Disconnect any mains-operated external alarm from the VFC external connector.
5 Remove the two cover securing screws and the cover from the VFC module.
6 Replace fuse F1 or F2, or both fuses, as required.
7 Refit the module cover and the two cover securing screws. Do not over-tighten the
screws.
FA48008
Jet Alignment and Nozzle Cleaning
Parts required
FA73527 M2 x 6 Cap Head Socket Screw—Pack
Equipment required
FA29036 Mk9 Nozzle Alignment Tool—Mk2
Non-serrated Tweezers as required
FA900003 Solvent Cleaning Bottle
FA900005 Beaker 0.25 Litre
FA940003 Eyeglass x9 Magnification
Ultrasonic bath
Empty 0.5 litre ink bottle
Beaker, stainless steel or glass
Correct solvent for the printer as required
Procedures

THE EYES AND SKIN.
CAUTION: Printhead Damage. Extended contact with solvent can damage the printhead. Do
not put the printhead into solvent to clean it and do not use an ultrasonic bath. These incorrect
methods can cause damage to the printhead and can make the warranty invalid.
FA48008
Correct jet alignment
WARNING: LETHAL VOLTAGE HAZARD. IF THE ‘COVER OFF OVERRIDE’ LINK IS FITTED
AND THE PRINTHEAD COVER TUBE IS REMOVED, THE 300 VOLTS DC AND THE EHT TO THE
PRINTHEAD ARE NOT DISABLED. THERE IS A DANGER OF ELECTRIC SHOCK FROM THE
CHARGE ELECTRODE AND THE DEFLECTOR PLATES.
BEFORE THE JET ALIGNMENT IS EXAMINED OR ADJUSTED, MAKE SURE THAT THE ‘COVER
OFF OVERRIDE’ LINK IS NOT FITTED.
WARNING IS IGNORED.
Refer to the description of the Cover Off Override link on page 3—58 for more information.
touch the Jet Test-Start button to start the jet.
89275
Figure 1. Jet Test-Start option on the Jet Functions screen

3 Remove the printhead cover tube.
FA48008
4 Examine the alignment of the jet with a magnifying eyeglass. The jet must pass
exactly through the vertical centre of the charge electrode and enter the gutter, as
shown in the following illustration.
The jet must enter the

vertical centre of the gutter
50% 50%
50% The jet must enter

the horizontal centre
50% of the gutter
40026
The jet must pass exactly

through the centre of
the charge electrode
Figure 2. Correct alignment of the jet into the gutter
FA48008
5 Examine the jet to make sure that it is 90 degrees to the nozzle face (Figure 3).
Misaligned jet
For correct jet alignment,

this angle must be
90 degrees
40395
Figure 3. Correct alignment of the jet from the nozzle

6 If there is no jet or the jet is incorrectly aligned because of dried ink or deposits in
the nozzle, perform the following ‘Nozzle Clear sequence’ procedure.
Nozzle Clear sequence

1 Touch the Jet Test-Stop button to stop the jet.
2 Turn the printhead upside down and put absorbent, lint-free paper towel around
the area below the nozzle (see Figure 5).
3 Access the Maintenance screen (Main Menu > Maintenance) and touch the Nozzle
Clear button to start a Nozzle Clear sequence.
89280
Figure 4. Nozzle Clear option on the Maintenance screen

FA48008
4 While the Nozzle Clear sequence is in operation (26 seconds), apply small amounts
of solvent to the nozzle face (indicated by the arrow in Figure 5). Make sure that the
solvent is drawn in through the nozzle.
40160
Figure 5. Nozzle Clear sequence—solvent applied to the nozzle face

5 When the Nozzle Clear sequence has finished, access the Jet Functions screen
(Main Menu > Maintenance > Jet Functions) and touch the Jet Test-Start button to
try to start the jet.
6 Examine the alignment of the jet. If the jet is incorrectly aligned or there continues
to be a blockage in the nozzle, touch the Jet Test-Stop button to stop the jet.
7 Repeat steps 3 to 6 until the jet is 90 degrees to the nozzle face. That is, perform a
Nozzle Clear sequence with an attempt to start the jet made after each sequence. Do
not repeat this process more than a further seven times. The Nozzle Clear
sequence must not be performed more than a total of eight times.
8 If the jet is now correctly aligned, this maintenance instruction can be terminated.
Turn off the printer, and refit the printhead cover tube.
9 If after eight Nozzle Clear sequences there continues to be no jet or the jet remains
incorrectly aligned because of a blockage in the nozzle, perform the following
‘Nozzle soak’ procedure.
10 If the jet is now 90 degrees to the nozzle face (see Figure 3) but the jet is incorrectly
aligned into the gutter, use the ‘Nozzle realignment’ procedure on page 5—140.
FA48008
Nozzle soak
CAUTION: Contamination of the Printhead. Blockages and print failures can occur if
contamination is allowed to enter the printhead nozzle assembly or the gun chamber. The
following procedure must be performed in a clean, dust-free environment, and a special Clean
Room is recommended. Maximum caution must be used when the nozzle assembly is fitted.
The nozzle assembly must not touch any fibres, and contact with the skin must be prevented.
Wear powder-free protective gloves during the following procedure to prevent contamination
of the printhead nozzle assembly and the gun chamber. If the standard protective gloves that
contain powder are worn, powder contamination can enter the nozzle assembly and the gun
chamber.
1 Turn off the printer.
2 Remove the two securing screws from the nozzle cover and remove the cover.
3 Clean the printhead with solvent, and make sure that the nozzle and the area
around the nozzle are completely clean.
4 Remove the two M2 x 6 securing screws from the base plate of the nozzle assembly,
and remove the nozzle assembly and O-ring. Put the O-ring somewhere clean and
protected.
5 Put the nozzle assembly on a paper clip or equivalent device and hang the nozzle
assembly in a beaker (stainless steel or glass, not plastic) of solvent. Make sure that
the nozzle face is facing up (see Figure 6).
40242
Figure 6. The nozzle assembly hung in a beaker of solvent

6 Put the beaker in an ultrasonic bath with some water for 20 minutes.
7 Clean the printhead with solvent. Make sure that the area around the aperture on
the gun body is completely clean.
8 Clean the nozzle O-ring with solvent.
9 Put the printhead vertically in a clamp, face upwards.
10 Hold the O-ring in the tweezers and carefully put the O-ring onto the base of the
nozzle assembly.
11 Carefully put the nozzle assembly with the O-ring onto the gun body. Make sure
that the O-ring remains in position on the nozzle assembly. Also, make sure that the
orientation of the nozzle assembly is correct, which is indicated by the cut-out in
the nozzle base plate. The cut-out must be uppermost when the nozzle assembly is
fitted.
12 Loosely fit two new M2 x 6 securing screws (FA73527).
FA48008
13 Tighten the two securing screws alternately and equally. Do not over-tighten the
screws. Do not use the ball end of the hexagonal key to tighten the screws, as this type of
tool damages the screw heads.
touch the Jet Test-Start button to start the jet.
16 Check for correct jet alignment into the gutter, which is described in ‘Correct jet
alignment’ at the start of this maintenance instruction. If the jet is now correctly
aligned, perform the following subprocedure to finish this maintenance instruction:
(a) Carefully refit the nozzle cover and securing screws, but make sure that the jet
alignment is not changed.
(b) Touch the Jet Test-Stop button to stop the jet.
(c) Turn off the printer.
(d) Refit the printhead cover tube.
17 If the jet is not 90 degrees to the nozzle face (see Figure 3 on page 5—136), the cause
can be a large amount of conductive salts in the nozzle, and the nozzle must be
replaced.
18 If the jet is now 90 degrees to the nozzle face (see Figure 3 on page 5—136) but the
jet is incorrectly aligned into the gutter, use the ‘Nozzle realignment’ procedure on
page 5—140.
FA48008
Nozzle realignment
1 Remove the two securing screws from the nozzle cover and remove the cover (if the
cover is not already removed).
2 Fit the lower part of the nozzle alignment tool to the nozzle, as shown in Figure 7.
40244
Figure 7. Lower part of the nozzle alignment tool fitted to the nozzle
FA48008
3 Fit the upper part of the nozzle alignment tool to the nozzle, as shown in Figure 8.
40245
Figure 8. Upper part of the nozzle alignment tool fitted to the nozzle
4 Carefully apply force to the alignment tool to move the nozzle to correct the
alignment problem. Refer to the illustrations in Figure 9 and Figure 10 that show
the direction to move the tool to correct the example alignment problems. For jet
alignment to be correct, the position of the jet in the charge electrode and the gutter
must match the conditions shown in Figure 11 on page 5—144.
FA48008
Alignment Jet position Correction 40246

problem in the gutter method
(gutter shown
upside down)
Figure 9. Examples of nozzle alignment problems and correction methods—1
FA48008
Alignment Jet position Correction 40247

problem in the gutter method
(gutter shown
upside down)
Figure 10. Examples of nozzle alignment problems and correction methods—2
FA48008
40248 Correct vertical and

horizontal position in
the gutter
50% 50%
50%
50%
Figure 11. Correct nozzle alignment

5 Stop the jet and then use the Start Printing button on the Home screen to restart the
jet. Repeat this operation two more times to make sure that the jet alignment is
maintained. Make sure that the jet is in a stable state during the start and stop
sequences, and that no warning or fault messages are reported.
6 Carefully refit the nozzle cover and securing screws, but make sure that the jet
alignment is not changed.
8 Refit the printhead cover tube.
9 The ‘Jet Alignment and Nozzle Cleaning’ maintenance instruction is now
completed.
FA48008
Ink Conversion
Introduction
This maintenance instruction describes how to change an 8900 printer fitted with a Mk11
Midi 62 µm printhead from one ink type to another ink type. Refer to the ‘Ink Conversion
Tables’ document in the 'Customer Service > Documentation and Videos > Ink Tables'
section of ExtraLinx (http://www.extralinx.com/) for the allowed ink conversions.
When the printer is turned on, the printhead type, Reference Pressure and Reference
Modulation are automatically read from the printhead. The system adjusts these values as
required for the ink and solvent combination that is selected in step 4 of this maintenance
instruction.
Before an ink conversion is started, the full Decommissioning procedure must be used to
empty the printer of ink and solvent, and completely flush the ink system. The old service
module is discarded.
Parts required
FA11100 8900 IP55 Easi-Change Service Kit
New ink and solvent types
Equipment required
FA78501 Decommissioning Kit
Procedure

THE EYES AND SKIN.
FA48008
Ink Conversion

2 Access the Decommissioning option (Main Menu > Maintenance > Decommissioning).
When the a safety warning and decommissioning confirmation screen is displayed,
touch Yes to display the first instruction screen (Removing the Service Module).
89281
89296
Figure 1. Removing the Service Module screen

3 Touch the Prepare for SM removal button and use the on-screen step-by-step
instructions to completely flush and drain the ink system.
4 When the full decommissioning procedure has been completed, access the Ink/
Solvent Selection screen (Main Menu > Printer Setup > Installation > Ink/Solvent).
Select the correct ink type for the ink that the printer is being converted to.
89309
Figure 2. Ink/Solvent Selection screen
FA48008
Ink Conversion
5 Fit a cartridge of the new ink and a cartridge of the new solvent to the printer.
6 Access the Commissioning option (Main Menu > Maintenance > Commissioning)
and use the on-screen step-by-step instructions to fill the new service module with
ink, and prime the solvent and ink lines.
7 The ‘Ink Conversion’ maintenance instruction is now completed.
FA48008
Ink Conversion
FA48008
Stuck Printhead Gutter Valve Correction
Introduction
If an 8900 printer has not been operated for a number of weeks, the printhead can
sometimes have weak or no gutter suction. Weak gutter suction can be caused by a part
blockage in the venturi, which must be removed and cleaned, or sometimes replaced.
If there is no gutter suction, the plunger in the Printhead Gutter valve may be stuck in the
closed position caused by dried ink in the valve. This problem can easily be corrected by the
following procedure.
Equipment required
FA66062 Gutter/Venturi Removal Tool
1.5 mm hexagonal key
1 mm diameter (maximum) drill bit
Procedure

THE EYES AND SKIN.
WARNING: LETHAL VOLTAGE HAZARD. IF THE ‘COVER OFF OVERRIDE’ LINK IS FITTED
AND THE PRINTHEAD COVER TUBE IS REMOVED, THE 300 VOLTS DC AND THE EHT TO THE
PRINTHEAD ARE NOT DISABLED. THERE IS A DANGER OF ELECTRIC SHOCK FROM THE
CHARGE ELECTRODE AND THE DEFLECTOR PLATES.
BEFORE ANY MAINTENANCE WORK IS DONE ON THE PRINTHEAD WHILE MAINS
ELECTRICAL POWER IS APPLIED, MAKE SURE THAT THE ‘COVER OFF OVERRIDE’ LINK IS
NOT FITTED.
WARNING IS IGNORED.
1 Make sure that the Cover Off Override link is not fitted (header PL215, pins C on
the IPM Assembly).
2 Turn on the printer. Make sure that the printer is in the ‘Idle’ state.
FA48008
3 Access the Valve Test screen (Main Menu > Maintenance > Valve Test).
89311
Figure 1. Valve Test screen

4 Touch and hold the PH Gutter button. If the valve is operating correctly, a clicking
sound will be heard from the printhead as the valve turns on and off. This result
indicates that a blockage in the venturi is the probable cause of no gutter suction,
and this procedure can be discontinued.
If valve operation cannot be heard, it is probable that the valve plunger is stuck.
5 Remove the printhead cover tube.
6 Refer to Figure 2 and remove the four M2 x 6 pan head screws (B) from the
printhead end plate (A).
89310
A E
D
C
Figure 2. Removal of the printhead end plate

7 Use the 1.5 mm hexagonal key to remove the M2 x 6 cap head screw (C).
8 Remove the printhead end plate. If the end plate does not separate easily from the
printhead, use the gutter/venturi removal tool. Insert the tool into the threaded
hole (D) on the end plate and wind the tool in until the end plate separates from the
printhead.)
FA48008
9 Insert the shank end of a 1 mm maximum diameter drill bit (or equivalent size
device) into the Gutter valve aperture (E). Press carefully until the valve plunger
releases and spring resistance is felt.
10 When the valve plunger has been released, return to the Valve Test screen, touch
and hold the PH Gutter button, and make sure that the gutter valve operation can
be heard.
11 Refit the printhead end plate, four M2 x 6 pan head screws, and M2 x 6 cap head
screw.
12 Start the jet and make sure that the alignment of the jet is correct and that the ink is
being drawn correctly into the gutter.
13 Refit the printhead cover tube.
14 The ‘Stuck Printhead Gutter Valve Correction’ maintenance instruction is now
completed.
FA48008
FA48008
CHAPTER 6: SYSTEM EVENTS
6.1 Introduction
This chapter describes the system events that can occur on the 8900 printer. System events
are divided into four categories:
1. System Failures
2. Print Failures
3. System Warnings
4. Information Events
System Failures, Print Failures, and System Warnings are events that can occur when there
is a problem with the printer, and are not a direct response to operator commands.
Information events are not failures or warnings, but are events that are reported when
normal printer operating functions have occurred.
Each event message is given a unique code number, which identifies the type and source of
the event, and each number is followed by a short description, for example:
“3.16 Gutter Override Active”
When a system event occurs, the internal alarm tone is activated twice for each current
event. For example, if two events are reported at the same time, the alarm tone is activated
four times. The Faults & Warnings Notification screen is displayed for each event. This
screen gives a description of the event with the date and time that the event occurred (the
timestamp). If several system events are reported at the same time, the events are displayed
in the order they were detected, not in the order of severity. Therefore, the scroll buttons
must be used to show all the events that have occurred.
89104
Figure 6-1. Faults & Warnings Notification screen

A prompt icon is displayed to the left of the event description on the Faults & Warnings
Notification screen. System Failures and Print Failures have a red triangle icon, and System
Warnings have a yellow triangle icon. If the OK button is touched, the event message is
acknowledged and the interface returns to the screen that was displayed when the event
occurred.
While a fault or warning condition exists on the printer, the related prompt icon is
displayed on the right side of the title bar of every screen. These icons are a continuous
indication that there is a problem on the printer. A green circle is displayed when there are
no current faults or warnings on the printer.
FA48008
When the prompt icon is touched on any screen, the Current Faults & Warnings screen is
displayed. This screen shows only the current event conditions that exist on the printer, in
the date and time order that the events last occurred.
89243
Figure 6-2. Current Faults & Warnings screen

On-screen help is available from the Current Faults & Warnings screen if the event line is
touched. These help instructions are only for use by operators of the printer, and are not
applicable to maintenance technicians.
If the History button is touched on the Current Faults & Warnings screen, the Faults &
Warnings History screen is displayed. This screen shows all the faults and warnings that
have occurred, with their timestamps, in date and time order. The Current button returns
the display to the Current Faults & Warnings screen.
If the Exit key is touched on the Current Faults & Warnings screen, the interface returns to
the screen that was displayed when the prompt icon was touched.
NOTE: If the Current Faults & Warnings screen or the Faults & Warnings History screen
is displayed and another system event occurs, the Faults & Warnings Notification
screen is not displayed. Instead, the event is added to the list on the displayed
screen.
FA48008
6.2 System event types
6.2.1 System Failures
These failures prevent normal printer operation.
6.2.2 Print Failures

These failures prevent printing.
6.2.3 System Warnings

These events are not serious enough to shut down the printer, but give an early warning of
potential problems.
6.2.4 Information events

Information events advise the operator about normal operating functions. These events are
not displayed on the Faults & Warnings Notification screen, but the events are logged on
the Faults & Warnings History screen. All of the possible information events are shown in
the following list:
 4.00 Jet Test-Start
 4.01 Jet Test-Stop
 4.02 Normal Start
 4.03 Normal Stop
 4.20 Solvent Added
 4.21 Ink Added
 4.22 Service Module Low
 4.23 Printing
 4.24 Powerup
 4.25 Filling Up
 4.27 Shutdown Incomplete (Failure)
 4.28 Internal Software Failure
 4.29 Powerdown
 4.30 Solvent Buffer Tank Low
 4.31 Printer Door Open
FA48008
6.3 Summary of system events
System Failures Print Failures System Warnings
1.03 Internal S/W Failure 2.00 Printhead Over Temperature 3.00 Shutdown Incomplete
(ASSERT)
1.40 EHT Board Missing 2.01 EHT Trip 3.05 Overspeed (Print Trigger)
1.42 I C Bus Failure
2
2.02 Phase Failure* 3.06 Overspeed (Synchronous Data)
1.43 Watchdog Trip 2.03 Time Of Flight Failure* 3.07 Overspeed (Asynchronous Data)
2.07 Internal Spillage 3.08 Overspeed (Line Speed)
2.08 Printer Over Temperature 3.09 Overspeed (Compensation)
2.09 Misaligned Ink Jet* 3.10 Under Speed (Line Speed)
2.11 Pressure Limit Reached* 3.12 Printhead Cover Off
2.12 Viscosity Out of Range* 3.13 Cover Override Active
2.20 Ink System Empty 3.15 Safety Override Active
2.21 Service Module Removed 3.16 Gutter Override Active
2.23 Charge Amplifier Trip 3.17 Gate Array Test Mode Active
2.24 Memory Low 3.18 Low Pressure
2.25 Memory Storage Low 3.24 Restart In Progress
2.26 Modulation Amplifier Trip 3.29 Overspeed (No Remote Data)
2.27 Service Module Requires Replacement 3.30 Remote Error
2.28 Valid UNIC Chip Not Found 3.40 Service Module Requires Replacement
2.29 Pump Drive Failure 3.41 Service Module Removed
2.30 Pressure Reading at Maximum 3.42 Service Module Requires Commissioning
2.31 Pressure Reading Suspect 3.43 Memory Low
2.32 Pressure Reading at Minimum 3.44 Memory Storage Low
2.33 Valve Drive 1 Failure 3.45 Service Module Replacement Due Within
One Month
2.34 Valve Drive 2 Failure 3.46 Pump Pressure Failure
2.35 Pump Stalled 3.47 Pump RPM Failure
2.43 Solvent System Empty 3.48 Pump RPM Limit Reached
3.49 Pump Current Limit Exceeded
3.50 Valve Supply
3.51 Pump Oscillating
3.52 Pump Power Limit Reached
3.56 Printhead Over Temperature
3.57 EHT Trip
3.58 Internal Spillage
3.59 Low Battery
3.60 Reset System Clock
3.65 Reverted To System Settings From
Last Successful Powerdown
3.66 System Settings Not Found, Reverted
To Defaults
3.68 Field Truncation
3.69 Remote Field Not Found
3.71 Jet Start Failure – Do Not Switch Off!
3.73 Ink Cartridge Not Found
3.74 Solvent Cartridge Not Found
3.77 Ink Cartridge Empty
Table 6-1. Summary table of system events
FA48008
System Failures Print Failures System Warnings
3.78 Solvent Cartridge Empty
3.79 Invalid Ink Cartridge
3.80 Invalid Solvent Cartridge
3.81 Ink Cartridge Expired
3.82 Solvent Cartridge Expired
3.83 Wrong Ink Type
3.84 Wrong Solvent Type
3.85 Easi-Change Service Key Not Found
3.86 Invalid Easi-Change Service Key
3.87 Easi-Change Service Key Already
Used
Table 6-1. Summary table of system events (continued)
*When the Jet Test-Start function is used, detection of these Print Failures is disabled.
FA48008
6.4 System Failures
System Failures occur when the software detects a condition that prevents further operation
of the printer. The printer must be restarted to clear the failure.
Most System Failures are reported while the software is initializing and the self-test startup
routines are being run. These processes are performed after the printer is turned on and
while the splash screen is displayed. The Home screen is displayed after the software
initialization and all the self tests have been completed.
WARNING: LETHAL VOLTAGE HAZARD. BECAUSE THE SYSTEM FAILURE “1.03 INTERNAL
SOFTWARE FAILURE” INDICATES A FAILURE IN THE MICROPROCESSOR, THE SOFTWARE
CANNOT BE DEPENDED ON TO SET THE PRINTER TO A SAFE STATE. THE EHT AND THE
300 VOLTS DC CAN CONTINUE TO BE GENERATED IN THE PRINTER.
MAXIMUM CAUTION MUST BE USED WHEN WORK IS DONE ON THE PRINTER WHILE THE
SYSTEM FAILURE “1.03 INTERNAL SOFTWARE FAILURE” EXISTS AND THE COVER IS
REMOVED. THE CORRECT, STANDARD ELECTRICAL SAFETY PRECAUTIONS MUST BE TAKEN.
WARNING IS IGNORED.
System Failures that occur during normal operation indicate major problems that prevent
continued printer operation. When the failure occurs, the software tries to set the printer to
a safe state with the following actions:
 Set the pressure to zero.
 Turn off the EHT.
 Close all valves.
 Turn off the 300 V DC.
System Failures immediately close the ink system and printhead Feed valves, which causes
printing to stop. A normal jet shutdown is not performed. This action can cause incorrect jet
alignment at the next startup, which can put ink onto the charge electrode and deflector
plates. Other failures can occur if these components are not cleaned with solvent to remove
the ink. If the printhead is left in this dirty condition, a lot of work can be required to
remove the dried ink deposits to correct a problem.
When a System Failure occurs, the internal alarm tone is activated twice and the Faults &
Warnings Notification screen is displayed. The external alarm is not activated because the
software cannot be sure of the ‘alarm enable’ state after some System Failures.
6.4.1 “1.03 Internal Software Failure”

This software failure is not defined. The failure message indicates that the software received
a signal that has errors, and the software was reset to a state that is not defined. If this
failure occurs, the fault is normally detected when the printer is in operation, after
successful completion of the startup system checks.
Possible causes:
 Software errors.
 A fault on the IPM Assembly.
 The printer rear cover is not correctly fitted or the printhead cover tube screw is not fitted.
 Dirty IPM Assembly caused by a damaged or missing air inlet filter.
 A large amount of EMC interference or spikes on the mains electrical supply.
 Static discharge to the printhead from the operating environment.
 A fault in the electrical connections.
FA48008
6.4.2 “1.40 EHT Board Missing”
Possible causes:
 The HVPM is not installed or is not correctly connected.
 An I2C fault on the IPM Assembly, or HVPM.
 The fuse on the HVPM PCB has failed.
 A fault in the 300 volts PSU in the HVPM.
6.4.3 “1.42 I2C Bus Failure”

This System Failure applies to the main system bus where the main processor is the master.
The main system bus runs around the IPM Assembly and to the high voltage power
module (HVPM) and the pump controller.
Possible causes:
 An I2C fault on the IPM Assembly, or HVPM.
 The fuse on the HVPM PCB has failed.
 An I2C cable fault between the IPM Assembly and the HVPM.
 A related cable fault.
6.4.4 “1.43 Watchdog Trip”

The watchdog is a hardware monitor that sets the system to a safe state if the software does
not write to the watchdog at regular intervals.
This failure is most likely to occur when the system crashes, and so the operator will not see
any fault reported anyway. The failure can also occur if the system is very busy and the
software does not have time to write to the watchdog.
If the failure occurs, the system must be turned off and turned on again to clear the failure.
FA48008
6.5 Print Failures
Print Failures occur when the software detects an electrical or mechanical failure that
prevents printing. When a Print Failure occurs, the internal alarm tone is activated twice,
the Faults & Warnings Notification screen is displayed, and a jet shutdown sequence is
started. The external alarm might be activated continuously, but this action depends on the
settings of the Alarm Setup options (Line Settings > Alarms).
Some Print Failures require a hardware reset before printing can continue (although some
message editing functions can remain available). To reset the hardware, the printer must be
turned off at the mains electrical supply switch and then turned on again. When these Print
Failures occur, the printer conditions cannot be changed until the hardware has been reset,
that is, the jet cannot be restarted. However, most Print Failures start a Normal Shutdown
sequence, and the jet can be restarted normally without the requirement to turn the printer
off and on again.
During a Print Failure shutdown, the software performs the following actions:
 Set the pressure to zero.
 Turn off the EHT.
 Close all valves in sequence.
 Turn off the 300 V DC.
6.5.1 “2.00 Printhead Over Temperature”
WARNING: HIGH TEMPERATURE HAZARD. WHEN THIS FAULT IS REPORTED, THE

PRINTHEAD AND COVER TUBE CAN BE VERY HOT.
MAXIMUM CAUTION MUST BE USED TO PREVENT SKIN BURNS AND TO DECREASE THE
RISK OF A FIRE. DO NOT TOUCH THE PRINTHEAD, OR TRY TO REMOVE THE PRINTHEAD
COVER TUBE UNTIL THE PARTS BECOME SAFELY COOL NATURALLY.
THERE IS A DANGER OF SEVERE BURNS TO THE HANDS IF THE PRINTHEAD COVER TUBE
IS REMOVED BEFORE IT HAS BECOME SAFELY COOL. THERE IS ALSO AN INCREASED RISK
OF FIRE CAUSED BY THE SUDDEN INCREASE OF AIR AROUND THE OPEN PRINTHEAD.
A temperature greater than 63 C has been detected at the printhead that indicates a high
ambient temperature or a possible fire condition.
Possible causes:
 The printhead is too close to the source of high temperature.
 Short circuit temperature sensor on the printhead PCB.
 Short circuit connection on the printhead connector.
NOTE: Hot substrates must be printed on from the side to prevent heat convection to the
printhead.
See also: System Warning ‘“3.56 Printhead Over Temperature”’
FA48008
6.5.2 “2.01 EHT Trip”
The EHT trip-sense software has detected that an EHT trip has occurred, that is, the EHT
output from the HVPM has been turned off.
Possible causes:
 A large amount of ink build-up on the EHT deflector plates.
 Satellite drops caused by high or low ink viscosity, which have collected on the
deflector plates.
 The ink has caused a short circuit between a deflector plate and another component in
the printhead, for example, the gutter.
 Static discharge.
 High humidity.
 Vibration.
 Unstable jet caused by contaminated ink or contamination in the nozzle.
 The printhead is too close to the substrate.
 There is no modulation.
 A fault on the printhead.
 A fault on the EHT power supply in the HVPM.
 A cable fault between the IPM Assembly and the HVPM.
 An EHT cable fault.
See also: System Warning ‘“3.57 EHT Trip”’
6.5.3 “2.02 Phase Failure”

The printer cannot find a valid phase position. This failure is normally connected with
invalid data from the hardware and can be caused if the printhead becomes very dirty with
ink, particularly around the CETOF assembly.
When the jet is operating, the printer adjusts the phase position to make sure that the
correct charge is applied to the drops to give a good print.
A phase failure occurs if the microprocessor has not received a phase feedback signal to
indicate the true phase position. If the phase position is not found after a set period of time,
the printer fails and performs a normal jet shutdown.
Possible causes:
 No jet:
 Nozzle blockage.
 There is no ink supply to the printhead (Ink System Feed valve failure).
 Low-quality jet break-up:
 Ink viscosity is too high or too low.
 The Reference Modulation is set very low.
 The modulation is too high or too low.
 There is no modulation signal.
FA48008
 Incorrect jet alignment:
 Part blockage in the nozzle.
 Contamination in the nozzle.
 Contaminated ink.
 Incorrect mechanical alignment.
 An obstruction to the ink jet, for example, a fine hair in the charge electrode slot.
 A fault on the Purge valve.
 Incorrect line setup.
 There is no charge to the charge electrode caused by bad connections, a fault on the
charge amplifier, or an incorrect charge DAC calibration.
 The printhead modulation cable is disconnected from the HVPM PCB. This fault will
also report the Print Failures ‘“2.03 Time Of Flight Failure”’and ‘“2.12 Viscosity Out of
Range”’.
 The printhead charge cable is disconnected from the IPM Assembly (SK200). This fault
will also report the Print Failures ‘“2.03 Time Of Flight Failure”’ and ‘“2.12 Viscosity
Out of Range”’.
 The ink system pump cable is disconnected from the IPM Assembly (PL200). This fault
will also report the Print Failures ‘“2.03 Time Of Flight Failure”’ and ‘“2.12 Viscosity
Out of Range”’, and the System Warning ‘“3.18 Low Pressure”’.
 A fault on the TOF amplifier in the printhead.
 A fault on the gate array circuitry on the IPM Assembly.
 Electrical conduction problems caused by contaminated ink.
 Heavy deposits of ink on the CETOF assembly.
 EHT tracking on the printhead, caused by very humid operating environments.
 A fault on the pressure transducer.
 A blockage in the restrictor fitted near the damper.
 A fault on the pump.
 A fault on the damper.
 A fault on the service module.
 A fault on the printhead PCB.
 A cable fault between the IPM Assembly and the printhead.
NOTES:
1. This failure detection is disabled when the Jet Test-Start function is used.
2. It is very unlikely that the 8900 printer will continue to detect phase while not
detecting Time of Flight.
FA48008
6.5.4 “2.03 Time Of Flight Failure”
After the jet has started, this failure occurs if there are no valid TOF readings for a period of
40 minutes.
Possible causes:
 Incorrect or no signal from the TOF sensor caused by a part blockage in the nozzle or
incorrect jet alignment.
 Incorrect drop break-off caused by incorrect modulation or ink viscosity.
 The ink viscosity is so far out of range that correctly measured TOF values are
considered random readings and are rejected.
 Heavy deposits of ink on the CETOF assembly.
 Noise (EMC) interference.
 The inter-print distance is too small to allow TOF measurement.
 A fault on the TOF amplifier in the printhead.
 A fault on the gate array or PIC circuitry on the IPM Assembly.
 Electrical conduction problems caused by contaminated ink.
 EHT tracking on the printhead, caused by very humid operating environments.
also report the Print Failures ‘“2.02 Phase Failure”’ and ‘“2.12 Viscosity Out of Range”’.
will also report the Print Failures ‘“2.02 Phase Failure”’ and ‘“2.12 Viscosity Out of
Range”’.
will also report the Print Failures ‘“2.02 Phase Failure”’ and ‘“2.12 Viscosity Out of
Range”’, and the System Warning ‘“3.18 Low Pressure”’.
 A blockage in the restrictor fitted near the damper.
 A fault on the printhead PCB.
 An I2C cable fault between the IPM Assembly and the printhead.
NOTE: This failure detection is disabled when the Jet Test-Start function is used.
FA48008
6.5.5 “2.07 Internal Spillage”
The spillage tray contains any ink or solvent spillage, which prevents fluid leaks from the
printer. If a pressurized ink leak occurs from an ink system pipe or component (for
example, the manifold assembly, or pump), spillage detectors stop the pump within 5
seconds of detection. There is no jet shutdown.
There is a detector fitted through (but insulated from) the floor of the stainless steel spillage
tray. When a spillage occurs, a short circuit is made between the detector and the tray
through the conductive fluid. This short circuit is detected on the IPM Assembly and
generates the System Failure ‘“2.07 Internal Spillage”’.
Possible causes:
 An overflow from the solvent tank.
 Incorrect ink refill procedure.
 A leak in the ink system.
 A fault in the spillage detection circuit on the IPM Assembly.
 A short circuit between the spillage detector and the spillage tray.
See also: System Warning ‘“3.58 Internal Spillage”’
6.5.6 “2.08 Printer Over Temperature”

This failure occurs if the maximum internal temperature of the printer cabinet is reached.
The temperature threshold of the cooling failure detection circuit is 75 °C.
Possible causes:
 A blockage in the air filter.
 Cooling fan failure, caused by any of the following:
 A fault in the electrical connections to the fan.
 Fan blade obstruction.
 A fault in the fan control-circuit.
 Fire within the printer cabinet.
 Short circuit in the printer thermistor on the IPM Assembly.
FA48008
6.5.7 “2.09 Misaligned Ink Jet”
The gutter sense circuit detects the flow of ink in the gutter. If ink flow is not detected in the
gutter for any reason (for example, an incorrectly aligned jet), the software shuts down the
jet with a quick stop sequence and reports this fault.
Under normal operating conditions with the jet running, a loss of ink in the gutter is
detected after approximately 20 seconds. During a Normal Start, a loss of ink in the gutter is
detected after approximately 3 seconds.
Gutter sense operation is disabled when the Jet Test-Start function is used.
Possible causes:
 Contamination in the nozzle.
 Part blockage in the nozzle.
 Blockage in the gutter.
 Contaminated ink.
 Incorrect mechanical alignment.
 An obstruction to the ink jet, for example, a fine hair in the charge electrode slot.
FA48008
6.5.8 “2.11 Pressure Limit Reached”
The software cannot increase the pressure enough to get a TOF measurement equal to the
Reference TOF. This failure can occur while the jet is in operation, that is, in the
‘Jet Running’ and ‘Printing’ states.
Possible causes:
 A large amount of ink on the TOF and phase sensors
 A blockage in the ink feed filter or the Service Module ink filter.
 The Purge valve or Gutter valve is leaking.
 A fault on the Solvent Add valve.
 A stuck Vent valve.
 Very high ink viscosity.
 There is no modulation.
 There is no charge voltage.
 A worn or damaged pump.
 The pressure transducer calibration value is incorrect.
 Incorrect printhead type selected.
 Large amount of noise on the phase signal or the TOF signal.
 A fault on the HVPM.
6.5.9 “2.12 Viscosity Out of Range”

The software cannot set Reference TOF at or below the Solvent Add Pressure. The printer
has added solvent 120 times without being able to adjust the pressure to below the Solvent
Add Pressure.
When the jet is operating, the normal TOF adjustment routine can add solvent if the Solvent
Add conditions are met (refer to Chapter 3: Technical Description > Ink system > Ink and
solvent flows > Solvent addition). A Solvent Add sequence allows a fixed amount of solvent
to be added to the service module. Normally, it takes approximately 3 minutes for the full
effect of the solvent addition to be seen at the nozzle.
After a solvent addition, the pressure is adjusted to control TOF. However, if after
2 minutes the pressure remains greater than the Solvent Add Pressure, a further solvent
addition is allowed. This addition is repeated until the pressure is below the Solvent Add
Pressure. A maximum limit of 25 solvent additions is allowed in any one TOF correction
loop. If the pressure has not decreased after this limit is reached, this failure is reported and
the jet is shut down.
FA48008
Possible causes:
 There is a leak from the Purge valve or Gutter valve.
 A fault on the Ink Add valve.
 A fault on the Solvent Add valve.
 A stuck Vent valve.
 A blockage in the solvent tank filter.
 There is a loss of pressure in the ink system and the pressure has been set to a high
artificial level to try to reach the Reference TOF. The result is that the number of solvent
additions can be more than the maximum limit, which causes this fault to be reported.
 A fault on the solvent tank level sensor or wiring.
 A fault on the solvent tank level float.
also report the Print Failures ‘“2.02 Phase Failure”’ and ‘“2.03 Time Of Flight Failure”’.
will also report the Print Failures ‘“2.02 Phase Failure”’ and ‘“2.03 Time Of Flight
Failure”’.
will also report the Print Failures ‘“2.02 Phase Failure”’ and ‘“2.03 Time Of Flight
Failure”’, and the System Warning ‘“3.18 Low Pressure”’.
 A fault on the HVPM.
 An I2C cable fault between the IPM Assembly and the printhead.
 A cable fault between the IPM Assembly and the pump.
6.5.10 “2.20 Ink System Empty”

If the ‘“3.77 Ink Cartridge Empty”’ event is detected while the jet is operating, the jet
continues for a period of time until the ink level in the service module is critically low, and
then the printer fails with the ‘“2.20 Ink System Empty”’ event. The period of time is
variable and depends on the environmental temperature and the rate of ink use, but is a
maximum of 12 hours.
This failure prevents the ink from being used completely, which can damage the pump if
the operator does not replace the ink cartridge when the ‘“3.77 Ink Cartridge Empty”’
warning occurs. This failure only occurs when the jet is operating, because the jet cannot
normally be started when the ink cartridge is empty.
FA48008
Possible causes:
 Ink cartridge not replaced.
 A fault on the service module level sensor or wiring.
 A fault on the service module level float.
 A fault on the transfer pump.
6.5.11 “2.21 Service Module Removed”

This failure occurs if the service module is removed from the printer when the jet is in the
‘Jet Running’ or ‘Printing’ states.
The event is triggered by a location sensor, which detects that the service module is not
fitted or is not correctly fitted.
Possible causes:
 The service module is not fitted.
 A fault on the service module (for example, the magnet is misaligned or not fitted).
 A fault on the service module location sensor or wiring, or the module is not completely
inserted.
See also: System Warning ‘“3.41 Service Module Removed”’
6.5.12 “2.23 Charge Amplifier Trip”

The Charge Amplifier Trip failure occurs when the 300 volts supply for the charge amplifier
in the printhead fails. This 300 volts is the same supply that the modulation amplifier in the
HVPM uses, so if one amplifier supply trips, both amplifiers are disabled. However, each
trip is reported individually.
Possible causes:
 A fault on the charge amplifier in the printhead.
 A short circuit (complete or part) in the printhead conduit or other related wiring.
 A fault in the 300 volts trip circuit for the charge amplifier in the HVPM.
 Ink contamination of the printhead charge electrode.
FA48008
6.5.13 “2.24 Memory Low”
This failure indicates that the amount of available random access memory (RAM) is very
low. The system software uses the RAM to operate, and this failure is reported when the
RAM use reaches 90%.
This failure can occur if the system software uses more than the normal amount of RAM.
If the failure occurs, the printer can be restarted to correct the problem.
See also: System Warning ‘“3.43 Memory Low”’
6.5.14 “2.25 Memory Storage Low”

This failure indicates that the amount of storage space left in the flash memory is very low.
When the flash memory use reaches 95%, this failure occurs.
The failure can occur if there are many messages or logos stored in the system. The operator
can delete some messages or logos to correct this problem.
6.5.15 “2.26 Modulation Amplifier Trip”

The Modulation Amplifier Trip failure occurs when the 300 volts supply for the modulation
amplifier fails. This 300 volts is the same supply that the charge amplifier in the printhead
uses, so if one amplifier supply trips, both amplifiers are disabled. However, each trip is
reported individually.
Possible causes:
 A fault on the modulation amplifier in the HVPM.
 A short circuit (complete or part) in the printhead conduit or other related wiring.
 A fault in the 300 volts trip circuit for the modulation amplifier in the HVPM.
 A fault in the printhead modulation crystal.
6.5.16 “2.27 Service Module Requires Replacement”

The time that remains to the next replacement of the service module is monitored. This
interval is measured in days and jet operating hours from the time that the service module
was installed. The times are shown on the Maintenance Times screen (Main Menu >
Maintenance > Maintenance Times > Maintenance Due Within and Maintenance Due By).
Refer to ‘Maintenance Times’ on page 5—18.
When one of the following conditions occurs, this fault is reported:
 The Maintenance Due Within time is more than 3 months of calculated jet operation
past the replacement time (zero hours).
or
 The current date is more than 3 months past the Maintenance Due By date.
Printing is prevented until the service module is replaced and the Maintenance Due
Within time and the Maintenance Due By date are reset. A prompt message is also
displayed every 24 hours until the service module is replaced.
See also: System Warning ‘“3.40 Service Module Requires Replacement”’.
FA48008
6.5.17 “2.28 Valid UNIC Chip Not Found”
The ID chip on the IPM Assembly is missing, cannot be identified, or is not operating
correctly. The printer cannot print when this fault exists.
6.5.18 “2.29 Pump Drive Failure”

The drive chip for the pump motor has reported a number of occurrences where the
short-term current limit was exceeded, or a single Hall-effect sensor in the pump motor had
failed. Normally, the short-term current limit is exceeded for a maximum of 5 seconds
during each startup. This event is reported each time that the fault continues for more than
5 seconds.
Possible causes:
 Very thin ink or very thick ink.
 The pump cannot rotate or the rotation is not smooth.
 A short circuit on a motor winding or pump cableform.
 A fault on the pump motor (Hall-effect sensor).
 An open circuit on the pump cableform.
6.5.19 “2.30 Pressure Reading at Maximum”

The pressure transducer indicates a voltage that is above specification at a power-up or
reset. If this event is reported, the CPU cannot use pressure mode control.
Possible causes:
 A fault on the pressure transducer cableform.
 An ink system blockage.
6.5.20 “2.31 Pressure Reading Suspect”

The pressure transducer indicates an unexpected pressure at a power-up or reset. If this
event is reported, the CPU cannot use pressure mode control.
Possible causes:
 An ink system blockage.
6.5.21 “2.32 Pressure Reading at Minimum”

The pressure transducer indicates a voltage that is below specification at a power-up or
reset. If this event is reported, the CPU cannot use pressure mode control.
Possible causes:
 A fault on the pressure transducer cableform.
FA48008
6.5.22 “2.33 Valve Drive 1 Failure”
The No. 1 valve driver chip has reached a current limit. This chip drives the Ink System
Feed, Solvent Add, Purge, and Ink Add valves, and so these four valves will not operate.
Possible causes:
 A short circuit on a valve.
 A short circuit on the valve cableform.
6.5.23 “2.34 Valve Drive 2 Failure”

The No. 2 valve driver chip has reached a current limit. This chip drives the Solvent Prime
valve and the printhead valves, and so these valves will not operate.
Possible causes:
 A short circuit on a valve.
 A short circuit on the valve cableform.
 A short circuit in the printhead conduit.
6.5.24 “2.35 Pump Stalled”

The printer cannot detect any pump rotation, although a drive voltage exists. This event
helps to identify the cause of a pressure or rpm failure.
Possible causes:
 A short circuit or open circuit on a motor winding.
 The ink system pump cable is disconnected from the IPM Assembly (PL200).
 A fault on the pump cableform.
6.5.25 “2.43 Solvent System Empty”

If the ‘“3.78 Solvent Cartridge Empty”’ event is detected while the jet is operating, the jet
continues for a period of time until the solvent level in the solvent tank is critically low, and
then the printer fails with the ‘“2.43 Solvent System Empty”’ event. The period of time is
variable and depends on the environmental temperature and the rate of solvent use, but is a
maximum of 12 hours.
This failure only occurs when the jet is operating, because the jet cannot normally be started
when the solvent is low.
Possible causes:
 Solvent cartridge not replaced.
 A fault on the solvent tank level sensor or wiring.
 A fault on the solvent tank level float.
FA48008
6.6 System Warnings
System Warnings advise the operator of potential problems that can have an effect on the
operation of the printer, but are not serious enough to require a shutdown. When a System
Warning event occurs, the internal alarm tone is activated twice and the Faults & Warnings
Notification screen is displayed. The external alarm might be activated twice, but this
action depends on the settings of the Alarm Setup options (Line Settings > Alarms).
6.6.1 “3.00 Shutdown Incomplete”

The printer was turned off before the shutdown sequence was completed or started.
This warning is reported at printer power-up. The warning indicates that the last time that
the printer was turned off, the jet was running or the printer had not completed the
shutdown sequence. The warning is repeated at every printer power-up until a full
jet-shutdown sequence is completed.
The following printer problems can occur at startup if the shutdown sequence was not
completed:
 A blockage in the nozzle.
 A dirty start.
 An incorrectly aligned jet.
6.6.2 “3.05 Overspeed (Print Trigger)”

Print triggers occurred faster than the printer can print. This warning indicates that the
printer received a second or false print trigger (and the delay expired) while it was still
printing the current message.
When the Print Trigger option (Line Settings > Advanced > Print Trigger) is set to an edge
or level trigger, each print delay is started after the trigger signal. A Print Go signal is
generated to start printing at the end of the delay. If the printer does not print the last
message before the delay ends, this warning is reported and the new message is not
printed. The result can be that there is no message printed on every second object.
Possible causes:
 The trigger device is providing false triggers because of electrical noise, or an incorrect
trigger device is being used in the application.
 The distance from the trigger device to the printhead is greater than the distance from
one product to the next.
 Incorrect message length.
FA48008
6.6.3 “3.06 Overspeed (Synchronous Data)”
A Print Go signal was received before the printer could generate the message data, and the
printer can fail to print the message. When this warning is reported, the printer can fail to
print one message but printing continues.
This warning indicates that one or more messages did not print because the printer did not
have time to generate the variable data of the message (for example, sequential numbers)
before the next Print Go signal. That is, the next Print Go signal was received while the
printer was generating the print data for the next message.
NOTE: This warning indicates that the printer cannot generate the print data fast enough,
compared with the System Warning ‘“3.05 Overspeed (Print Trigger)”’, which
indicates that the printer cannot print the rasters fast enough.
Possible causes:
 The amount of variable data in the message is too large for the current rate of print
triggers.
 False triggers from the trigger device.
6.6.4 “3.07 Overspeed (Asynchronous Data)”

A Print Go signal was received before the printer could generate the message data for an
asynchronous event. The message can be printed with missing asynchronous data.
An asynchronous command can be received while printing is in progress, which tries to
change the printed message. For example, invert or reverse the message. The software
considers that the data has not been received and can ignore the command, but this
response depends on the software setting. If the command is ignored, the printer continues
to print the previous message.
Possible causes:
 The printer received a command to change the message during the delay time.
 ‘Time change’ related data (a sequential message with a time trigger) changed after the
delay time started.
6.6.5 “3.08 Overspeed (Line Speed)”

The production line is moving too fast to allow the printer to generate the raster. Normally,
this problem occurs because the shaft encoder is generating more pulses than the gear ratio
has been calculated for. The gear ratio calculation uses the pulses per mm (Encoder Pitch)
setting and the Print Width setting.
Possible causes:
 The shaft encoder gear ratio is too big.
 The shaft encoder gear wheel is too small compared to the pulses per mm (Encoder
Pitch) setting.
 The production line speed is faster than the maximum speed for the message style
(raster).
FA48008
6.6.6 “3.09 Overspeed (Compensation)”
This warning message is like ‘“3.08 Overspeed (Line Speed)”’. The production line is
moving too fast, or the print delay is too short to perform line speed compensation.
Possible causes:
 The Print Delay setting is too small.
 The shaft encoder gear ratio is too big.
 The shaft encoder gear wheel is too small compared to the pulses per mm (Encoder
Pitch) setting.
 The production line speed is faster than the maximum speed for the message style
(raster).
6.6.7 “3.10 Under Speed (Line Speed)”

The Print Width value is too big, which causes the shaft encoder counter to register more
than the maximum value.
Possible causes:
 The shaft encoder gear ratio is too small.
 The shaft encoder gear wheel is too big.
 The production line is moving too slowly or has stopped.
6.6.8 “3.12 Printhead Cover Off”
WARNING: LETHAL VOLTAGE HAZARD. WHEN THE ‘COVER OFF OVERRIDE’ LINK IS FITTED
AND THE PRINTHEAD COVER TUBE IS REMOVED, 300 VOLTS DC CONTINUES TO BE
SUPPLIED TO THE CHARGE ELECTRODE. THE EHT ALSO CONTINUES TO BE SUPPLIED TO
THE DEFLECTOR PLATES.
THE CORRECT, STANDARD ELECTRICAL SAFETY PRECAUTIONS MUST BE TAKEN WHEN
WORK IS DONE ON THE PRINTHEAD WITH THE ‘COVER OFF OVERRIDE’ LINK FITTED AND
WITH THE COVER TUBE REMOVED. DO NOT FIT THE LINK PERMANENTLY AND DO NOT
LEAVE THE PRINTER UNATTENDED WHILE THE LINK IS FITTED.
WARNING IS IGNORED.
This warning is reported if the printhead cover tube is removed. When the cover tube is
removed, the ±4.4 kV EHT supply to the deflector plates is automatically turned off and
printing is paused. Printing is restarted between 1 and 2 seconds after the cover tube is
refitted. The red strobe LED also illuminates when the cover tube is removed.
See also: System Warning ‘“3.13 Cover Override Active”’.
‘Printhead cover tube detection’ on page 3—11.
FA48008
6.6.9 “3.13 Cover Override Active”
WARNING: LETHAL VOLTAGE HAZARD. WHEN THE ‘COVER OFF OVERRIDE’ LINK IS FITTED
AND THE PRINTHEAD COVER TUBE IS REMOVED, 300 VOLTS DC CONTINUES TO BE
SUPPLIED TO THE CHARGE ELECTRODE. THE EHT ALSO CONTINUES TO BE SUPPLIED TO
THE DEFLECTOR PLATES.
WARNING: THE CORRECT, STANDARD ELECTRICAL SAFETY PRECAUTIONS MUST BE
TAKEN WHEN WORK IS DONE ON THE PRINTHEAD WITH THE ‘COVER OFF OVERRIDE’ LINK
FITTED AND WITH THE COVER TUBE REMOVED. DO NOT FIT THE LINK PERMANENTLY AND
DO NOT LEAVE THE PRINTER UNATTENDED WHILE THE LINK IS FITTED.
WARNING: THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS
SAFETY WARNING IS IGNORED.
This warning is reported if the Cover Off Override link is fitted on the IPM Assembly.
When this software-readable link is fitted, the EHT and charge voltages remain on while the
printhead cover tube is removed (that is, the voltages are not automatically disabled). This
condition allows the printing to continue for fault diagnosis purposes. The red strobe LED
is also illuminated. After the printhead cover tube is removed, and then the link is fitted (or
the printhead cover tube is refitted), there is a delay of between 1 and 2 seconds before
printing restarts.
NOTE: The presence of the Cover Off Override link must be confirmed with the Printhead
Cover Override option on the Installation screen. Refer to ‘Pins C Cover Off
Override’ on page 3—58.
See also: System Warning ‘“3.12 Printhead Cover Off”’ above.
6.6.10 “3.15 Safety Override Active”
WARNING: LETHAL VOLTAGE HAZARD. IF THE ‘SAFETY OVERRIDE’ LINK IS FITTED WHILE
THE “PRINTHEAD OVER TEMPERATURE” OR “EHT TRIP” FAULT CONDITIONS EXIST,
300 VOLTS DC CONTINUES TO BE SUPPLIED TO THE PRINTHEAD.
THE CORRECT, STANDARD ELECTRICAL SAFETY PRECAUTIONS MUST BE TAKEN WHEN
WORK IS DONE ON THE PRINTHEAD WITH THE ‘SAFETY OVERRIDE’ LINK FITTED. DO NOT
FIT THE LINK PERMANENTLY AND DO NOT LEAVE THE PRINTER UNATTENDED WHILE THE
LINK IS FITTED.
WARNING IS IGNORED.
This warning is reported if the Safety Override link is fitted on the IPM Assembly.
When this link is fitted, the Printhead Over Temperature sense, fluid spillage detection and
EHT Trip-sense software do not disable the 300 volts, ink system pump, feed valves, and
EHT. However, the EHT Trip-sense will disable the EHT within the HVPM even if the link
is fitted. This link can be fitted, with caution, to help the fault diagnosis.
6.6.11 “3.16 Gutter Override Active”

This warning is reported if the Gutter Sense Override link is fitted on the IPM Assembly.
Under normal jet running conditions, the Gutter Sense Override link prevents the Print
Failure ‘“2.09 Misaligned Ink Jet”’ from being reported.
FA48008
6.6.12 “3.17 Gate Array Test Mode Active”
This warning is reported if the Built In Self-Test link is fitted on the IPM Assembly. When
this link is fitted, the gate array is put in test mode.
This link is for software diagnostic purposes only.
6.6.13 “3.18 Low Pressure”

Each time the jet is started, a pressure and filter test is performed. A test pressure of 235 LPB
is set (Set Pressure) for 5 seconds, and the pressure transducer checks the pressure in the ink
system. For the system to operate correctly, these two pressures must be approximately the
same. If the difference between the Set Pressure and the pressure transducer reading
(Actual Pressure) is greater than 5 LPB, this warning is reported. Jet operation is allowed to
continue.
The primary function of this test is the detection of ink system faults or pressure loss. The
test pressure is greater than the normal operating pressures, so printing can continue with a
filter that has a part blockage, and so the jet is not shut down.
Possible causes:
 A blockage in the Service Module ink filter
 Some other loss of pressure in the ink system.
 A fault in the pump drive circuit.
will also report the Print Failure ‘“2.35 Pump Stalled”’ first, followed by possible
failures ‘“2.02 Phase Failure”’, ‘“2.03 Time Of Flight Failure”’ and ‘“2.12 Viscosity Out
of Range”’.
6.6.14 “3.24 Restart In Progress”

During a normal startup only, the printer is trying to restart the jet after the first attempt to
start the jet failed. A further two restart attempts are made, but if these attempts are not
successful, the printer fails.
Possible causes:
 The jet was incorrectly aligned during startup and the restart sequence is trying to clear
a possible blockage.
6.6.15 “3.29 Overspeed (No Remote Data)”

This warning occurs in Single print mode. The printer tried to print a message that contains
one or more remote fields, and no data was received from the communications interface to
fill these remote fields.
Possible causes:
 Print rate is too fast.
 Data was sent too late.
 The baud rate is too low.
6.6.16 “3.30 Remote Error”

This warning advises the operator that the printer has received the ‘Set Remote Error’
command (121) through the remote communications interface (RCI). If this event occurs,
contact your local Linx Service Centre.
FA48008
6.6.17 “3.40 Service Module Requires Replacement”
When the Maintenance Due Within (hours) time reaches zero or the Maintenance Due By
date is reached, this warning is reported. The warning is displayed each time the printer is
turned on, until the service module is replaced and the Maintenance Due Within time and
the Maintenance Due By date are reset. A prompt message is also displayed each time the
jet is started and every 24 hours until the service module is replaced.
See also: Print Failure ‘“2.27 Service Module Requires Replacement”’
6.6.18 “3.41 Service Module Removed”

This warning occurs if the service module is removed from the printer when the jet is in the
‘Idle’ state.
The event is triggered by a location sensor, which detects that the service module is not
fitted or is not correctly fitted.
NOTE: The following option buttons are disabled when the service module is removed.
Maintenance screen: Nozzle Flush, Nozzle Clear, Jet Monitor, Jet Sequences,
Decommissioning, From Storage, and Into Storage.
Jet Functions screen: Jet Test-Start, Jet Monitor, and Nozzle Clear.
Valve Test screen: Jet Monitor.
See also: Print Failure ‘“2.21 Service Module Removed”’
6.6.19 “3.42 Service Module Requires Commissioning”

This warning occurs if the printer cannot fill the service module to the required level within
8 minutes of a Start Printing request by the operator. The printer will not go into the
‘Printing’ state because the ink level in the service module remains too low at the end of this
period.
Possible causes:
 A new (empty) service module was fitted and the on-screen procedure for the service
module replacement was not performed. When the service module is replaced, the
Commissioning option must be used to fill the service module with ink (Main Menu >
Maintenance > Commissioning).
 A service module was fitted that does not have an acceptable level of ink.
6.6.20 “3.43 Memory Low”

This warning indicates that the amount of available random access memory (RAM) is low.
The system software uses the RAM to operate, and this warning is reported when the RAM
use reaches 85%.
This warning can occur if the system software uses more than the normal amount of RAM.
If the warning occurs, the printer can be restarted to correct the problem.
See also: Print Failure ‘“2.24 Memory Low”’
FA48008
6.6.21 “3.44 Memory Storage Low”
This warning indicates that the amount of storage space left in the flash memory is low.
When the flash memory use reaches 90%, the warning is reported.
The warning can occur if there are many messages or logos stored in the system. The
operator can delete some messages or logos to clear this warning.
See also: Print Failure ‘“2.25 Memory Storage Low”’
6.6.22 “3.45 Service Module Replacement Due Within One

Month”
When one of the following conditions occurs, this warning is reported:
 The Maintenance Due Within time is less than 1 month of calculated jet operation.
or
 The current date is less than 30 days before the Maintenance Due By date.
This warning is displayed each time the printer is turned on, and the jet can be started
normally. A prompt message is also displayed each time the jet is started and every 24
hours until the service module is replaced.
6.6.23 “3.46 Pump Pressure Failure”

The difference between the current pressure reading and the requested pressure is greater
than a preset threshold. There are two thresholds: normal (25 LPB) and purge (50 LPB). The
thresholds are exceeded during pressure request changes, but a possible problem is
indicated if the fault continues for more than 5 seconds.
Possible causes:
 Very thin ink.
 A worn pump.
 An obstruction in the ink system.
 The venturi is not fitted.
FA48008
6.6.24 “3.47 Pump RPM Failure”
The difference between the rpm reading and the requested rpm is greater than a preset
threshold. The threshold is set to 200 rpm. The threshold is exceeded during pressure
request changes, but a possible problem is indicated if the fault continues for more than 5
seconds.
Possible causes:
 An obstruction in the ink system.
6.6.25 “3.48 Pump RPM Limit Reached”

The speed of the pump motor reached its allowed maximum value. This is not normally a
problem, but can be an indication that the requested pressure is not reached.
Possible causes:
 A worn motor.
 There is no ink, or very thin ink.
6.6.26 “3.49 Pump Current Limit Exceeded”

The drive chip for the pump motor has reported a number of occurrences where the
long-term current limit was exceeded. The long-term current limit is exceeded on startup
and purge, but a problem can be indicated if the fault continues for more than 5 seconds
and there is a pressure failure reported.
Possible causes:
6.6.27 “3.50 Valve Supply”

The 24 V supply is outside the range of 22.0 V to 28.0 V. The valves and motor can fail to
operate correctly.
Possible causes:
 A fault on the LVPSU.
 A fault on the cableform between the LVPSU and the IPM Assembly.
 A large amount of current was drawn.
FA48008
6.6.28 “3.51 Pump Oscillating”
The control system for the pump motor drive cannot stop pressure oscillations. The IPM
Assembly automatically decreases the gain to get control, but reports an error until the
pressure request changes.
Possible causes:
 An obstruction in the venturi.
6.6.29 “3.52 Pump Power Limit Reached”

This warning indicates that the power for the pump motor was decreased to prevent the
motor from becoming too hot.
Possible causes:
6.6.30 “3.56 Printhead Over Temperature”

The description of this warning is the same as the System Failure ‘“2.00 Printhead Over
Temperature”’ but the conditions under which it is reported are different. If the Safety
Override link is already fitted and a printhead over temperature condition occurs, this
warning is reported instead of the System Failure ‘“2.00 Printhead Over Temperature”’.
If the Safety Override link is removed while this warning exists, the warning is replaced by
the System Failure ‘“2.00 Printhead Over Temperature”’.
NOTE: If the Safety Override link is fitted while the System Failure ‘“2.00 Printhead Over
Temperature”’ exists, the failure is NOT replaced by this System Warning ‘“3.56
Printhead Over Temperature”’.
6.6.31 “3.57 EHT Trip”

The description of this warning is the same as the System Failure ‘“2.01 EHT Trip”’ but the
conditions under which it is reported are different. If the Safety Override link is already
fitted and an EHT trip condition occurs, this warning is reported instead of the System
Failure ‘“2.01 EHT Trip”’.
the System Failure ‘“2.01 EHT Trip”’.
NOTE: If the Safety Override link is fitted while the System Failure ‘“2.01 EHT Trip”’
exists, the failure is NOT replaced by this System Warning ‘“3.57 EHT Trip”’.
6.6.32 “3.58 Internal Spillage”

The description of this warning is the same as the System Failure ‘“2.07 Internal Spillage”’
but the conditions under which it is reported are different. If the Safety Override link is
already fitted and an internal spillage condition occurs, this warning is reported instead of
the System Failure ‘“2.07 Internal Spillage”’.
the System Failure ‘“2.07 Internal Spillage”’.
NOTE: If the Safety Override link is fitted while the System Failure ‘“2.07 Internal
Spillage”’ exists, the failure is NOT replaced by this System Warning ‘“3.58 Internal
Spillage”’.
FA48008
6.6.33 “3.59 Low Battery”
The system has detected that the battery voltage is low (less than 3.8 V) and will charge the
battery. The printer must remain turned on for at least 90 minutes to charge the battery
correctly. Battery charging stops if the battery has only two functional cells, or the internal
temperature of the printer cabinet exceeds 75 °C.
The battery is used to save data during the power-down process, and to supply the
real-time clock while the printer is turned off. Therefore, the battery must be in a good
charge state.
6.6.34 “3.60 Reset System Clock”

The system has detected that the real-time clock has been reset to zero, and one possible
cause is a flat battery. This warning is a prompt for the operator to reset the system date and
time.
6.6.35 “3.65 Reverted To System Settings From Last Successful

Powerdown”
This warning is reported at printer startup if the software cannot load the system settings
that were in use before the last printer power-down. The software loads the last set of
system settings that was correctly saved. The reason for this error is file corruption caused
by an incorrect printer shutdown.
6.6.36 “3.66 System Settings Not Found, Reverted To Defaults”

This warning is reported at printer startup if the software cannot load the system settings
that were in use before the last printer power-down, and cannot find any of the previously
saved system settings. The default settings are loaded instead. The reason for this error can
be file corruption caused by an incorrect printer shutdown the very first time, or major file
corruption.
6.6.37 “3.68 Field Truncation”

This warning occurs if the allocated size (in pixels) of the Remote field in a message is not
large enough to contain the remote data that is being downloaded into the field. And so, not
all of the remote data is downloaded into the field.
Possible causes:
 Wrong primary and secondary keyboards selected for the printer.
6.6.38 “3.69 Remote Field Not Found”

A Remote field exists in a message, but the referenced Remote field has subsequently been
deleted from the Remote Field List screen (Printer Setup > Communications > Edit
Connection > Remote Field List). The printer does not recognize the deleted field in the list
and no remote data is downloaded into the field in the message. To correct the problem, the
Remote field can be recreated in the list.
6.6.39 “3.71 Jet Start Failure – Do Not Switch Off!”

This warning is reported if the jet fails to start. When this warning is displayed, the printer
must not be turned off until the printer status changes from 'Aborting' to ‘Fault’. The printer
can then be turned on again and the jet restarted.
FA48008
6.6.40 “3.73 Ink Cartridge Not Found”
This warning is reported if the printer cannot detect any valid RFID tag in the ink cartridge
receptacle. (The printer does not have any other method to detect the presence of a
cartridge.)
Possible causes:
 The cartridge is not a Linx ink cartridge.
 The printer cannot decode the RFID tag data because the data is corrupted.
6.6.41 “3.74 Solvent Cartridge Not Found”

This warning is reported if the printer cannot detect any valid RFID tag in the solvent
cartridge receptacle. (The printer does not have any other method to detect the presence of a
cartridge.)
Possible causes:
 The cartridge is not a Linx solvent cartridge.
 The printer cannot decode the RFID tag data because the data is corrupted.
6.6.42 “3.77 Ink Cartridge Empty”

When the printer calculates that the ink cartridge is empty, the printer makes 10 attempts to
take more ink from the cartridge. If no more ink is found after 10 attempts, and the level
sensor in the service module detects a low ink level, the cartridge is marked as empty and
this warning is reported.
If this event is detected before the jet is started, the jet cannot be started until the event is
cleared (that is, the ink cartridge is replaced). If the event is detected while the jet is
operating, the jet continues for a period of time until the ink level in the service module is
critically low, and then the printer fails with the ‘“2.20 Ink System Empty”’ event. The
period of time is variable and depends on the environmental temperature and the rate of
ink use, but is a maximum of 12 hours.
The warning is automatically cleared when the ink cartridge is replaced and the ink level in
the service module is above the level sensor.
Possible causes:
 There is a blockage between the ink cartridge and the Ink Cartridge valve.
6.6.43 “3.78 Solvent Cartridge Empty”

When the printer calculates that the solvent cartridge is empty, the printer makes
5 attempts to take more solvent from the cartridge. If no more solvent is found after
5 attempts, and the level sensor in the solvent tank detects a low solvent level, the cartridge
is marked as empty and this warning is reported.
If this event is detected before the jet is started, the jet cannot be started until the event is
cleared (that is, the solvent cartridge is replaced). If the event is detected while the jet is
operating, the jet continues for a period of time until the solvent level in the solvent tank is
critically low, and then the printer fails with the ‘“2.43 Solvent System Empty”’ event. The
period of time is variable and depends on the environmental temperature and the rate of
solvent use, but is a maximum of 12 hours.
The warning is automatically cleared when the solvent cartridge is replaced and the solvent
level in the solvent tank is above the level sensor.
Possible causes:
 There is a blockage between the solvent cartridge and the Solvent Cartridge valve.
FA48008
6.6.44 “3.79 Invalid Ink Cartridge”
This warning is reported if the printer cannot decode the response from the RFID tag on the
ink cartridge.
Possible causes:
 The cartridge is not a Linx ink cartridge.
 The RFID tag data is corrupted.
6.6.45 “3.80 Invalid Solvent Cartridge”

solvent cartridge.
Possible causes:
 The cartridge is not a Linx solvent cartridge.
 The RFID tag data is corrupted.
6.6.46 “3.81 Ink Cartridge Expired”

This warning is reported if the RFID tag on the ink cartridge indicates that the ink cartridge
is no longer in date.
6.6.47 “3.82 Solvent Cartridge Expired”

This warning is reported if the RFID tag on the solvent cartridge indicates that the solvent
cartridge is no longer in date.
6.6.48 “3.83 Wrong Ink Type”

This warning is reported if the RFID tag on the ink cartridge indicates that the ink cartridge
does not contain the correct ink type for the printer.
6.6.49 “3.84 Wrong Solvent Type”

This warning is reported if the RFID tag on the solvent cartridge indicates that the solvent
cartridge does not contain the correct solvent type for the printer.
6.6.50 “3.85 Easi-Change Service Key Not Found”

This event occurs during the replacement of the service module if the user does not insert
the Easi-Change® Service Key when prompted.
NOTE: Normally, the user does not see this warning on the screen because the on-screen
help message overrides the warning message.
6.6.51 “3.86 Invalid Easi-Change Service Key”

Easi-Change® Service Key.
Possible causes:
 The device is not a Linx Easi-Change® Service Key.
 The RFID data on the Easi-Change® Service Key is corrupted.
6.6.52 “3.87 Easi-Change Service Key Already Used”

This warning is reported if the user tries to use an Easi-Change® Service Key that was
already used. The Easi-Change® Service Key can be used only once.
FA48008
FA48008
INDEX
NOTE: In the following Index, entries contained within double quotation marks are
event messages.
Symbols
24 volts external alarm 3—63
300 volts power supply 2—2, 3—46
6-way fluid connector assembly 3—4, 3—9, 3—35
A
access door, front 3—2, 3—3, 3—22
damper replacement 5—105
latch replacement 5—101
removal and installation 5—95
sensor replacement 5—107
access panels
left (service module) 3—2, 3—3
rear 3—2, 3—3, 3—4
removal 5—57
right (air filter) 3—2, 3—3
Actual Modulation 5—11
Actual Phase 5—14
Actual Pressure 3—28, 3—35, 5—11, 6—24
Actual TOF 3—12, 3—18, 3—19, 3—39, 5—13
air filter 3—4, 3—5
access panel 3—2, 3—3
cleaning 3—5
housing 3—2, 3—4
alarm output 3—2, 3—63
alarm, internal 3—51
alignment, jet and nozzle 3—21
antistatic precautions 5—48
B
baffle vents
electronics system 3—2, 3—3, 3—4
ink system 3—2, 3—3, 3—5
barb fittings 3—24
battery back-up 3—51
Built-In Self-Test link 3—58
Buzzer link 3—57
C
cabinet 3—1
specifications 2—1
Calibrate Touch Screen option 5—20
Calibration screen 5—33
Charge Gain (%) 5—37
conduit length 5—37
EHT Gain (%) 5—37
Gutter 5—38
Nudge button 5—35
Pressure Transducer (mV) 5—37
printhead PCB serial number 5—37
printhead serial number 5—36
Ref Mod 5—38
Ref Press 5—38
calibration value, pressure transducer 3—28
capacitive coupling 3—15, 3—16
cartridges needle stem assemblies
replacement 5—111
FA48008
Linx 8900 Maintenance Manual Index—1 Jun 2015
cartridges receptacle 3—2
replacement 5—111
cartridges, ink and solvent 3—31
cautions (safety) 1—1
CE approval checklist 5—49
“Charge Amplifier Trip” 6—16
charge calibration factor 3—21
charge electrode 3—8
charge electrode and time of flight (CETOF) assembly 3—9, 3—18
charge electrode plates 3—13
Charge Gain (%) option 5—37
charge timing 3—15
charged ink drops 3—8
Clean Touch Screen option 5—20
Commissioning option 3—41
Commissioning Valve Test screen 5—30
conduit length 2—4, 5—37
conduit, printhead 2—4, 3—2, 3—3
Consumables History screen 5—43
Current Ink Usage 5—45
Current Solvent Usage 5—45
Ink Cartridges Used 5—44
Ink Level 5—44
Recent Ink Cartridges 5—45
Recent Solvent Cartridges 5—45
Reset 5—45
Service Module Life 5—44
Solvent Cartridges Used 5—44
Solvent Level 5—44
cooling fan. See fan, cooling
Cover Off Override link 3—58, 6—23
“Cover Override Active” 6—23
CPU PCB 3—4
Current Ink Usage button 5—45
Current Solvent Usage button 5—45
D
damper 3—4, 3—28
replacement 5—81
decommissioning kit 5—39
Decommissioning option 5—39
decommissioning procedure 5—40
deflector plates 3—9, 3—16
display 3—5
double pole/neutral fusing 1—3, 5—47
downloading software 3—60, 3—67
drop charge 3—15
drop charging circuit 3—17
drop deflection 3—13, 3—16
dual alarm 3—65
E
Easi-Change Service Key 3—25, 5—16, 5—31
“Easi-Change Service Key Already Used” 6—31
“Easi-Change Service Key Not Found” 6—31
“EHT Board Missing” 6—7
EHT cables and connectors 3—47
EHT calibration voltage 3—47
EHT Gain (%) option 5—37
EHT power supply 2—2, 3—47
EHT trip 3—47
“EHT Trip” 6—9, 6—28
EHT voltage 3—16, 3—47
EHT Voltage Adjustment (Printer) screen 5—37
electronics system
FA48008
Jun 2015 Index—2 Linx 8900 Maintenance Manual
access for maintenance 5—59
removal 5—60
electrostatic charge 3—13
electrostatic field 3—13, 3—15, 3—16
EMC compliance 2—6
enclosure protection compliance 2—6
environmental compliance 2—6
environmental specification 2—1
Ethernet interface 3—2, 3—67
external print trigger (photocell) 3—61
external signals 3—61
alarm output 3—2, 3—63
connectors 3—2, 3—3, 3—61
dual alarm 3—65
Ethernet interface 3—2, 3—67
multi-stage alarm 3—66
product sensors 3—2
serial interface (RS-232) 3—2, 3—67
shaft encoder 3—2, 3—62
USB interface 3—67
F
fan, cooling 3—4, 3—49
Festo fittings 3—24
“Field Truncation” 6—29
filter, mains electrical supply 3—4
filters
ink cartridge feed filter 2—4, 3—31
in-line filters, 6-way fluid connector 2—4, 3—4, 3—10
main ink filter 2—4, 3—24, 3—35
printhead feed filter 2—4, 3—8
solvent cartridge feed filter 2—4, 3—31
solvent tank pick-up tube filter 2—4
first aid 1—5
eye contact with inks or solvents 1—6
ingestion of inks or solvents 1—6
inhalation of solvent fumes 1—6
skin contact with inks or solvents 1—6
flash memory 3—52
flow charts, troubleshooting 4—1
flow diagrams, ink system 3—35
fluid level sensors
electrical connections
service module 3—25
solvent tank 3—29
Hall-effect switch 3—25
service module 3—25
service module ink level activation 2—3
solvent level activation 2—3
solvent tank 3—29
fluid lines, colour codes of 3—10
fluid spillage detector 3—24
From Storage option 5—24, 5—42
fuses
HVPM 3—46
mains electrical supply 3—4, 3—45
fusing, double pole/neutral 1—3, 5—47
G
“Gate Array Test Mode Active” 6—24
guard drops 3—17
gun chamber 3—8
gutter 3—13
Gutter option 5—38
“Gutter Override Active” 6—23
FA48008
gutter sense 3—59, 5—38
Gutter Sense Override link 3—59, 6—23
Gutter Threshold Trial Value screen 5—38
gutter vacuum 3—16
Gutter valve
stuck valve correction 5—149
Gutter Valve Reset option 5—24
gutter, jet alignment into the 3—21
H
Hall-effect switch, fluid level sensors 3—25
high voltage power module (HVPM) 1—3, 2—2, 3—4, 3—46
cooling 3—4
fuse 3—46
replacement 5—115
historic correction 3—15, 3—16
I
I/O PCB 3—4
links 3—57
test points 3—54
“I2C Bus Failure” 6—7
I2C-bus 3—60
information events 6—3
ink and solvent cartridges 3—31
access door 3—3
ink cartridge 3—2, 3—22
capacity 2—3
“Ink Cartridge Empty” 6—30
“Ink Cartridge Expired” 6—31
ink cartridge feed filter 2—4, 3—31
“Ink Cartridge Not Found” 6—30
Ink Cartridge valve 3—32, 3—33, 3—41, 3—48
Ink Cartridges Used button 5—44
ink conversion 5—145
ink density 3—12
Ink Level button 5—44
Ink Prime option 5—24
Ink Prime–Valve Unstick option 5—24
ink system 3—22
flow diagrams 3—35
pipe connections 3—24
removal 5—58
“Ink System Empty” 6—15
Ink System Feed valve 3—28, 3—35, 3—48
ink viscosity 3—12, 3—13, 3—15, 3—18, 3—19, 3—39
inks and solvents (safety) 1—4
in-line filters
6-way fluid connector 2—4, 3—4, 3—10
interlocks, safety 3—60
internal alarm 3—51
“Internal Software Failure” 6—6
“Internal Spillage” 3—24, 6—12, 6—28
Into Storage option 5—24, 5—42
“Invalid Easi-Change Service Key” 6—31
“Invalid Ink Cartridge” 6—31
“Invalid Solvent Cartridge” 6—31
IPM Assembly 3—4, 3—51
cooling 3—4
replacement 3—60, 5—117
J
jet alignment 3—21
jet alignment and nozzle cleaning 5—133
FA48008
Jet Functions screen 5—21
Jet Monitor 5—23
Jet Test-Start 5—21
Jet Test-Stop 5—22
Nozzle Clear 5—23
Start Print 5—22
Stop Print 5—22
Test Print 5—22
Jet Monitor button 5—23
Jet Monitor screen 5—9
Jet Run Time (Present) 5—18
Jet Run Time (Total) 5—18
Jet Sequences screen 5—23
From Storage 5—24
Gutter Valve Reset 5—24
Ink Prime 5—24
Ink Prime–Valve Unstick 5—24
Into Storage 5—24
Nozzle Clear 5—24
Nozzle Flush 5—24
Reset All Valves 5—24
Reset Solvent Tank Valves 5—24
Safely Remove SM 5—25
Solvent Prime 5—25
Solvent Pump Auto Flush 5—25
Solvent Pump Flush 5—25
jet shutdown 3—33
jet speed 3—9, 3—13
“Jet Start Failure – Do Not Switch Off!” 6—29
Jet Test-Start option 5—21
Jet Test-Stop option 5—22
K
keyboard 3—6
L
last chance filter (printhead feed filter) 2—4, 3—8
replacement 3—8
lethal voltages 1—3
links, I/O PCB 3—57
“Low Battery” 6—29
“Low Pressure” 6—24
low voltage power supply unit (LVPSU) 2—2, 3—46
M
main ink filter 2—4, 3—24, 3—35
main ink pump and motor assembly
replacement 5—65
mains (VFC) external alarm 3—63
mains electrical supply
cable 3—44
cable connector protection box 3—2, 3—3
filter 3—4, 3—45
fuses 3—4, 3—45
power on switch 3—2, 3—3
printer connector 3—45
Maintenance Due By 5—19
Maintenance Due Within 5—18
maintenance instructions
Cartridges Receptacle Replacement 5—111
Correct Installation of Mk11 Printheads 5—53
Front Access Door Damper Replacement 5—105
Front Access Door Latch Replacement 5—101
Front Access Door Removal and Installation 5—95
Front Access Door Sensor Replacement 5—107
FA48008
High Voltage Power Module Replacement 5—115
Ink Conversion 5—145
IPM Assembly Replacement 5—117
Jet Alignment and Nozzle Cleaning 5—133
Main Ink Pump and Motor Assembly Replacement 5—65
Manifold Valves Replacement 5—91
Modulation Range Checks 5—123
Pressure Transducer and Damper Replacement 5—81
Printer Installation 5—51
Rear Access Panel Removal & Access Preparation 5—57
RFID Module and Cable Replacement 5—99
Solvent Priming Unit and Valve Replacement 5—77
Solvent Recovery Unit Replacement 5—85
Solvent Tank Level Sensor Replacement 5—71
Solvent Tank Pick-up Tube Replacement 5—69
Solvent Tank Replacement 5—75
Stuck Printhead Gutter Valve Correction 5—149
Touch Screen Assembly Replacement 5—121
Transfer Pump Replacement 5—87
Venturi Replacement 5—63
VFC Module Installation 5—127
Maintenance options availability 5—3
Maintenance screen 5—1, 5—2
maintenance terminology 5—47
Maintenance Times screen 5—18
Jet Run Time (Present) 5—18
Jet Run Time (Total) 5—18
Maintenance Due By 5—19
Maintenance Due Within 5—18
Power On Time (Present) 5—18
Power On Time (Total) 5—18
manifold valves
replacement 5—91
manifold, venturi 3—4, 3—35
memory capacity 2—5
“Memory Low” 6—17, 6—25
“Memory Storage Low” 6—17, 6—26
micrometre (SI unit) 3—22
minimum bend radius, conduit 2—4
“Misaligned Ink Jet” 3—59, 5—38, 6—13
modulation 3—14, 3—20
modulation amplifier 2—2, 3—47
“Modulation Amplifier Trip” 6—17
modulation frequency 3—14, 3—47
modulation range checks 5—123
modulation voltage 3—14
multi-stage alarm 3—66
N
needle stem assemblies, cartridges
replacement 5—111
nozzle alignment 3—21
nozzle assembly 3—8
nozzle cleaning 5—133
Nozzle Clear option 5—8, 5—23, 5—24
Nozzle Flush option 5—7, 5—24
NPN/PNP selection, print trigger 3—61
O
option plate 3—3
“Overspeed (Asynchronous Data)” 6—21
“Overspeed (Compensation)” 6—22
“Overspeed (Line Speed)” 6—21
“Overspeed (No Remote Data)” 6—24
“Overspeed (Print Trigger)” 6—20
FA48008
“Overspeed (Synchronous Data)” 6—21
P
phase control 3—17
“Phase Failure” 6—9
phase packet 3—17
phase position 3—17
phasing 3—9, 3—18, 3—20
photocell input 3—61
Photocell Type option 3—61
piezoelectric crystal 3—8, 3—14
pipe connections 3—24
PNP/NPN selection, print trigger 3—61
port sealing plugs, service module 5—17
positive air line 3—10
positive air pump 3—49
Power On Time (Present) 5—18
Power On Time (Total) 5—18
power specifications 2—1
present detector, service module 3—25
“Pressure Limit Reached” 6—14
“Pressure Reading at Maximum” 6—18
“Pressure Reading at Minimum” 6—18
“Pressure Reading Suspect” 6—18
pressure relief valve (PRV) 3—29
pressure transducer 3—4, 3—28
calibration value 3—28
electrical connections 3—28
Pressure Transducer (mV) option 5—37
pressure transducer and damper 3—4, 3—28
replacement 5—81
Pressure Transducer Calibration screen 5—37
Print Failures 6—8
2.00 Printhead Over Temperature 3—11, 6—8
2.01 EHT Trip 6—9
2.02 Phase Failure 6—9
2.03 Time Of Flight Failure 6—11
2.07 Internal Spillage 3—24, 6—12
2.08 Printer Over Temperature 3—49, 6—12
2.09 Misaligned Ink Jet 3—59, 5—38, 6—13
2.11 Pressure Limit Reached 6—14
2.12 Viscosity Out of Range 3—19, 3—39, 6—14
2.20 Ink System Empty 6—15
2.21 Service Module Removed 6—16
2.23 Charge Amplifier Trip 6—16
2.24 Memory Low 6—17
2.25 Memory Storage Low 6—17
2.26 Modulation Amplifier Trip 6—17
2.27 Service Module Requires Replacement 6—17
2.28 Valid UNIC Chip Not Found 6—18
2.29 Pump Drive Failure 6—18
2.30 Pressure Reading at Maximum 6—18
2.31 Pressure Reading Suspect 6—18
2.32 Pressure Reading at Minimum 6—18
2.33 Valve Drive 1 Failure 6—19
2.34 Valve Drive 2 Failure 6—19
2.35 Pump Stalled 6—19
2.43 Solvent System Empty 3—19, 3—29, 3—39, 6—19
print quality 3—21
printer configuration code 3—60, 5—117
printer installation 5—51
“Printer Over Temperature” 3—49, 6—12
printhead
characteristics 3—21
conduit 2—4, 3—2, 3—3
FA48008
cover tube detection 3—11
feed filter (last chance filter) 2—4
replacement 3—8
installation 5—53
PCB serial number 5—37
positive air pump 3—49
replacement 3—21
serial number 5—36
strobe LED 3—16
temperature 5—16
temperature sensor 3—11
Printhead Characteristics option 5—43
“Printhead Cover Off” 6—22
Printhead Cover Override option 3—59
“Printhead Over Temperature” 3—11, 6—8, 6—28
printing performance 2—5
product sensors 3—2
pump and motor assembly 3—4, 3—26, 3—35, 3—48
“Pump Current Limit Exceeded” 6—27
“Pump Drive Failure” 6—18
“Pump Oscillating” 6—28
“Pump Power Limit Reached” 6—28
“Pump Pressure Failure” 6—26
“Pump RPM Failure” 6—27
“Pump RPM Limit Reached” 6—27
“Pump Stalled” 6—19
Purge valve 3—32, 3—33, 3—48
R
rasters 3—13, 3—16
Recent Ink Cartridges button 5—45
Recent Solvent Cartridges button 5—45
Ref Mod option 5—38
Ref Press option 5—38
Reference Modulation 3—14, 3—21, 5—11, 5—21
Reference Modulation Offset (Printer) screen 5—38
Reference Pressure 3—19, 3—21, 5—11, 5—15, 5—21
Reference Pressure Offset (Printer) screen 5—38
Reference TOF 3—12, 3—19, 3—20, 3—39, 5—12
regulatory approvals 2—5
“Remote Error” 6—24
“Remote Field Not Found” 6—29
Replace Service Module option 3—25, 5—16
Reset All Valves option 5—24
Reset button, Consumables History 5—45
Reset Solvent Tank Valves option 5—24
“Reset System Clock” 6—29
“Restart In Progress” 6—24
“Reverted To System Settings From Last Successful Powerdown” 6—29
RFID module 3—25, 3—31, 3—51, 5—16, 5—31
replacement 5—99
RFID tag
ink and solvent cartridges 3—31
service module 3—25, 5—16, 5—31
S
Safely Remove SM option 5—25
safety
first aid 1—5
eye contact with inks or solvents 1—6
ingestion of inks or solvents 1—6
inhalation of solvent fumes 1—6
skin contact with inks or solvents 1—6
inks and solvents 1—4
FA48008
lethal voltages 1—3
test printing 1—7
warnings and cautions 1—1
safety compliance 2—5
safety interlocks 3—60
“Safety Override Active” 6—23
Safety Override link 3—58
serial interface (RS-232) 3—2, 3—67
Service level timeout 5—1
service module 3—4, 3—24, 3—35
access panel 3—2, 3—3
capacity 2—3, 3—25
dimensions 2—3
fluid level 3—25
fluid level sensors 3—25
fluid level sensors activation 2—3
port sealing plugs 5—17
present detector 3—25
electrical connections 3—25
replacement 3—5, 3—25, 3—41
replacement interval 3—24, 5—19
Service Module Life button 5—44
“Service Module Removed” 6—16, 6—25
“Service Module Replacement Due Within One Month” 6—26
“Service Module Requires Commissioning” 6—25
“Service Module Requires Replacement” 6—17, 6—25
Set Pressure 3—12, 3—19, 3—39, 5—9
shaft encoder 3—2, 3—62
voltage selection 3—62
shutdown and startup 3—20
“Shutdown Incomplete” 6—20
software downloading 3—60, 3—67
Solvent Add count 5—15
Solvent Add Pressure 3—12, 3—19, 3—39, 5—15
Solvent Add Time 3—39
Solvent Add valve 3—32, 3—33, 3—39, 3—48
solvent addition 3—12, 3—19, 3—33, 3—39
maximum 3—19
solvent cartridge 3—2, 3—22
capacity 2—3
“Solvent Cartridge Empty” 3—29, 6—30
“Solvent Cartridge Expired” 6—31
solvent cartridge feed filter 2—4, 3—31
“Solvent Cartridge Not Found” 6—30
Solvent Cartridge valve 3—32, 3—33, 3—41, 3—48
Solvent Cartridges Used button 5—44
solvent jet 3—25
Solvent Level button 5—44
Solvent Prime option 5—25
Solvent Prime valve 3—26, 3—35, 3—48
solvent priming unit 3—4, 3—25
replacement 5—77
Solvent Pump Auto Flush option 5—25
Solvent Pump Flush option 5—25
solvent recovery unit 3—4, 3—30
replacement 5—85
“Solvent System Empty” 3—19, 3—29, 3—39, 6—19
solvent tank 3—4, 3—29, 3—39
capacity 2—3, 3—29
fluid level sensor 3—29
fluid level sensor activation 2—3
replacement 5—75
solvent tank level sensor
replacement 5—71
solvent tank pick-up tube
filter 2—4
FA48008
replacement 5—69
Solvent Top-up valve 3—32, 3—33, 3—41, 3—48
spillage detector 3—24
replacement 5—107
spillage tray 2—1, 3—22
Start Print option 5—22
startup and shutdown 3—20
Stop Print option 5—22
strobe LED, printhead 3—16
system diagram 3—52
system events 6—1
System Failures 6—6
1.03 Internal Software Failure 6—6
1.40 EHT Board Missing 6—7
1.42 I2C Bus Failure 6—7
1.43 Watchdog Trip 6—7
“System Settings Not Found, Reverted To Defaults” 6—29
System Warnings 6—20
3.00 Shutdown Incomplete 6—20
3.05 Overspeed (Print Trigger) 6—20
3.06 Overspeed (Synchronous Data) 6—21
3.07 Overspeed (Asynchronous Data) 6—21
3.08 Overspeed (Line Speed) 6—21
3.09 Overspeed (Compensation) 6—22
3.10 Under Speed (Line Speed) 6—22
3.12 Printhead Cover Off 6—22
3.13 Cover Override Active 6—23
3.15 Safety Override Active 6—23
3.16 Gutter Override Active 6—23
3.17 Gate Array Test Mode Active 6—24
3.18 Low Pressure 6—24
3.24 Restart In Progress 6—24
3.29 Overspeed (No Remote Data) 6—24
3.30 Remote Error 6—24
3.40 Service Module Requires Replacement 6—25
3.41 Service Module Removed 6—25
3.42 Service Module Requires Commissioning 6—25
3.43 Memory Low 6—25
3.44 Memory Storage Low 6—26
3.45 Service Module Replacement Due Within One Month 6—26
3.46 Pump Pressure Failure 6—26
3.47 Pump RPM Failure 6—27
3.48 Pump RPM Limit Reached 6—27
3.49 Pump Current Limit Exceeded 6—27
3.50 Valve Supply 6—27
3.51 Pump Oscillating 6—28
3.52 Pump Power Limit Reached 6—28
3.56 Printhead Over Temperature 6—28
3.57 EHT Trip 6—28
3.58 Internal Spillage 6—28
3.59 Low Battery 6—29
3.60 Reset System Clock 6—29
3.65 Reverted To System Settings From Last Successful Powerdown 6—29
3.66 System Settings Not Found, Reverted To Defaults 6—29
3.68 Field Truncation 6—29
3.69 Remote Field Not Found 6—29
3.71 Jet Start Failure – Do Not Switch Off! 6—29
3.73 Ink Cartridge Not Found 6—30
3.74 Solvent Cartridge Not Found 6—30
3.77 Ink Cartridge Empty 6—30
3.78 Solvent Cartridge Empty 3—29, 6—30
3.79 Invalid Ink Cartridge 6—31
3.80 Invalid Solvent Cartridge 6—31
3.81 Ink Cartridge Expired 6—31
3.82 Solvent Cartridge Expired 6—31
3.83 Wrong Ink Type 6—31
FA48008
3.84 Wrong Solvent Type 6—31
3.85 Easi-Change Service Key Not Found 6—31
3.86 Invalid Easi-Change Service Key 6—31
3.87 Easi-Change Service Key Already Used 6—31
T
tank, solvent 3—4
temperature sensor, printhead 3—11
test points, I/O PCB 3—54
Test Print option 5—22
test printing (safety) 1—7
tilt angle, printer 2—3
time of flight 3—9, 3—12, 3—18, 3—19, 3—20, 3—39
measurement 3—9, 3—13, 3—18
sensors 3—9, 3—13, 3—17, 3—18
“Time Of Flight Failure” 6—11
touch screen, user interface 3—2, 3—3, 3—5
replacement 5—121
transfer pump 3—4, 3—30, 3—39
replacement 5—87
troubleshooting flow charts 4—1
U
“Under Speed (Line Speed)” 6—22
UNIC 3—51, 3—60, 5—117
USB connector 3—2
USB interface 3—67
USB memory device 3—60, 3—67
user interface touch screen 3—2, 3—3, 3—5
V
vacuum, gutter 3—16
“Valid UNIC Chip Not Found” 6—18
“Valve Drive 1 Failure” 6—19
“Valve Drive 2 Failure” 6—19
valve drives 3—51
Valve Reset option 5—42
“Valve Supply” 6—27
Valve Test screen 5—26
All Valves Off button 5—26
Jet Monitor button 5—30
Modulation adjustment button 5—29
Phase parameter 5—30
Power parameter 5—29
Pressure adjustment button 5—27
RPM adjustment button 5—28
TOF parameter 5—30
Transfer Pump option 5—30
valve states 5—26
valves
Ink Cartridge valve 3—32, 3—33, 3—41, 3—48
Ink System Feed valve 3—28, 3—35, 3—48
Purge valve 3—32, 3—33, 3—48
Solvent Add valve 3—32, 3—33, 3—39, 3—48
Solvent Cartridge valve 3—32, 3—33, 3—41, 3—48
Solvent Prime valve 3—26, 3—35, 3—48
Solvent Top-up valve 3—32, 3—33, 3—41, 3—48
Vent valve 3—32, 3—34, 3—39, 3—41, 3—48
valves manifold 3—4, 3—32
Vent valve 3—32, 3—34, 3—39, 3—41, 3—48
venturi 3—27, 3—35
replacement 5—63
venturi manifold 3—4, 3—35
VFC alarm
output conditions 3—64
FA48008
relay operation 3—64
VFC module 3—2, 3—63
connections 3—65
installation 5—127
multi-stage alarm connections 3—66
“Viscosity Out of Range” 3—19, 3—39, 6—14
Viscosity Settle Time 3—19, 3—39
viscosity, ink 3—12, 3—13, 3—15, 3—18, 3—19, 3—39
W
warm-up time 3—19, 3—39
warnings (safety) 1—1
“Watchdog Trip” 6—7
“Wrong Ink Type” 6—31
“Wrong Solvent Type” 6—31
FA48008

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8900_MMCover_EN_Iss1.PMD 1 28/05/2015, 15:46

Amdt Incorporated by Date of Amdt Incorporated by Date of

CHAPTER 1: SAFETY ................................................................... 1—1

CHAPTER 2: GENERAL AND COMPLIANCE INFORMATION ... 2—1

CHAPTER 4: TROUBLESHOOTING............................................. 4—1

CHAPTER 5: MAINTENANCE....................................................... 5—1

INDEX .................................................................................... INDEX—1

CHAPTER 1: SAFETY ...................................................................................... 1—1

CHAPTER 3: TECHNICAL DESCRIPTION...................................................... 3—1

CHAPTER 5: MAINTENANCE.......................................................................... 5—1

Correct Installation of Mk11 Printheads ................................................................................ 5—53

Rear Access Panel Removal & Access Preparation............................................................. 5—57

Venturi Replacement ............................................................................................................... 5—63

Main Ink Pump and Motor Assembly Replacement .............................................................. 5—65

Solvent Tank Pick-up Tube Replacement.............................................................................. 5—69

Solvent Tank Level Sensor Replacement .............................................................................. 5—71

Solvent Priming Unit and Valve Replacement .......................................................................5—77

Pressure Transducer and Damper Replacement...................................................................5—81

Solvent Recovery Unit Replacement ......................................................................................5—85

Transfer Pump Replacement ...................................................................................................5—87

Manifold Valves Replacement .................................................................................................5—91

Front Access Door Removal and Installation ........................................................................5—95

RFID Module and Cable Replacement ....................................................................................5—99

Front Access Door Latch Replacement................................................................................5—101

Front Access Door Damper Replacement............................................................................5—105

Front Access Door Sensor Replacement .............................................................................5—107

Cartridges Receptacle Replacement ....................................................................................5—111

High Voltage Power Module Replacement ...........................................................................5—115

IPM Assembly Replacement ..................................................................................................5—117

Touch Screen Assembly Replacement.................................................................................5—121

Modulation Range Checks.....................................................................................................5—123

VFC Module Installation ........................................................................................................ 5—127

Jet Alignment and Nozzle Cleaning ..................................................................................... 5—133

Ink Conversion ....................................................................................................................... 5—145

Stuck Printhead Gutter Valve Correction ............................................................................ 5—149

CHAPTER 6: SYSTEM EVENTS.......................................................................6—1

CHAPTER 3: TECHNICAL DESCRIPTION...................................................... 3—1

CHAPTER 5: MAINTENANCE.......................................................................... 5—1

VFC Module Installation .........................................................................................................5—127

CHAPTER 6: SYSTEM EVENTS ...................................................................... 6—1

Component positional references

Important note symbol

 Linx 8900 Service Information CD (part number FA48009)

WARNING: GENERAL SAFETY. REGARDLESS OF THE LEVEL OF PERCEIVED HAZARD, THE

1.2 Safety warnings and cautions

The mandatory Hand Protection warning symbol is an indication that solvent-resistant

Irritant substance hazard

Electric shock hazard

Hot surface hazard

1.3 Lethal voltages

WARNING: LETHAL VOLTAGE HAZARD. DANGEROUS VOLTAGES EXIST IN THIS

WARNING: LETHAL VOLTAGE HAZARD—DOUBLE POLE/NEUTRAL FUSING. THIS

1.3.2 High voltage power module (HVPM)

WARNING: THIS PRINTER MUST BE EARTHED.

1.5 Inks and solvents

WARNING: HAZARDOUS SUBSTANCES. THIS PRINTER USES SOLVENT AND

1.6 Heavy equipment hazard

WARNING: HEAVY EQUIPMENT HAZARD. THE WEIGHT OF THE 8900 PRINTER IS

1.7 Sharp needles hazard

1.8 First aid

Eye contact with inks or solvents

Skin contact with inks or solvents