4900 Maintenance Manual MP65557-1 PDF

Linx 4900 Ink Jet Printer
Maintenance Manual
4900
Continuous Ink Jet
Printer
MAINTENANCE
MANUAL
MP65557–1
Linx 4900 Maintenance Manual Nov 2003
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MP65557–1
Nov 2003 (ii) Linx 4900 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.
Amdt Incorporated by Date of Amdt Incorporated by Date of

No. (Name) Incorporation No. (Name) Incorporation
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MP65557–1 Amdt 01
Linx 4900 Maintenance Manual (iii) Jan 2006
Amdt 01 MP65557–1
Jan 2006 (iv) Linx 4900 Maintenance Manual
Copyright Notice
This publication may not be reproduced, stored in a retrieval system, or transmitted in
whole or in part, in any form or by any means, electronic, mechanical, photocopying,
recording, or otherwise, for any purpose without the written permission of Linx Printing
Technologies plc.
Neither whole nor part of the product described in this manual may be adapted or
reproduced in any material form without prior written permission of Linx Printing
Technologies plc.
This First edition published November 2003

© Linx Printing Technologies plc.
LINX® is the Registered Trademark

of
Linx Printing Technologies plc.
Unauthorized use of the LINX Trademark is strictly forbidden.
Disclaimer
Information of a technical nature, and particulars of the product and its use are given by
Linx in good faith. However, it is acknowledged that there may be errors or omissions in
this manual.
Linx shall not be liable for any loss or damage arising from the use of any information,
particulars or errors in this manual, or maintenance carried out by unauthorized personnel,
or any incorrect use of the product, whatsoever.
At all times the printer must be operated with Linx approved spares and consumables.
About this Manual

The purpose of this manual is to provide the service engineer with sufficient information to
carry out maintenance tasks on the LINX® 4900 Continuous Ink Jet Printer. The
information contained in this manual is relevant to Version 1.0 software or later versions,
unless otherwise stated.
Products described in this manual are subject to continuous development, and reviews of
this manual will be made accordingly in subsequent amendments or reissues.
Linx will be pleased to receive any correspondence relating to this manual and the
information contained herein.
For further information or help with Linx products please contact:
Linx Printing Technologies plc
Burrel Road
St Ives
Cambridgeshire
PE27 3LA
UK
Tel: + 44 (0) 1480 302100
Fax: + 44 (0) 1480 302116
or visit our website at www.linx.co.uk
MP65557–1
Linx 4900 Maintenance Manual (v) Nov 2003
Document Conventions
Text Conventions
Certain typographical conventions are used throughout this maintenance manual to
indicate keyboard and control panel keys, and cross-references to other sections or
manuals.
NOTE: The word ‘key’ in this manual describes any of the keys physically located on the
printer control panel and the keyboard. Keys are always ‘pressed’ to achieve an
effect.
Control Panel Keys

Reference to a key on the control panel is made as follows:
… press the [stop] key to …
this identifies the key labelled ‘stop’ on the control panel.
Keyboard Keys
Reference to a key on the keyboard is made as follows:
… press the [alt] key to …
this identifies the key labelled ‘alt’ on the keyboard.
Display Messages
Reference to a displayed message or printer status is made in double quotation marks, as
follows:
… the system displays the Print Failure message “3.04 Solvent Low” when …
Cross-references
Where a cross-reference is made to another section or subsection within this manual (an
internal cross-reference), the reference is shown in single quotation marks, as follows:
… refer to ‘Ink System’ in ‘Chapter 3: Technical Description’, for further
information …
Where a cross-reference is made to a screen or menu option within this manual (an
internal cross-reference), a route reference is shown as follows:
… refer to Chapter 4: Setup Menu > Remote Setup Menu > Serial Parameters >
Baud Rate, for further information …
Where a cross-reference is made to another publication (an external cross-reference), the
reference is shown in italics, as follows:
… refer to the 4900 Ink Jet Printer Operating Manual, for further information …
Refer to the ‘Contents’ and ‘Index’ pages to locate the references quickly.
Menu and Screen Conventions

Unless otherwise stated, the menus and screens shown in this manual reflect the
following:
• Software Version 1.0
• Printer status—”Jet Off”
• Password access level—Level D (Service Level)
MP65557–1
Nov 2003 (vi) Linx 4900 Maintenance Manual
Contents
Amendment Record .......................................................................................... iii
Copyright Notice ................................................................................................. v
Disclaimer .......................................................................................................... v
About this Manual .............................................................................................. v
Document Conventions ..................................................................................... vi
Text Conventions ......................................................................................... vi
Menu and Screen Conventions ................................................................... vi
Contents ........................................................................................................... vii
List of Figures ............................................................................................ xv
CHAPTER 1: GENERAL .............................................................. 1—1

1.1 Introduction ............................................................................................ 1—1
1.2 Technical Data ........................................................................................ 1—1
1.2.1 Printer Configurations ................................................................... 1—1
1.2.2 Environmental ............................................................................... 1—1
1.2.3 Power Requirements ..................................................................... 1—2
1.2.4 Cabinet .......................................................................................... 1—2
1.2.5 Low Voltage Power Supply Unit .................................................... 1—2
1.2.6 EHT Power Supply Unit ................................................................ 1—2
1.2.7 Ink System .................................................................................... 1—3
1.2.8 Printhead ....................................................................................... 1—4
1.2.9 Printing Performance Data ............................................................ 1—4
1.2.10 Memory Capacity ........................................................................ 1—6
1.2.11 Regulatory Approvals .................................................................. 1—6
1.3 Abbreviations and Glossary ................................................................... 1—8
CHAPTER 2: SAFETY .................................................................. 2—1

2.1 Introduction ............................................................................................ 2—1
2.2 Warnings, Cautions and Notes .............................................................. 2—1
2.2.1 Warnings ....................................................................................... 2—1
2.2.2 Cautions ........................................................................................ 2—2
2.2.3 Notes ............................................................................................. 2—2
2.3 Lethal Voltages ....................................................................................... 2—3
2.4 Inks and Solvents ................................................................................... 2—4
2.4.1 Precautions ................................................................................... 2—4
2.4.2 First Aid ......................................................................................... 2—5
2.5 Test Printing ........................................................................................... 2—6
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 Top Cover ...................................................................................... 3—1
3.2.3 Base Unit ...................................................................................... 3—2
3.2.4 Ink System .................................................................................... 3—2
3.2.5 Cooling and Air Filter ..................................................................... 3—2
3.3 User Interface ......................................................................................... 3—4
3.3.1 Keyboard and Display ................................................................... 3—4
3.3.2 Control Panel LEDs ....................................................................... 3—4
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3.4 Printhead Components .......................................................................... 3—6
3.4.1 Gun Chamber and Nozzle Assembly ............................................ 3—7
3.4.2 Charge Electrode .......................................................................... 3—7
3.4.3 Strobe LED .................................................................................... 3—7
3.4.4 Deflector Plates ............................................................................. 3—7
3.4.5 Phase and TOF Sensors ............................................................... 3—7
3.4.6 Printhead Cover Sensor ................................................................ 3—8
3.4.7 Printhead Temperature Sensor ..................................................... 3—8
3.4.8 Printhead Feed and Purge Valves ................................................ 3—9
3.4.9 In-Line Feed Filter ......................................................................... 3—9
3.4.10 Standard Gutter Restrictor ........................................................ 3—10
3.4.11 In-Line Gutter Check Valve ........................................................ 3—10
3.4.12 Electrical and Fluid Connections ............................................... 3—10
3.5 Printhead Principles of Operation ........................................................ 3—11
3.5.1 Overview ..................................................................................... 3—11
3.5.2 Printhead Types .......................................................................... 3—11
3.5.3 Modulation .................................................................................. 3—12
3.5.4 Drop Charge ................................................................................ 3—14
3.5.5 Historic Correction ....................................................................... 3—15
3.5.6 Drop Deflection ........................................................................... 3—15
3.5.7 Phasing ....................................................................................... 3—15
3.5.8 Time Of Flight (TOF) ................................................................... 3—17
3.5.9 Viscosity Control ......................................................................... 3—17
3.5.10 Guard Drops .............................................................................. 3—18
3.5.11 Starting Up and Shutting Down ................................................. 3—19
3.5.12 Jet/Nozzle Alignment ................................................................. 3—20
3.5.13 Quality ....................................................................................... 3—20
3.5.14 Printhead/Nozzle Replacement ................................................. 3—20
3.6 Ink System ........................................................................................... 3—21
3.6.1 General Description .................................................................... 3—21
3.6.2 Venturi Manifold Assembly .......................................................... 3—24
3.6.3 Valves .......................................................................................... 3—25
3.6.4 Ink System Connections ............................................................. 3—26
3.6.5 Ink and Solvent Flows ................................................................. 3—27
3.6.6 Startup and Shutdown Sequences .............................................. 3—32
3.6.7 Other Operating Sequences ....................................................... 3—40
3.6.8 Ink Type Dependent Parameters ................................................ 3—46
3.7 Electrical Components ......................................................................... 3—49
3.7.1 Overview ..................................................................................... 3—49
3.7.2 Mains Power Cable ..................................................................... 3—49
3.7.3 Mains Power Supply Switch ........................................................ 3—50
3.7.4 Power On Switch ......................................................................... 3—50
3.7.5 Mains Filter .................................................................................. 3—50
3.7.6 Mains Input Fuses ....................................................................... 3—50
3.7.7 Low Voltage Power Supply Unit (LVPSU) ................................... 3—50
3.7.8 EHT Power Supply Unit (EHTPSU) ............................................ 3—51
3.7.9 Ink System Pump ........................................................................ 3—52
3.7.10 Ink System Valves and Cableform Assembly ............................ 3—52
3.7.11 Cooling Fan ............................................................................... 3—53
3.7.12 Printhead Positive Air Pump (optional) ...................................... 3—53
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3.8 Electronics and Software ..................................................................... 3—54
3.8.1 Overview ..................................................................................... 3—54
3.8.2 Circuit Diagrams .......................................................................... 3—54
3.8.3 IPM PCB ..................................................................................... 3—55
3.8.4 Display PCB ................................................................................ 3—62
3.8.5 Software ...................................................................................... 3—62
3.9 External Signals ................................................................................... 3—63
3.9.1 Primary Trigger ............................................................................ 3—63
3.9.2 Secondary Trigger ....................................................................... 3—64
3.9.3 Shaft Encoders ........................................................................... 3—66
3.9.4 Primary Trigger and Shaft Encoder Configurations ..................... 3—68
3.9.5 Alarm Output ............................................................................... 3—70
3.9.6 Serial Interface ............................................................................ 3—73
3.9.7 D-Type Connector Assembly ....................................................... 3—74
CHAPTER 4: SETUP MENU ........................................................ 4—1

4.1 Introduction ............................................................................................ 4—1
4.2 Current Message Screen ....................................................................... 4—1
4.3 Password Access ................................................................................... 4—2
4.4 Total Menu Options ................................................................................ 4—3
4.5 Option Availability ................................................................................... 4—3
4.6 Selecting and Changing Menu Options .................................................. 4—5
4.7 Option Description .................................................................................. 4—5
4.7.1 Password ...................................................................................... 4—5
4.7.2 Print Height ................................................................................... 4—6
4.7.3 Normalise Message Type .............................................................. 4—7
4.7.4 Print Width .................................................................................... 4—8
4.7.5 Print Delay ..................................................................................... 4—9
4.7.6 Print Count .................................................................................. 4—10
4.7.7 Reverse Message (non-DC Configuration) ................................. 4—10
4.7.8 Message Orientation (v1.5 S/W & DC Configuration) ................. 4—11
4.7.9 Bold Ratio ................................................................................... 4—12
4.7.10 Set Time .................................................................................... 4—13
4.7.11 Set Date .................................................................................... 4—13
4.7.12 Julian Date Format .................................................................... 4—13
4.7.13 Primary Trigger .......................................................................... 4—13
4.7.14 Shaft Encoder ........................................................................... 4—15
4.7.15 Auto Power Down ...................................................................... 4—18
4.7.16 Ink Type Selection ..................................................................... 4—20
4.7.17 Mod. Tracking Slope ................................................................. 4—20
4.7.18 Head Height .............................................................................. 4—21
4.7.19 Printhead Setup ........................................................................ 4—21
4.7.20 Alarm ......................................................................................... 4—24
4.7.21 Change Password ..................................................................... 4—26
4.7.22 Change Language ..................................................................... 4—27
4.7.23 Change Configuration ............................................................... 4—28
4.7.24 Remote Setup Menu (RS232) ................................................... 4—29
4.7.25 Diagnostics Menu ...................................................................... 4—35
4.7.26 Solv Add Time ........................................................................... 4—35
4.8 Passwords ............................................................................................ 4—37
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CHAPTER 5: MAINTENANCE ..................................................... 5—1
5.1 Introduction ............................................................................................ 5—1
5.2 Diagnostics Menu ................................................................................... 5—1
5.2.1 Password Access .......................................................................... 5—1
5.2.2 Total Menu Options ....................................................................... 5—2
5.2.3 Option Availability .......................................................................... 5—2
5.2.4 Selecting and Changing Menu Options ......................................... 5—4
5.3 Option Description .................................................................................. 5—5
5.3.1 Start Jet ......................................................................................... 5—5
5.3.2 Stop Jet ......................................................................................... 5—5
5.3.3 Quick Start Jet ............................................................................... 5—6
5.3.4 Start Print ...................................................................................... 5—7
5.3.5 Stop Print ...................................................................................... 5—7
5.3.6 Test Print ....................................................................................... 5—7
5.3.7 Clear Nozzle .................................................................................. 5—8
5.3.8 Nozzle Flush ................................................................................. 5—9
5.3.9 Monitor Jet .................................................................................. 5—10
5.3.10 System Times ........................................................................... 5—12
5.3.11 System Configuration ................................................................ 5—14
5.3.12 Phase ........................................................................................ 5—16
5.3.13 Phase Offset ............................................................................. 5—16
5.3.14 Ref Pressures ........................................................................... 5—16
5.3.15 Pressure Tracking ..................................................................... 5—17
5.3.16 Set Pressure ............................................................................. 5—18
5.3.17 Modulation Tracking .................................................................. 5—18
5.3.18 Set Modulation .......................................................................... 5—18
5.3.19 Filter Purge ................................................................................ 5—19
5.3.20 Phase Fault ............................................................................... 5—19
5.3.21 Phase Period ............................................................................ 5—19
5.3.22 Auto Phase ................................................................................ 5—20
5.3.23 TOF Correction ......................................................................... 5—20
5.3.24 TOF Warm Up ........................................................................... 5—20
5.3.25 Calibration ................................................................................. 5—21
5.3.26 Alarm Test ................................................................................. 5—22
5.3.27 Generate Test Pattern ............................................................... 5—22
5.3.28 System Flush ............................................................................ 5—23
5.3.29 Valve Test .................................................................................. 5—24
5.4 Maintenance Instructions ..................................................................... 5—25
5.4.1 Introduction ................................................................................. 5—25
5.4.2 Maintenance Terminology ........................................................... 5—25
5.4.3 Antistatic Precautions .................................................................. 5—26
5.4.4 Good Practice ............................................................................. 5—26
5.4.5 4900 CE Approval Checklist ........................................................ 5—27
5.4.6 Scheduled Maintenance Checklist .............................................. 5—28
5.4.7 Maintenance Instruction Documents ........................................... 5—28
Scheduled Maintenance ............................................................. 5—29
Printhead Cleaning for Pigmented Inks ...................................... 5—37
Draining the Ink System .............................................................. 5—41
Ink Dip Tube Replacement .......................................................... 5—45
3-way Fluid Connector Filter Replacement ................................. 5—49
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Main Ink Filter Replacement ....................................................... 5—53
IPM PCB Calibration ................................................................... 5—61
Printhead Valves Tests ................................................................ 5—65
Ink System Feed Valve Test ........................................................ 5—67
Purge and Gutter Valves Tests .................................................... 5—69
Solvent Flush Valve Tests ........................................................... 5—73
Solvent Top-up (Solvent Add) Valve Tests .................................. 5—77
Jet Alignment and Nozzle Cleaning ............................................ 5—81
Modulation Range Checks .......................................................... 5—89
Blocked Gutter Clearance Procedure ......................................... 5—91
System Flush Procedure ............................................................. 5—95
Ink Conversion Calibration (Offset Calibration) ......................... 5—109
Calibrated Nozzle Replacement (Offset Calibration) ................ 5—115
Printer Installation Procedure .................................................... 5—121
24-volt Alarm Beacon Fitting (Printer Mounted) ........................ 5—123
Mains (VFC) External Alarm Conversion .................................. 5—127
Positive Air Pump Fitting Instructions ........................................ 5—131
Printhead Feed Valve Replacement ......................................... 5—135
Printhead Feed Valve Filter Replacement ................................. 5—139
Correct Installation of Mk7 Printheads ...................................... 5—143
Changing the Orientation of Mk7 Right-Angled Printheads ...... 5—149
Auto Mains Power Off Bypass Kit Fitting Procedure ................. 5—153
CHAPTER 6: SYSTEM EVENTS .................................................. 6—1

6.1 Introduction ............................................................................................ 6—1
6.2 System Event Types .............................................................................. 6—1
6.2.1 Event Reporting ............................................................................ 6—1
6.2.2 System Failures ............................................................................ 6—1
6.2.3 Print Failures ................................................................................. 6—1
6.2.4 System Warnings .......................................................................... 6—1
6.3 Warning & Fault Reporting Configuration ............................................... 6—2
6.3.1 Print Status Screen ....................................................................... 6—2
6.4 System Event Designations ................................................................... 6—6
6.5 System Failures ..................................................................................... 6—7
6.5.1 “1.00 Internal Failure” .................................................................. 6—7
6.5.2 “1.01 Stack Overflow” .................................................................. 6—8
6.5.3 “1.02 Corrupt Program Data” ...................................................... 6—8
6.5.4 “1.03 Unexpected Interrupt” ........................................................ 6—8
6.5.5 “1.04 Unexpected RST” .............................................................. 6—8
6.5.6 “1.05 Unexpected NMI” ............................................................... 6—9
6.5.7 “1.07 System RAM” ..................................................................... 6—9
6.5.8 “1.12 Language Version” ............................................................. 6—9
6.5.9 “1.13 No Raster Data” ................................................................. 6—9
6.5.10 “1.14 Raster Version” ................................................................ 6—9
6.5.11 “1.16 No Fonts” ......................................................................... 6—9
6.5.12 “1.17 Font Version” .................................................................. 6—10
6.5.13 “1.20 Logo Version” ................................................................. 6—10
6.5.14 “1.21 Pixel RAM” ..................................................................... 6—10
6.5.15 “1.22 Date Format Version” ..................................................... 6—10
6.5.16 “1.34 Invalid Configuration” ..................................................... 6—10
6.5.17 “1.35 No UNIC Chip” ................................................................ 6—10
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6.6 Print Failures ........................................................................................ 6—11
6.6.1 “2.00 Printhead Over Temperature” .......................................... 6—12
6.6.2 “2.01 EHT Trip” .......................................................................... 6—12
6.6.3 “2.02 Phase Failure” .................................................................. 6—13
6.6.4 “2.03 Time Of Flight Failure” ..................................................... 6—14
6.6.5 “2.04 300V Power Supply” ........................................................ 6—14
6.6.6 “2.05 Ink Tank Empty” ............................................................... 6—14
6.6.7 “2.06 Solvent Tank Empty” ........................................................ 6—14
6.6.8 “2.07 Internal Spillage” .............................................................. 6—15
6.6.9 “2.09 Misaligned Ink Jet” ........................................................... 6—15
6.6.10 “2.11 Pressure Limit Reached” ................................................ 6—15
6.6.11 “2.12 Viscosity” ........................................................................ 6—16
6.6.12 “2.13 Hardware Safety Trip” .................................................... 6—16
6.7 System Warnings ................................................................................. 6—17
6.7.1 “3.00 Shutdown Incomplete” ..................................................... 6—17
6.7.2 “3.02 Memory Corrupt” .............................................................. 6—17
6.7.3 “3.03 Ink Low” ........................................................................... 6—18
6.7.4 “3.04 Solvent Low” .................................................................... 6—18
6.7.5 “3.05 Over Speed (Print Trigger)” .............................................. 6—18
6.7.6 “3.06 Over Speed (Synchronous Data)” .................................... 6—19
6.7.7 “3.07 Over Speed (Asynchronous Data)” .................................. 6—19
6.7.8 “3.11 Scheduled Maintenance Req’d” ....................................... 6—19
6.7.9 “3.12 Printhead Cover Off” ........................................................ 6—20
6.7.10 “3.13 Cover Override Active” ................................................... 6—20
6.7.11 “3.14 Power Off Override Active” ............................................. 6—20
6.7.12 “3.15 Safety Override Active” .................................................. 6—21
6.7.13 “3.16 Gutter Override Active” .................................................. 6—21
6.7.14 “3.17 Gate Array Test Mode Active” ........................................ 6—21
6.7.15 “3.18 Low Pressure” ................................................................ 6—21
6.7.16 “3.20 No Time Of Flight” .......................................................... 6—22
6.7.17 “3.26 User Data Corrupt” ......................................................... 6—22
6.7.18 “3.29 No Message Stored” ...................................................... 6—22
6.7.19 “3.30 Message Name Exists” .................................................. 6—22
6.7.20 “3.31 Message Memory Full” .................................................. 6—22
6.7.21 “3.32 Remote Error” ................................................................ 6—22
6.7.22 “3.33 Synchronisation” ............................................................. 6—22
CHAPTER 7: TROUBLESHOOTING ........................................... 7—1

7.1 Introduction ............................................................................................ 7—1
7.2 How to Use the Flow Charts ................................................................... 7—1
7.3 First Steps .............................................................................................. 7—3
7.4 Fault Recording ...................................................................................... 7—3
7.5 When Flow Charts Seem Inappropriate ................................................. 7—3
7.6 Miscellaneous Faults .............................................................................. 7—3
7.7 List of Flow Charts ................................................................................. 7—5
FC001 Troubleshooting Start ................................................................. 7—6
FC002 Jet .............................................................................................. 7—7
FC003 Modulation .................................................................................. 7—8
FC004 Charge ........................................................................................ 7—9
FC005 Phase ....................................................................................... 7—10
FC006 Low Pressure ........................................................................... 7—11
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FC007 Ink Quality ................................................................................ 7—12
FC008 Low Viscosity Ink ...................................................................... 7—13
FC009 High Viscosity Ink ..................................................................... 7—14
FC0010 EHT Deflection ....................................................................... 7—15
FC0011 Print ........................................................................................ 7—16
FC0012 Print Quality ............................................................................ 7—17
FC200 2.00 Printhead Over Temperature ............................................ 7—18
FC201 2.01 EHT Trip ........................................................................... 7—19
FC202 2.02 Phase Failure ................................................................... 7—20
FC203 2.03 Time Of Flight Failure ....................................................... 7—21
FC204 2.04 300V Power Supply .......................................................... 7—22
FC205 2.05 Ink Tank Empty ................................................................. 7—23
FC206 2.06 Solvent Tank Empty .......................................................... 7—24
FC207 2.07 Internal Spillage ................................................................ 7—25
FC209 2.09 Misaligned Ink Jet ............................................................. 7—26
FC211 2.11 Pressure Limit Reached ................................................... 7—27
FC212 2.12 Viscosity ........................................................................... 7—28
FC213 2.13 Hardware Safety Trip ........................................................ 7—29
FC999 Final Test .................................................................................. 7—30
CHAPTER 8: TRAINING DOCUMENTATION ............................... 8—1

Course One: Printer Operation .................................................................... 8—1
Module 01 – Introduction .............................................................................. 8—3
Module 02 – Continuous Ink Jet Printing ..................................................... 8—4
Module 03 – Getting Started and Printing Messages ................................... 8—5
Module 04 – Navigating the 4900 ................................................................ 8—6
Module 05 – Creating and Editing Messages ............................................... 8—7
Module 06 – Stopping Print and Shutting Down ........................................... 8—8
Module 07 – Looking After Your Printer ........................................................ 8—9
Module 08 – Routine Maintenance ............................................................ 8—10
Module 09 – Line Installation ..................................................................... 8—11
Module 10 – Review ................................................................................... 8—12
CHAPTER 9: ILLUSTRATED PARTS LIST ................................. 9—1

9.1 Introduction ............................................................................................ 9—1
9.2 Abbreviations .......................................................................................... 9—1
4900 Top Cover Assembly ..................................................................... 9—3
4900 Front Cabinet Assembly ................................................................ 9—5
4900 Rear Cabinet Assembly ................................................................. 9—7
4900 Ink System Assembly (1) ............................................................... 9—9
4900 Ink System Assembly (2) ............................................................. 9—11
4900 Electronics Assembly—IPM PCB ................................................ 9—13
INDEX .......................................................................................... 10—1
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List of Figures
Figure Page
CHAPTER 1: GENERAL ................................................................................. 1—1

Figure 1-1. Printer Configurations ................................................................................................ 1—1
CHAPTER 2: SAFETY ..................................................................................... 2—1

Figure 2-1. Test Printing into a Non-metallic Container ................................................................ 2—6
CHAPTER 3: TECHNICAL DESCRIPTION ..................................................... 3—1

Figure 3-1. 4900 Printer Base Unit and Main Components .......................................................... 3—3
Figure 3-2. 4900 European User Interface .................................................................................. 3—5
Figure 3-3. The Mk7 Ultima Printhead Main Components ........................................................... 3—6
Figure 3-4. 3-Way Fluid Connector Containing the In-line Feed Filter .......................................... 3—9
Figure 3-5. In-Line Gutter Check Valve ...................................................................................... 3—10
Figure 3-6. Modulation of the Ink Jet Using a Piezoelectric Crystal ........................................... 3—12
Figure 3-7. Correct Drop Breakoff Observed in the Charge Electrode ....................................... 3—13
Figure 3-8. Charge and Modulation Synchronization (Phasing) ................................................. 3—16
Figure 3-9. Guard Drops ............................................................................................................ 3—18
Figure 3-10. Static Ink System ................................................................................................... 3—23
Figure 3-11. Venturi Manifold Assembly and Valves ................................................................... 3—24
Figure 3-12. Section View of the Venturi .................................................................................... 3—25
Figure 3-13. 4900 Ink System Pipe Connections ....................................................................... 3—26
Figure 3-14. Primary Circuit ....................................................................................................... 3—28
Figure 3-15. Secondary Circuit (Normal Running after Start Purge) .......................................... 3—29
Figure 3-16. Solvent Addition ..................................................................................................... 3—31
Figure 3-17. Printhead Dependent Parameters Table ................................................................ 3—33
Figure 3-18. Normal Start Summary Table ................................................................................. 3—34
Figure 3-19. Quick Start Summary Table ................................................................................... 3—34
Figure 3-20. Restart Summary Table ......................................................................................... 3—35
Figure 3-21. Normal Shutdown (2 m conduit) Summary Table ................................................... 3—36
Figure 3-22. Normal Shutdown (4 m conduit) Summary Table ................................................... 3—37
Figure 3-23. Ink System after a Successful Normal Shutdown .................................................. 3—38
Figure 3-24. Quick Stop Summary Table ................................................................................... 3—39
Figure 3-25. Purge Dry Cycle Summary Table ........................................................................... 3—40
Figure 3-26. Feed Dry Cycle Summary Table ............................................................................ 3—40
Figure 3-27. Nozzle Clear Summary Table ................................................................................ 3—41
Figure 3-28. Flush Cycle Summary Table .................................................................................. 3—42
Figure 3-28. Flush Cycle Summary Table (continued) ............................................................... 3—43
Figure 3-29. Filter Purge Summary Table .................................................................................. 3—43
Figure 3-30. Gutter Dry Cycle Summary Table .......................................................................... 3—44
Figure 3-31. Empty Tank Summary Table .................................................................................. 3—44
Figure 3-32. Solvent Drain Summary Table ............................................................................... 3—44
Figure 3-33. Nozzle Flush Summary Table ................................................................................ 3—45
Figure 3-34. Ink Type Dependent Parameters Table (Ultima Printhead) .................................... 3—46
Figure 3-35. Ink Type Dependent Parameters Table (Ultima plus Printhead) ............................. 3—47
Figure 3-36. Ink Type Dependent Parameters Table (Mini Printhead) ........................................ 3—48
Figure 3-37. LVPSU Input Details .............................................................................................. 3—50
Figure 3-38. LVPSU Output Details ........................................................................................... 3—51
Figure 3-39. EHTPSU Input/Output Details ............................................................................... 3—52
Figure 3-40. Valve Cableform Details ........................................................................................ 3—53
Figure 3-41. Circuit and Interconnecting Diagrams’ List ............................................................. 3—54
Figure 3-42. IPM PCB Link Default Settings .............................................................................. 3—60
Figure 3-43. Fault Conditions and Actions ................................................................................. 3—60
Figure 3-44. IPM PCB Test Points and Links Locations ............................................................. 3—61
Figure 3-45. Primary Trigger—NPN Configuration ..................................................................... 3—63
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Linx 4900 Maintenance Manual (xv) Jan 2006
Figure 3-46. Primary Trigger—PNP Configuration ..................................................................... 3—64
Figure 3-47. Primary Trigger Debounce Timings ....................................................................... 3—64
Figure 3-48. Secondary Trigger—NPN Configuration ................................................................ 3—65
Figure 3-49. Secondary Trigger—PNP Configuration ................................................................ 3—65
Figure 3-50. Secondary Trigger Debounce Timings ................................................................... 3—65
Figure 3-51. 5 V Single-Ended Shaft Encoder Connections ...................................................... 3—66
Figure 3-52. 24 V Single-Ended Shaft Encoder Connections .................................................... 3—66
Figure 3-53. 5 V Quadrature Shaft Encoder Connections .......................................................... 3—67
Figure 3-54. 24 V Quadrature Shaft Encoder Connections ........................................................ 3—67
Figure 3-55. Two Devices Triggering a Single Printer ................................................................ 3—68
Figure 3-56. Two Devices Triggering Four Printers .................................................................... 3—68
Figure 3-57. One Sensor Triggering up to Eight Printers ........................................................... 3—69
Figure 3-58. 24 Volts External Alarm Pin Connections ............................................................... 3—70
Figure 3-59. Mains External Alarm (Volt-free) Pin Connections ................................................. 3—70
Figure 3-60. Summary of the VFC Relay Operation .................................................................. 3—72
Figure 3-61. RS232 Interface Cable Pin Connections ............................................................... 3—73
Figure 3-62. Correct Assembly of the IP67 D-Type Connector .................................................. 3—74
CHAPTER 4: SETUP MENU ........................................................................... 4—1

Figure 4-1. Current Message Screen ........................................................................................... 4—1
Figure 4-2. Password Screen ...................................................................................................... 4—2
Figure 4-3. Setup Menu ............................................................................................................... 4—3
Figure 4-4. Setup Menu Option AvailabilityTable .......................................................................... 4—4
Figure 4-5. Table of Message Type Print Height Ranges ............................................................. 4—6
Figure 4-6. Normalise Message Type Adjustment ....................................................................... 4—7
Figure 4-7. Deflector Plate and Gutter Clipping ........................................................................... 4—8
Figure 4-8. Message Type Minimum Delay Default Values .......................................................... 4—9
Figure 4-9. Message Printed with ‘Reverse Message’ Off ......................................................... 4—10
Figure 4-10. Message Printed with ‘Reverse Message’ On ....................................................... 4—10
Figure 4-11. Message Orientation Menu (Static Mode) .............................................................. 4—11
Figure 4-12. ‘Normal’ Message Orientation ................................................................................ 4—11
Figure 4-13. ‘Reverse’ Message Orientation .............................................................................. 4—11
Figure 4-14. ‘Invert’ Message Orientation .................................................................................. 4—11
Figure 4-15. ‘Reverse and Invert’ Message Orientation ............................................................. 4—11
Figure 4-16. Message Orientation Menu (Secondary Trigger Mode) ......................................... 4—12
Figure 4-17. Bold Ratio Setting .................................................................................................. 4—12
Figure 4-18. Julian Date Format ................................................................................................ 4—13
Figure 4-19. Message Type Ideal Pitch Values .......................................................................... 4—16
Figure 4-20. Auto Power Down Menu ........................................................................................ 4—18
Figure 4-21. Auto Power Down Message Screen ...................................................................... 4—19
Figure 4-22. Power Down Message Screen .............................................................................. 4—19
Figure 4-23. Printhead Setup Menu ........................................................................................... 4—21
Figure 4-24. “Deleting NVR” Advisory Message Screen ............................................................ 4—22
Figure 4-25. Printhead Code Composition ................................................................................. 4—23
Figure 4-26. Alarm Menu ........................................................................................................... 4—24
Figure 4-27. Alarm Invert Operation ........................................................................................... 4—26
Figure 4-28. Change Password Menu ....................................................................................... 4—26
Figure 4-29. Change Language Menu ....................................................................................... 4—27
Figure 4-30. Change Language Option Default Settings ............................................................ 4—27
Figure 4-31. Configuration Menu ............................................................................................... 4—28
Figure 4-32. “Deleting Messages” Advisory Message Screen .................................................... 4—29
Figure 4-33. Remote Setup Menu (RS232) ............................................................................... 4—29
Figure 4-34. Transfer Parameters Menu .................................................................................... 4—30
Figure 4-35. Serial Parameters Menu ........................................................................................ 4—31
Figure 4-36. Flow Control Menu ................................................................................................ 4—32
Figure 4-37. Message Delimiters Menu ..................................................................................... 4—32
Figure 4-38. Print Control Menu ................................................................................................. 4—33
Figure 4-39. Print Mode Menu ................................................................................................... 4—34
Amdt 01 MP65557–1
Jan 2006 (xvi) Linx 4900 Maintenance Manual
CHAPTER 5: MAINTENANCE ......................................................................... 5—1
Figure 5-1. Diagnostics Menu ...................................................................................................... 5—2
Figure 5-2. Diagnostics Menu Option Availability ......................................................................... 5—3
Figure 5-3. Monitor Jet Screen .................................................................................................. 5—10
Figure 5-4. System Times Screen ............................................................................................. 5—12
Figure 5-5. Scheduled Maintenance Intervals ............................................................................ 5—13
Figure 5-6. System Configuration Menu .................................................................................... 5—14
Figure 5-7. Message Type Menu ............................................................................................... 5—14
Figure 5-8. 4900 Language Groups ........................................................................................... 5—15
Figure 5-9. Enabled Options Screen Example ........................................................................... 5—15
Figure 5-10. Pressure Refs Menu .............................................................................................. 5—16
Figure 5-11. Calibration Menu .................................................................................................... 5—21
Figure 5-12. Select Message Menu ........................................................................................... 5—22
Figure 5-13. Message Options Screen ...................................................................................... 5—22
Figure 5-14. Editing the Test Pattern in the Edit Message Screen ............................................. 5—23
Figure 5-15. System Flush Menu ............................................................................................... 5—23
Figure 5-16. Valve Test Menu .................................................................................................... 5—24
5.4 Maintenance Instructions ....................................................................... 5—25

Scheduled Maintenance .......................................................................................................... 5—29
Figure 1. Removing the Air Filter ............................................................................................... 5—32
Printhead Cleaning for Pigmented Inks ................................................................................. 5—37

Figure 1. Correct Area of the Printhead to Wash with Solvent ................................................... 5—38
Figure 2. Correct Area of the Printhead to Clean with the Brush ................................................ 5—39
Figure 3. Washing the Printhead Cover Tube with Solvent ........................................................ 5—40
Draining the Ink System .......................................................................................................... 5—41

Figure 1. System Flush Menu: Process Options ........................................................................ 5—41
Figure 2. System Flush Menu: “Check Solvent OK” Instruction ................................................. 5—42
Figure 3. Feed Damper Orientation with Drain Tube Connected ............................................... 5—43
Figure 4. System Flush Menu: Sequence Options ..................................................................... 5—43
Figure 5. System Flush Menu: “Empty Tank In Progress…” ...................................................... 5—44
Ink Dip Tube Replacement ...................................................................................................... 5—45

Figure 1. Ink Dip (Pick-up) Tube and Filter Assembly ................................................................ 5—45
3-way Fluid Connector Filter Replacement ........................................................................... 5—49

Figure 1. 3-way Fluid Connector Disassembled ......................................................................... 5—50
Main Ink Filter Replacement ................................................................................................... 5—53

Figure 1. Correct Assembly of the Main Ink Filter Fluid Connections ......................................... 5—55
Figure 2. Applying Thread Lubricant to Pre-LOT #L087 Main Ink Filter Fluid Connections ........ 5—55
Figure 3. Enclosing One End of the Main Ink Filter with a Rubber Glove ................................... 5—56
Figure 4. Both Ends of the Main Ink Filter Enclosed in Rubber Gloves ...................................... 5—57
IPM PCB Calibration ................................................................................................................ 5—61

Figure 1. Calibration Menu ........................................................................................................ 5—63
Printhead Valves Tests ............................................................................................................ 5—65

Figure 1. Feed Valve Switched On in the Valve Test Menu ........................................................ 5—65
Ink System Feed Valve Test .................................................................................................... 5—67

Figure 1. Printhead Feed Valve Switched On in the Valve Test Menu ........................................ 5—67
Purge and Gutter Valves Tests ............................................................................................... 5—69

Figure 1. Monitor Jet Screen ..................................................................................................... 5—69
Figure 2. Purge/Gutter Test Fluid Connector Fitted in the 3-way Fluid Connector ...................... 5—70
Figure 3. Testing for a Leaking Purge or Gutter Valve (closed) .................................................. 5—71
MP65557–1 Amdt 01
Linx 4900 Maintenance Manual (xvii) Jan 2006
Solvent Flush Valve Tests ....................................................................................................... 5—73
Figure 1. Solvent Flush Valve Switched On in the Valve Test Menu ........................................... 5—74
Figure 2. Printhead Feed Valve Switched On in the Valve Test Menu ........................................ 5—74
Figure 3. Creating Bubbles to Test the Solvent Flush Valve for Leakage ................................... 5—75
Solvent Top-up (Solvent Add) Valve Tests ............................................................................ 5—77

Figure 1. Creating Bubbles to Test the Solvent Top-up (Solvent Add) Valve for Leakage ........... 5—77
Figure 2. Solvent Top-up (Solvent Add) Valve Switched On in the Valve Test Menu .................. 5—78
Jet Alignment and Nozzle Cleaning ....................................................................................... 5—81

Figure 1. Correct Alignment of the Jet into the Gutter ................................................................ 5—82
Figure 2. Correct Alignment of the Jet from the Nozzle .............................................................. 5—83
Figure 3. Nozzle Clear Sequence—Applying Solvent to the Nozzle Face .................................. 5—84
Figure 4. Suspending the Nozzle in a Beaker of Solvent ........................................................... 5—85
Modulation Range Checks ...................................................................................................... 5—89

Figure 1. Monitor Jet Screen ..................................................................................................... 5—89
Figure 2. Under Modulation—Expected Deterioration when Reference Mod is < Vm1 .............. 5—90
Figure 3. Over Modulation—Expected Deterioration when Reference Mod is > Vm2 ................ 5—90
Blocked Gutter Clearance Procedure .................................................................................... 5—91

Figure 1. Gutter Clear Fluid Connector Fitted in the 3-way Fluid Connector .............................. 5—92
System Flush Procedure ......................................................................................................... 5—95

Figure 1. System Flush Menu: Process Options ...................................................................... 5—102
Figure 2. System Flush Menu: “Check Solvent OK” Instruction ............................................... 5—102
Figure 3. Feed Damper Orientation with Drain Tube Connected ............................................. 5—103
Figure 4. System Flush Menu: Sequence Options ................................................................... 5—104
Figure 5. System Flush Menu: “Empty Tank In Progress…” .................................................... 5—104
Figure 6. System Flush Menu: “Turn Off Tap On Bleed Line” Instruction ................................. 5—105
Figure 7. System Flush Menu: “Fill Ink Tank with 0.5ltr of Solvent” Instruction ......................... 5—105
Figure 8. System Flush Menu: “Flush Cycle In Progress…” .................................................... 5—105
Figure 9. System Flush Menu: Sequence Options ................................................................... 5—106
Figure 10. System Flush Menu: “Turn Off Tap On Bleed Line” Instruction ............................... 5—106
Figure 11. System Flush Menu: “Solvent Drain In Progress…” ................................................ 5—107
Ink Conversion Calibration (Offset Calibration) .................................................................. 5—109

Figure 1. Example of Reference Pressure and Reference Modulation Offset Table ................ 5—109
Figure 2. Reference Pressure Value in the Printhead Code Option ......................................... 5—110
Figure 3. Reference Modulation Value in the Printhead Code Option ...................................... 5—110
Figure 4. Correct Fitting of the Printhead Calibration Label on the Conduit .............................. 5—111
Figure 5. Approved Ink Types for Use in 4900 Printers with Mk7 Ultima Printheads, and Allowed Ink
Conversions ............................................................................................................................ 5—112
Figure 6. Approved Ink Types for Use in 4900 Printers with Mk7 Ultima plus Printheads, and Allowed
Ink Conversions ....................................................................................................................... 5—113
Figure 7. Approved Ink Types for Use in 4900 Printers with Mk7 Mini Printheads, and Allowed Ink
Conversions ............................................................................................................................ 5—114
Calibrated Nozzle Replacement (Offset Calibration) .......................................................... 5—115

Figure 1. Example of Reference Pressure and Reference Modulation Offset Table ................ 5—117
Figure 2. Reference Pressure Value in the Printhead Code Option ......................................... 5—117
Figure 3. Reference Modulation Value in the Printhead Code Option ...................................... 5—117
Figure 4. Correct Alignment of the Jet into the Gutter .............................................................. 5—118
Figure 5. Correct Fitting of the Printhead Calibration Label on the Conduit .............................. 5—119
24-volt Alarm Beacon Fitting (Printer Mounted) ................................................................. 5—123

Figure 1. Alarm Beacon Mounting Bracket Fitted to the Stalk Assembly .................................. 5—123
Figure 2. Fitting the Alarm Beacon to the Rear of the Printer ................................................... 5—124
Figure 3. Alarm Option Settings for Testing the Alarm Beacon ................................................. 5—125
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Jan 2006 (xviii) Linx 4900 Maintenance Manual
Mains (VFC) External Alarm Conversion ............................................................................. 5—127
Figure 1. Alarm Option Settings for Testing the Mains External Alarm ..................................... 5—128
Positive Air Pump Fitting Instructions ................................................................................. 5—131

Figure 1. Locations of the Positive Air Pump and Air Supply Pipe ............................................ 5—132
Figure 2. Connecting the Positive Air Pipe to the Pump A1–C1 Barb ....................................... 5—133
Figure 3. Printhead Positive Air Pipe Outlet ............................................................................. 5—134
Printhead Feed Valve Replacement ..................................................................................... 5—135

Figure 1. Printhead Upper Cover and Securing Screws ........................................................... 5—136
Figure 2. Printhead Feed Valve Assembly ............................................................................... 5—136
Figure 3. Printhead Feed Valve Component Parts ................................................................... 5—137
Printhead Feed Valve Filter Replacement ............................................................................ 5—139

Figure 1. Printhead Upper Cover and Securing Screws ........................................................... 5—139
Figure 2. Printhead Feed Valve Assembly ............................................................................... 5—140
Figure 3. Printhead Feed Valve Component Parts ................................................................... 5—140
Changing the Orientation of Mk7 Right-Angled Printheads ............................................... 5—149

Figure 1. Removing the Right-Angle Adaptor Top Section ....................................................... 5—149
Figure 2. Changing the Orientation of the Right-Angle Adaptor Bottom Section ...................... 5—150
Auto Mains Power Off Bypass Kit Fitting Procedure .......................................................... 5—153
Figure 1. Location of the Auto Power On/Off Connector PL4 on the IPM PCB ........................ 5—153
Figure 2. Rear View of the Printer Showing the Auto Power On/Off Cableform ....................... 5—154
Figure 3. Front View of the Printer Showing the Auto Power On/Off Cableform ....................... 5—154
Figure 4. 4900 Auto Mains Power Off Bypass Kit .................................................................... 5—155
CHAPTER 6: SYSTEM EVENTS ..................................................................... 6—1

Figure 6-1. Event Message Displayed in the Current Message Screen Status Line ..................... 6—1
Figure 6-2. Accessing the Print Status Screen ............................................................................. 6—2
Figure 6-3. Event List Menu ......................................................................................................... 6—3
Figure 6-4. Warning Information Menu ........................................................................................ 6—3
Figure 6-5. Warning Message Configuration Menu ..................................................................... 6—4
Figure 6-6. Fault Information Menu .............................................................................................. 6—5
Figure 6-7. Fault Message Configuration Menu ........................................................................... 6—5
Figure 6-8. System Event Designations Table ............................................................................. 6—6
Figure 6-9. Print Failure Screen ................................................................................................. 6—11
CHAPTER 7: TROUBLESHOOTING .............................................................. 7—1

Figure 7-1. Simple Flow Chart Example ...................................................................................... 7—1
Figure 7-2. How to Use a Flow Chart ........................................................................................... 7—2
Figure 7-3. Flow Chart Record Sheet .......................................................................................... 7—4
Figure 7-4. List of Troubleshooting Flow Charts .......................................................................... 7—5
Figure 7-5. FC001 Troubleshooting Start ..................................................................................... 7—6
Figure 7-6. FC002 Jet .................................................................................................................. 7—7
Figure 7-7. FC003 Modulation ..................................................................................................... 7—8
Figure 7-8. FC004 Charge ........................................................................................................... 7—9
Figure 7-9. FC005 Phase .......................................................................................................... 7—10
Figure 7-10. FC006 Low Pressure ............................................................................................. 7—11
Figure 7-11. FC007 Ink Quality .................................................................................................. 7—12
Figure 7-12. FC008 Low Viscosity Ink ....................................................................................... 7—13
Figure 7-13. FC009 High Viscosity Ink ....................................................................................... 7—14
Figure 7-14. FC0010 EHT Deflection ......................................................................................... 7—15
Figure 7-15. FC0011 Print ......................................................................................................... 7—16
Figure 7-16. FC0012 Print Quality ............................................................................................. 7—17
Figure 7-17. 2.00 Printhead Over Temperature ......................................................................... 7—18
Figure 7-18. FC201 2.01 EHT Trip ............................................................................................. 7—19
Figure 7-19. FC202 2.02 Phase Failure ..................................................................................... 7—20
MP65557–1 Amdt 01
Linx 4900 Maintenance Manual (xix) Jan 2006
Figure 7-20. FC203 2.03 Time Of Flight Failure ......................................................................... 7—21
Figure 7-21. FC204 2.04 300V Power Supply ............................................................................ 7—22
Figure 7-22. FC205 2.05 Ink Tank Empty .................................................................................. 7—23
Figure 7-23. FC206 2.06 Solvent Tank Empty ........................................................................... 7—24
Figure 7-24. FC207 2.07 Internal Spillage ................................................................................. 7—25
Figure 7-25. FC209 2.09 Misaligned Ink Jet .............................................................................. 7—26
Figure 7-26. FC211 2.11 Pressure Limit Reached ..................................................................... 7—27
Figure 7-27. FC212 2.12 Viscosity ............................................................................................. 7—28
Figure 7-28. FC213 2.13 Hardware Safety Trip ......................................................................... 7—29
Figure 7-29. FC999 Final Test ................................................................................................... 7—30
CHAPTER 9: ILLUSTRATED PARTS LIST .................................................... 9—1

Figure 9-1. Part Description Abbreviation Table ........................................................................... 9—1
Amdt 01 MP65557–1
Jan 2006 (xx) Linx 4900 Maintenance Manual
CHAPTER 1: GENERAL
1.1 Introduction
The Linx 4900 Continuous Ink Jet Printer is a fast, reliable, non-contact printer capable of
applying sell-by dates, batch codes, logos and other variable information to a wide range of
substrates on the production line.
1.2 Technical Data

1.2.1 Printer Configurations
A new configuration code option is introduced in v1.5 System Software.
Dairy Coder (SS to DC Upgrade)

This configuration code enables the Mini printhead option and associated message types,
additional Ultima and Ultima plus stitched message types, and the Dynamic Message
Orientation feature. The DC configuration is only available with an IPM PCB Revision 7
and later revisions.
When the 4900 printer is configured as a DC, the letters “DC” are displayed in the bottom
left corner of the startup splash screen.
NOTES:
1. The Ultima or Ultima plus printheads can also be used with the DC printer.
2. The Mini printhead can only be used in the DC configuration.
v1.5 49083
Speed: Standard High Speed Super High DC
Speed (SS) (HS) Speed (SHS) (SHS)
Lines of print: 1 2 1 2 1 2 1 2
Printheads: Ultima ● ● ● ● ● ● ● ●
Ultima plus ● ● ● ● ● ● ● ●
Mini – – – – – – ● ●
Figure 1-1. Printer Configurations
1.2.2 Environmental
Operating temperature: +5 °C to +45 °C ambient, except were ink type imposes
additional limitations
Humidity range: Maximum of 90% relative humidity, non–condensing
Acoustic emission: Less than 70 dBA
Protection rating: Printer protected to IP55 in respect of water and dust
MP65557–1 Amdt 01
Linx 4900 Maintenance Manual 1—1 Jan 2006
1.2.3 Power Requirements
Voltage: Single phase, 100 V (3 A) to 230 V (1 A) a.c., 50/60 Hz
Power rating: 200 VA
This equipment is a Class 1 earthed appliance as defined by EN 60950. Electrical
connections at the rear of the cabinet comply with the extra low voltage safety
requirements as defined by EN 60950.
WARNING: THIS PRINTER MUST BE EARTHED/GROUNDED.

The integrity of the insulation resistance between the live conductors and earth has been
tested in accordance with the test defined in EN 60950.
The integrity of the protective earthing conductors has been tested in accordance with the
test defined in EN 60950.
1.2.4 Cabinet
Construction
Base tray unit: Stainless steel
Top cover: Stainless steel
Dimensions
External height: 236 mm (including filler caps)
External width: 483 mm
External depth: 590 mm (excluding mains connector cover)
Weight
Printer weight: 19.5 kg (excluding ink, solvent and packaging)
1.2.5 Low Voltage Power Supply Unit

Input: 85 V a.c. to 264 V a.c. 50/60 Hz
Outputs (100 W total): +5.1 V d.c. ±5%, 2.5 A
+12 V d.c. ±5%, 0.9 A
–16 V d.c. ±5%, 0.4 A
+24 V d.c. ±5%, 2.5 A
1.2.6 EHT Power Supply Unit

Inputs: +24 V d.c. ±5%, < 1.2 A
0 V to +10 V d.c. (EHT output level control)
Outputs: 0 V to +10 kV d.c. max. ±5%, 10 µA
+300 V d.c. ±5%, 10 mA to 46 mA
Amdt 01 MP65557–1
Jan 2006 1—2 Linx 4900 Maintenance Manual
1.2.7 Ink System
ATEX Directive 94/9/EC
Description
The ATEX (ATmosphere EXplosible) Directive 94/9/EC is applicable to equipment and
protective systems intended for use in potentially explosive atmospheres. For the 4900
Continuous Ink Jet printer, this directive is only applicable to the Ink System.
Refer to ‘ATEX EU Declaration of Conformity Certificate’ in the section ‘Regulatory
Approvals’ of this chapter.
Type and Classification

Ink system type: AS16087/AS16096
ATEX classification: II 3G IIA T4

where:
II is the equipment group
3 is the equipment category
G is explosive atmospheres caused by gases, vapours or
mists
IIA is the gas group
T4 is the temperature class
IMPORTANT: The above ATEX information does not mean that the 4900 Continuous Ink
Jet printer can be used in any environment. CIJ printers cannot be used, 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 be present.
Construction
Ink system enclosure: Self-contained, stainless steel
Ink tank: Natural polyethylene
Solvent tank: Natural polyethylene
Environmental
Protection rating: Protected to IP65 relative to the printer cabinet
Electrical Connections
Construction: • Double insulated
• In accordance with the requirements for equipment
operating in Zone 2
Maximum Surface Temperature

Valves’ solenoids: 107 °C under fault conditions
Pressure
Pressure range: Up to 65 p.s.i./4.49 bar (255 bits) normal operating
pressure
Maximum pressure: 90 p.s.i./6.21 bar (353 bits) under fault conditions
MP65557–1 Amdt 01
Capacity
Ink and solvent tanks: 1600 ml maximum; 1440 ml usable
Fluid Level Control

Ink & solvent tanks sense low: Warning reported at approximately 740 ml, leaving 690 ml
of usable ink or solvent
Performance
Solvent consumption: Please contact Linx for information on solvent
consumption
Inks
Ink capability: Refer to the ‘Ink Type Dependent Parameters’ tables at the
end of the ‘Ink System’ section in ‘Chapter 3: Technical
Description’
1.2.8 Printhead
Types
Mini: Mk7 (50 µm nozzle jewel diameter)
Ultima: Mk7 (62 µm nozzle jewel diameter)
Ultima plus Mk7 (75 µm nozzle jewel diameter)
Construction
Printhead: Thermoplastic polyester body
Cover tube: Stainless steel
Conduit adaptor: Stainless steel
Dimensions
Straight and Right-Angled Printheads

Printhead body length: Straight printhead 222 mm, excluding conduit fitting (see
also conduit minimum bend radius below for clearance)
Right-angled printhead 261 mm, including conduit fitting
Printhead body diameter: 42 mm
Conduit length: 2 m or 4 m
Conduit diameter: 16.5 mm
Conduit minimum bend radius: 75 mm (static applications)
150 mm (dynamic applications)
1.2.9 Printing Performance Data

Further information can be found in the Linx CIJ print performance data pamphlet for the
Mk7 printhead types, or in the Linx 4900 Ink Jet Printer Operating Manual, Issue 1 with its
supplements, or later issue.
Amdt 01 MP65557–1
Mini (50 µm)—Dairy Coder Only
Lines of print: Up to two lines of 7 High characters
No. of message types (rasters): 15
Maximum speed: 6.83 m/s—one line of 5 High characters using message
types:
4T 1×5 WIDE 6.83m/s
8T 1×5 WIDE 6.83m/s
Minimum character height: 2.0 mm nominal at default EHT using message types:
8T 1×7 Quality 1.30m/s
8T 1×7 Speed 1.95m/s
4T 1×5 WIDE 6.83m/s
8T 1×5 WIDE 6.83m/s
Maximum character height: 4.56 mm nominal at default EHT using message types:
Ultima (62 µm)

type 5 Linear Wide
Minimum character height: 2.2 mm using message type 5 Linear Wide (at –5% EHT)
Maximum character height: 7.4 mm using message type 16 Linear Wide (at 0% EHT)
Ultima plus (75 µm)

type 5 Linear Wide
Minimum character height: 2.7 mm using message type 5 Linear Wide (at –5% EHT)
Maximum character height: 8.8 mm using message type 16 Linear Wide (at 0% EHT)
Printhead to Substrate Distance (recommended)

Mini: 4 mm or 8 mm, depending on message type. For more
information, refer to the Linx 4900 Ink Jet Printer Operating
Manual, Issue 1 with its supplements, or later issue
Ultima: 12 mm
Ultima plus 12 mm
MP65557–1 Amdt 01
1.2.10 Memory Capacity
Message storage: Up to 50 (dynamic allocation)
Logo storage: Up to 100
1.2.11 Regulatory Approvals

Safety
Approved in accordance with TÜV/GS requirements.
Machinery Directive
98/37/EC
Low Voltage Directive

73/23/EEC as amended by 93/68/EEC
Applicable European Safety Standards

EN 292-1:1991 Safety of Machinery. Basic concepts, general principles for
design. Basic terminology, methodology.
EN 292-2:1991 Safety of Machinery. Basic concepts, general principles for
design. Technical principles and specifications.
EN 60204-1:1997 Safety of machinery. Electrical equipment of machines.
Specification for general requirements.
EN 60950:1992 Specification for safety of information technology
equipment, including electrical business equipment.
Electromagnetic Compatibility (EMC)
EMC Directive
89/336/EEC as amended by 92/31/EEC and 93/68/EEC
Applicable European EMC Standards

EN 61000-6-2:2001 Electromagnetic compatibility (EMC). Generic standards.
Immunity standard for industrial environments.
EN 61000-6-4:2001 Electromagnetic compatibility (EMC). Generic standards.
Emission standard for industrial environments.
Applicable USA EMC Standards

FCC 47CFR, Part 15. Class A device
Enclosure Protection
EN 60529:1991 Specification for degrees of protection provided by
enclosures (IP code).
ATEX EU Declaration of Conformity Certificate

NOTE: The ATEX EU Declaration of Conformity certificate provided opposite is only
applicable to the Ink System.
Amdt 01 MP65557–1
MP65557–1 Amdt 01
1.3 Abbreviations and Glossary
a.c. or AC alternating current
ADC Analogue to Digital Converter
ATEX ATmosphere EXplosible
CPU Central Processing Unit
d.c. or DC direct current
DC Dairy Coder
DAC Digital to Analogue Converter
DVM Digital Voltmeter
DPP Deflector and Phase Plate
EHT Extra High Tension (voltage)
EHTPSU Extra High Tension Power Supply Unit
EMC Electromagnetic Compatibility
EPROM Erasable Programmable Read-Only Memory
FC Fault Code
Flash Memory High density, non-volatile, read/write memory IC, which holds
the system software program
IC Integrated Circuit
IP International Protection
IPM Integrated Processor Module
LCD Liquid Crystal Display
LK Link
LVPSU Low Voltage Power Supply Unit
MEK Methyl Ethyl Ketone
Mk Mark (followed by a number indicating a particular design, model,
version, as in Mk7 Printhead)
N/A Not Available or Not Applicable
NiMH Nickel Metal Hydride
NMI Non-Maskable Interrupt
NVR Non-Volatile RAM
PCB Printed Circuit Board
PDEM Product Detector/Encoder Multiplexer
Pixel The smallest size of spot on the screen that makes up the displayed
message
PL Plug (connector with male pins/contacts)
PLC Programmable Logic Controller
PLCC Plastic Leadless Chip Carrier
PLD Programmable Logic Device
Print Go An internal logic signal that initiates print, normally preceded by a
print trigger
Print registration The horizontal position of a printed message on a substrate
Amdt 01 MP65557–1
Print trigger A logic signal generated by a product sensor, which initiates
printing of a single message
p.s.i. pounds per square inch (lb/in2); (imperial unit of pressure)
PSU Power Supply Unit
r.f. radio frequency
RAM Random Access Memory
Raster A variable line of drops printed at 90 degrees to the direction of
production line travel, which create characters that are made up of
one or more rasters
SK Socket (connector with female pins/contacts)
SRAM Static Random Access Memory; a low density, volatile,
reprogrammable memory
Substrate Surface (product) on which printing is done
S/W Software
t.b.a. To be announced
TFT Thin-Film Transistor
TOF Time Of Flight
TP Test Point
UNIC Unique Number Identification Chip
USB Universal Serial Bus
VFC Volt-Free Contacts
VGA Video Graphics Array
MP65557–1 Amdt 01
Amdt 01 MP65557–1
Jan 2006 1 — 10 Linx 4900 Maintenance Manual
CHAPTER 2: SAFETY
2.1 Introduction
WARNING: SAFETY. IRRESPECTIVE OF THE LEVEL OF PERCEIVED HAZARD,

THE SAFETY PROCEDURES OUTLINED IN THIS SERVICE MANUAL MUST BE
FOLLOWED.
This chapter provides essential information concerning the precautions to be taken to
ensure that all maintenance and related tasks are carried out with the maximum possible
safety.
Therefore, it is essential that all operators of a Linx ink jet printer read and understand this
safety chapter before attempting to operate or carry out any maintenance tasks on it.
Personal injury may occur if the following are not observed:
• Only trained personnel should operate, or carry out maintenance tasks on, the printer
• The main electrical power supply must be disconnected before carrying out cleaning or
any other maintenance work within the printer cabinet, unless it is essential to have
power applied to the printer in order to carry out the task
2.2 Warnings, Cautions and Notes

At appropriate points within the text of this manual, WARNINGS, CAUTIONS and
NOTES are provided. These are designed to bring to the attention of the reader
information about the avoidance of hazards, and the safe handling and correct use of a
product.
The definitions of WARNINGS, CAUTIONS and NOTES are as follows.
2.2.1 Warnings
A WARNING alerts the reader to possible hazards that may cause loss of life, physical
injury, or illness.
Wherever a WARNING appears in this manual, the text is preceded by either a specific
warning symbol or a general warning symbol, examples of which are shown and described
below.
MP65557–1
Linx 4900 Maintenance Manual 2—1 Nov 2003
Specific Warning Symbols
The following specific warning symbols are used to alert the reader to the mandatory
requirement to wear safety glasses and solvent-resistant protective gloves when there is a
risk of exposure to inks or solvents:
The following specific warning symbol is used to alert the reader to the risk of exposure to,
and the hazards of, lethal voltages:
The following specific warning symbol is used to alert the reader to the risk of fire due to
the highly flammable nature of a substance:
The following specific warning symbol is used to alert the reader to the fact that a
particular substance is an irritant to the eyes and the respiratory system:
General Warning Symbol

The following general warning symbol is used to alert the reader to other harmful or
potentially lethal activities:
2.2.2 Cautions
A CAUTION alerts the reader to a possible hazard that may cause damage to the printer,
other goods or the environment, but is not a danger to personnel.
2.2.3 Notes
A NOTE provides additional information of an advisory nature or of particular interest.
The following hand symbol may be shown beside an IMPORTANT note to indicate that the
reader should pay particular attention to the information given:
MP65557–1
Nov 2003 2—2 Linx 4900 Maintenance Manual
2.3 Lethal Voltages
WARNING: LETHAL VOLTAGE. DANGEROUS VOLTAGES ARE PRESENT IN

THIS EQUIPMENT WHEN ELECTRICAL POWER IS APPLIED. EXTREME CARE
MUST BE TAKEN WHEN MAKING ANY ADJUSTMENTS WHILE POWER IS
APPLIED TO THE PRINTER AND THE COVER IS REMOVED. THE CORRECT,
STANDARD ELECTRICAL SAFETY PRECAUTIONS MUST BE TAKEN. SWITCH
OFF THE PRINTER BEFORE REMOVING OR REFITTING ANY COMPONENTS
OR LINKS. THERE IS A DANGER OF DEATH OR INJURY FROM ELECTRIC
SHOCK IF THE CORRECT SAFETY PRECAUTIONS ARE NOT TAKEN.
When the printer cabinet cover is removed, the mains supply and the 300 volts d.c. supply
are accessible.
WARNING. LETHAL VOLTAGE. IF A MAINS-POWERED EXTERNAL ALARM

IS CONNECTED TO THE PRINTER, THERE MAY BE MAINS VOLTAGE ON THE
PCB ATTACHED TO THE ALARM CONNECTOR AND ON THE IPM PCB IN THE
AREA OF THE EXTERNAL ALARM RELAY, EVEN IF THE PRINTER IS
ISOLATED FROM ITS OWN MAINS POWER SUPPLY. WHEN THE PRINTER
TOP COVER IS REMOVED, DO NOT TOUCH THE ALARM CONNECTOR PCB
OR THE IPM PCB IN THE AREA OF THE EXTERNAL ALARM RELAY. FAILURE
TO OBSERVE THIS SAFETY WARNING COULD RESULT IN ELECTRIC SHOCK,
WHICH MAY CAUSE INJURY OR DEATH.
To avoid the danger of electric shock, when the printhead cover tube is removed printing is
stopped. In addition, the charge electrode voltage is limited to less than 10 volts instead of
the normal 300 volts, and the +8 kV supply to the deflector plates is switched off.
WARNING: THIS PRINTER MUST BE EARTHED.
MP65557–1
2.4 Inks and Solvents
WARNING: HAZARDOUS SUBSTANCES. MANY OF THE INKS USED WITH

THIS PRINTER ARE SOLVENT-BASED AND AS SUCH CAN BE HAZARDOUS.
THEY ARE HIGHLY FLAMMABLE AND IRRITATING TO THE EYES AND
RESPIRATORY SYSTEM.
SAFETY GLASSES AND SOLVENT-RESISTANT PROTECTIVE GLOVES MUST
BE WORN WHEN HANDLING INKS AND SOLVENTS, WHEN WORKING ON
THE PRINTER, AND WHEN CARRYING OUT CLEANING OPERATIONS.
FAILURE TO COMPLY WITH THIS SAFETY WARNING COULD RESULT IN
IRRITATION AND REVERSIBLE LOCAL DAMAGE TO THE EYES, AND NON-
ALLERGIC CONTACT DERMATITIS.
Make sure you know the relevant hazards, safety precautions and first aid procedures
before you use a hazardous substance. Read the Material Safety Data Sheet applicable to
the substance to obtain this information. Ensure you have all the relevant safety data
sheets and that they are available on site. If they are not, contact your distributor.
The following paragraphs summarize the precautions to be taken and first aid procedures.
2.4.1 Precautions
It is essential that the following precautions are observed:
• Read the relevant ink and solvent Material Safety Data Sheets
• Do not smoke or use naked flames near the printer or ink and solvent storage areas
and containers
• Wear safety glasses that comply with the appropriate British and European Directives
when handling inks and solvents, or when inspecting or repairing the printer. The eye
protection symbol shown above is used in this manual, where appropriate, to remind
personnel of the mandatory requirement to WEAR SAFETY GLASSES
• Wear approved, solvent-resistant gloves when handling inks and solvents, when
inspecting or repairing the printer, or at any time when your hands may come into
contact with inks or solvents. The hand protection symbol shown above is used in
this manual, where appropriate, to remind personnel of the mandatory requirement to
WEAR SAFETY GLOVES. Barrier creams may help to protect areas of exposed skin
but are not a substitute for full physical protection. They should not be applied once
exposure has occurred
• Never clean your hands with solvent; use an approved hand cleanser
• Ensure that the area is adequately ventilated at all times when working on the printer,
and with inks and solvents
• Smoking, eating and drinking are to be prohibited in areas of storage and use
• Remove all spilt ink and solvent, and any build-up of ink deposits immediately, using
the correct solvent for the ink being used
• Do not overfill the printer’s ink and solvent tanks. Refer to the 4900 Operating Manual
for details on how to correctly refill the ink system
• Remove all spilt ink and solvent immediately, from both the interior and exterior of
the printer, and from the surrounding area, using the correct solvent type for the ink
type being used
MP65557–1
• Remove any build-up of ink deposits from the interior of the printer, using the correct
solvent type for the ink type being used
• Store all inks and solvents in their original containers, tightly closed, in a well
ventilated cabinet away from any source of heat
• All waste ink and solvent must be disposed of correctly in accordance with local
regulations and must not be allowed to enter the water drainage system
2.4.2 First Aid

The following are summaries of the applicable first aid procedures for exposure to inks and
solvents.
Eye Contact
If contact lenses are worn, remove these first. Use an approved emergency eyewash
solution as directed on the bottle label. Alternatively, irrigate eyes copiously with clean
running water and continue doing so for at least 10 minutes, holding the eyelids apart.
Obtain medical attention immediately.
Skin Contact
Remove any contaminated clothing. Wash the affected area thoroughly with soap and
water, or use a proprietary skin cleaner. Do NOT use solvents or thinners. Obtain
medical attention if irritation persists after washing.
Inhalation
Remove the affected person to fresh air immediately. Keep the affected person warm and
at rest. If breathing is irregular or has stopped, administer artificial respiration and obtain
immediate medical attention. Give nothing by mouth. If unconscious, place the affected
person in the recovery position and seek medical advice.
Ingestion
If accidentally swallowed, obtain immediate medical attention. Rinse mouth thoroughly
with water and give 200 ml to 300 ml (half a pint) of water to drink. Keep at rest. Do
NOT induce vomiting.
MP65557–1
2.5 Test Printing
Printing drops hold a charge, which is not dissipated until the drops make contact with the
substrate. If test printing is carried out into a container, a charge can build up in the
collected ink, which may eventually, suddenly discharge to earth causing the ink to ignite.
To avoid this risk of fire, it is extremely important to make sure that the ink itself is earthed
in order to dissipate the charge. If a metal container is used, this can be achieved by
connecting the container to an earth point. If a non-metallic container is used (e.g. glass or
plastic), one end of a length of wire should be placed directly into the ink, and the other
end connected to an earth point (see Figure 2-1). The knurled cover tube securing screw on
the printhead may be used as an earth point. To ensure correct printer operation, this is
the only time that the printhead cover tube securing screw should be used for the
purpose of earthing.
49201
ULTIMA
Figure 2-1. Test Printing into a Non-metallic Container
MP65557–1
CHAPTER 3: TECHNICAL
DESCRIPTION
3.1 Introduction
This chapter provides a technical description of the function of the various sub-systems,
modules and components that comprise the Linx 4900 Ink Jet Printer. The following topics
are covered in this chapter:
3.2 Cabinet
3.3 User Interface
3.4 Printhead Components
3.5 Printhead Principles of Operation
3.6 Ink System
3.7 Electrical Components
3.8 Electronics and Software
3.9 External Signals
3.2 Cabinet
3.2.1 Introduction
The purpose of the cabinet is to house and support the modules that comprise the printer,
and to protect them from contamination. The printer cabinet is designed to meet an
International Protection (IP) rating of IP55 in respect of water and dust ingress.
The cabinet is a two-piece structure consisting of a top cover and a base tray unit.
3.2.2 Top Cover

The stainless steel top cover is secured at the front and rear to the stainless steel base unit.
The top cover hooks under a locating flange at the rear of the base unit, and is lowered into
place and secured by a latch at the front. The latch is locked by rotating it through 90
degrees using a special tool, which is available to service engineers.
The top cover houses the keyboard, LCD screen, and the Display PCB, which form the
interface between the operator and the printer. The keyboard is an integral part of the top
cover. The LCD screen is mounted directly onto the underside of the top cover with the
Display PCB mounted on stand-off pillars above it.
MP65557–1
3.2.3 Base Unit
The base unit houses the following main components: the ink system enclosure; electronics
system (IPM PCB); mains power on/off and control switches; mains filter and fuses; low
voltage power supply unit (LVPSU); EHT power supply unit (EHTPSU); cooling fan and
air filter; optional printhead positive air pump.
The back plate of the base unit allows entry of the printhead conduit and the non-user-
removable mains power supply cable. The mains power supply cable enters the rear of the
printer below the on/off switch. External connectors for RS232, product sensors, shaft
encoders and the alarm output are also provided on the back plate. All the connectors are
IP67 rated.
The cabinet also provides fixing points on the rear face for the alarm beacon.
3.2.4 Ink System

The ink system is further protected by, and housed within, a self-contained stainless steel
enclosure that is integral to the printer base unit. The lid of the ink system is formed by the
top cover and a gasket when closed. When the top cover is correctly fitted, the ink system
enclosure is sealed to a minimum IP65 rating with respect to the electronics enclosure.
Protective caps for the ink and solvent filler tubes are situated on the upper, rear surface of
the top cover.
3.2.5 Cooling and Air Filter

The air intake for the cooling fan is on the underside of the base unit. A cabinet air filter is
included, located beneath the fan in its own housing. The cooling air flows in through the
air filter, around the inside of the cabinet and out through a mesh grill in the cabinet base.
The air filter, located on the right-hand side of the base unit, may be removed for cleaning
or replacement. This is achieved by pulling the loop attached to the filter to remove it from
its housing. The filter should be cleaned using compressed air blown through in the reverse
direction to the normal air flow, or replaced if it is severely blocked or damaged.
There is a natural air vent for the ink system on the lower rear face of the base unit.
The following illustration provides a view of the 4900 printer base unit showing the
locations of the main components:
MP65557–1
External Alarm Output,
Primary Trigger and
Shaft Encoder
Connectors
MP65557–1
Ink System 49164 Printhead Conduit
Enclosure entry/exit
Pressure
Transducer Mains Filter and Fuses
(located below Mains
Power On/Off Switch Unit)
Ink System
Linx 4900 Maintenance Manual

Valves Mains
Power Cable
IPM PCB
Cooling Fan
3—3
Mains Power On/Off
Switch Unit
LVPSU
Top Cover
Securing Latch
Ink System
Pump/Motor Assy
Positive Air Pump Air Filter
(optional)
Mains Power On
EHTPSU
Nov 2003
Control Switch Air Filter Housing
Figure 3-1. 4900 Printer Base Unit and Main Components
3.3 User Interface
The user interface consists of a keyboard and a display, with associated control keys and
indicators.
3.3.1 Keyboard and Display

The keyboard includes 48 alphanumeric keys (QWERTY layout) and 10 standard control
keys, on a tactile membrane keypad, which are used to input and edit messages.
The display is positioned above the keyboard and is a Liquid Crystal Display (LCD)
screen with cold cathode back-lighting. Its contrast setting is software-controlled. There
are left, right, up, and down arrow control keys associated with the display, and [start]
and [stop] keys are also provided to the left of the display.
Before printing can take place, a message or messages must be created. A message is a
structure describing the text or pattern to be printed. Each message consists of one or more
fields, which can be of a number of types. For example, a text field is simply fixed text that
will not change from one print to the next; a time field displays the actual time (or the time
offset by a specific amount) and will change accordingly from one print to the next. Refer
to the 4900 Ink Jet Printer Operating Manual for details about creating and editing messages.
3.3.2 Control Panel LEDs

Fail
The software controlled red Fail LED lights when a System Failure or a Print Failure occurs
and remains lit until the printer is powered down.
Warning
The software controlled red Warning LED lights when there are one or more active System
Warning errors on the printer. These errors can be viewed (and cleared) via the EVENT
LIST menu (CURRENT MESSAGE screen > F2 : Check Status). Once the last remaining
error has been cleared the LED extinguishes.
Ready
The software controlled green Ready LED lights when the printer is ready to print, i.e.
when the jet is running, a message is loaded, and the [start] key has been pressed.
Power
The green Power LED remains on while the printer is powered up. It is not under software
control.
The following illustration shows the 4900 standard European user interface:
MP65557–1
49010
Figure 3-2. 4900 European User Interface
MP65557–1
3.4 Printhead Components
The following subsection identifies the main components of the printhead and describes
their basic functions together with various other aspects of the printhead. The illustration
below shows the location of the main printhead components:
Printhead Conduit 49200

to control unit
and ink system
Printhead Feed and

Purge Valves
(inside the cover)
Cover Tube
Securing Screw
ULTIMA
Gun Body and Chamber

(under Mounting Board) Nozzle Assembly Cover
Nozzle
Charge Electrode
Mounting Board Charge Strobe LED

(in Charge Electrode slot)
+8 kV
Deflector Plate 0V Deflector Plate
(incorporating Phase and
TOF Sensors)
Gutter
Figure 3-3. The Mk7 Ultima Printhead Main Components
MP65557–1
3.4.1 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 located beneath the printhead component mounting board, directly
below the nozzle assembly. Within the chamber the ink is pulsed (modulated) by the effect
of a piezoelectric crystal causing the ink jet to break up into drops.
The modulated jet is forced from the nozzle assembly through a precisely machined hole in
a small jewel (located in the nozzle cap) of 50 µm, 62 µm or 75 µm, depending on the type
of printhead.
3.4.2 Charge Electrode

The charge electrode is used to apply a charge to individual ink drops as they break off
from the ink jet. Drops that are required for printing are charged, while drops that are not
required for printing remain uncharged and travel to the gutter, returning to the ink tank
for reuse.
3.4.3 Strobe LED

A red light-emitting diode (LED) is located in the centre of the charge electrode slot, so that
it is behind the jet break-up point, when viewed from the front of the printhead. The
stroboscopic effect of the LED allows the details of the jet break-up to be examined with an
eyeglass, which can be useful for diagnostic purposes.
3.4.4 Deflector Plates

An electrostatic field is generated between the two deflector plates. As the ink jet passes
through the field, charged (printing) drops are deflected in proportion to the amount of
charge they carry, while uncharged (non-printing) drops are unaffected by the field. The
uncharged, and therefore undeflected, drops enter the gutter where they are drawn back
through the system to the ink tank for reuse.
The combination of the speed of the drops travelling through the field and the charge given
to them is accurately determined to ensure that each drop is positioned correctly on the
substrate (the surface onto which the pattern is to be printed).
3.4.5 Phase and TOF Sensors

There are two sensors incorporated in the 0 volt deflector plate and this assembly is called
the Deflector and Phase Plate (DPP). These sensors are used to monitor the jet to ensure that
the printer is operating correctly. The first sensor (nearest the nozzle) is called the Phase
Sensor; the second sensor (nearest the gutter) is called the Time Of Flight (TOF) Sensor.
During startup, and at intervals between printing patterns, the printer monitors the jet
performance. Signals are picked by the two sensors from the passing drops and these
signals are used by the printer for two functions. The first is to ensure that the drops are
receiving the optimum charge for consistent print quality—this is called phasing. The
second function is to measure the velocity of the jet by timing the flight of the drops
between two fixed points—the Phase sensor and the TOF sensor. This is called the Time Of
Flight measurement.
The phase and TOF readings are checked routinely to optimize print quality.
MP65557–1 Amdt 01
3.4.6 Printhead Cover Sensor
This sensor is a Hall effect switch that is used to detect the presence of the printhead cover
tube and is situated within the printhead body. A small magnet inside the cover tube
activates the Hall effect switch when the cover tube is fitted to the printhead. Activation of
the Hall effect switch enables the print process by switching on the deflector plate EHT
circuit. When the cover tube magnet is moved away from the Hall effect switch by
approximately 3 mm (which is insufficient to allow access to the potentially dangerous
charge electrode and deflector plates), the switch is deactivated. This disables the EHT
circuit, and printing is suspended. Printing is resumed 6 seconds after the printhead cover
tube is refitted.
3.4.7 Printhead Temperature Sensor

The printhead is also fitted with a thermistor, which has the following two functions.
Over Temperature
Firstly, it acts as a safety sensor so that if a local printhead temperature in excess of 60 °C is
detected, the printer is immediately shut down in a controlled way. In addition, the Print
Failure message “2.00 Printhead Over Temperature” is displayed in the screen status line
to warn of the printhead’s ‘over temperature’ condition.
Ink Density
Secondly, the temperature monitored by the sensor is used to compensate for variations in
ink density at the extremes of the printer’s operating temperature range.
Under normal operating conditions the Set Pressure is varied as the ink viscosity changes,
to maintain a constant TOF. For example, as the ink viscosity increases due to solvent
evaporation, the Set Pressure is increased to maintain a constant TOF (at Reference TOF)
with the thicker ink. If the Set Pressure reaches the predetermined Solvent Add Pressure,
solvent is added to the ink to decrease the viscosity and thus maintain the Actual TOF at
Reference TOF. Refer to ‘Solvent Addition’ in the section ‘Ink System’ later in this chapter.
Whilst the pressure required to achieve the correct TOF is viscosity-dependent, it is also
affected by temperature and, more importantly, by ink density. For example, at lower
temperatures when the ink is more dense, it is necessary to drive the jet at a greater
pressure to maintain the correct TOF. Therefore, the printhead temperature is monitored
and the Set Pressure is adjusted accordingly to compensate for the greater ink density.
The Solvent Add Pressure is offset by an amount determined by the printhead
temperature. This prevents the printer from adding solvent too early to dilute the ink at
low temperatures, when the ink is at a higher density but is at the ideal viscosity.
The above principle applies, but in reverse, when there is a high printhead temperature
and the ink density is low.
This pressure compensation explains why the Reference Pressure may be seen to change at
extreme operating temperatures in the PRESSURE REFS screen (Setup menu > Diagnostics
menu > Ref Pressures option).0
See also: ‘Viscosity Control’ in the section ‘Printhead Principles of Operation’ later in this
chapter.
‘Solvent Addition’ in the section ‘Ink System’ later in this chapter.
Amdt 01 MP65557–1
3.4.8 Printhead Feed and Purge Valves
During the time that the printer is switched off, small amounts of residual ink-stained
solvent can form into ‘slugs’ in the pipes between the printhead nozzle and the ink system
feed and purge valves.
Printhead feed and purge valves are incorporated in the Mk7 printhead, which prevent the
slugs from reaching the gun. The normal shutdown sequence is therefore as follows.
Solvent is flushed through the system to clear the printhead gun, and the feed and purge
lines of ink. The solvent is fed directly to the printhead feed valve and out to the gun
chamber. Towards the end of the shutdown sequence the gun–to–printhead feed valve
pipe is cleared of solvent. The printhead feed valve is then closed and the gun-to-printhead
purge valve pipe is cleared of solvent.
At the end of the shutdown sequence the printhead feed and purge valves are closed,
effectively sealing off the ink system from the printhead nozzle. Therefore, any slugs of
ink-stained solvent that may form in the feed and purge lines are contained, keeping the
nozzle clean in preparation for the next startup.
Feed Valve
The printhead feed valve is a 24-volt, electrically-operated, solenoid valve. It is fitted with
an integral 15 µm filter on the Mini and Ultima printhead, and a 35 µm filter on the Ultima
plus printhead.
NOTE: All specified filter sizes are nominal ratings.
Purge Valve
The printhead purge valve is a ball-and-spring type of non-return valve (NRV), which is
designed to open at a positive pressure difference of approximately 8 bits.
3.4.9 In-Line Feed Filter

This component is a stainless steel in-line filter fitted in the feed line within the printhead
3-way fluid connector. Its purpose is to provide increased protection for the printhead from
ink-borne particles, which could cause a blocked nozzle. The filter size is 5 µm for Mini and
Ultima printheads, and 35 µm for the Ultima plus printhead.
The filter is also colour-coded: black for Mini and Ultima printheads; white for the Ultima
plus printhead. It is most important when replacing an in-line feed filter that a black filter (5
µm) is fitted to a black 3-way fluid connector female part (printhead side); and a white
filter (35 µm) is fitted to a white 3-way fluid connector female part (printhead side).
68053
Assembly Filter
screw
O-ring gasket
Locating
lug
Locating
recess
Figure 3-4. 3-Way Fluid Connector Containing the In-line Feed Filter
MP65557–1 Amdt 01
3.4.10 Standard Gutter Restrictor
During normal running conditions, air is drawn into the gutter with the ink that is
returning to the ink tank. This volume of air flowing with the ink in the gutter return line
causes the solvent in the ink to evaporate, which in turn causes an increase in solvent
consumption.
A restrictor is fitted in the printhead gutter return line to control the airflow. This reduces
solvent consumption and, consequently, the volume of vented solvent fumes.
The gutter restrictor is currently fitted as standard inside the gutter return line of the Mk7
Mini, Ultima and Ultima plus printheads (2-metre conduits only), and as such is part of the
printhead assembly. The restrictor is held in place with a clip, and is located on the
printhead side of the 3-way fluid connector within the printer cabinet.
3.4.11 In-Line Gutter Check Valve

Where the application of a printer requires that the printhead is mounted below the level of
the printer, there is a small risk that ink can siphon from the ink tank when the printer is
not in use. To eliminate the possibility of this occurring, a check valve can be fitted in the
gutter return line of Mini, Ultima and Ultima plus printheads.
48007
FLOW
Figure 3-5. In-Line Gutter Check Valve

This check valve is available as a spare part only; it is not fitted to Mini, Ultima or Ultima
plus printheads as standard.
3.4.12 Electrical and Fluid Connections

The printhead is connected to the printer via a number of electrical cables and fluid lines.
The various electrical connections are either labelled with letter identifications, or are
polarized sockets and plugs.
A 3-way fluid connector is used to connect the three fluid lines to the printer, which are
colour-coded as follows: feed line—red stripe; purge line—blue stripe; gutter line—no
stripe. The connector is also colour-coded: black for Mini and Ultima printheads; white for
the Ultima plus printhead.
Amdt 01 MP65557–1
3.5 Printhead Principles of Operation
3.5.1 Overview
The following is a brief overview of the basic principles of operation of the ink jet
printhead. This is followed by a more detailed description of each part of the process.
A character is formed on the substrate from ink drops emitted from a printhead. The
structure of the character is determined by whether a drop is printed or discarded. The
drops are emitted from the printhead in lines known as rasters, and each raster has a certain
number of drops that determines the potential height of a character. The character is built
up from successive rasters as the substrate travels past the printhead.
Inside the printhead, the jet of ink is produced by forcing electrically-conductive ink under
pressure through a precisely machined hole in an industrial sapphire (jewel), which is
located in the printhead nozzle cap. Prior to it exiting the nozzle, the ink is pulsed
(modulated) to produce a constant stream of modulated ink. This stream is directed along
the length of the printhead, via the charge electrode where the ink drops are formed, to a
gutter which collects non-printing drops and returns them under vacuum to the main ink
storage tank.
Ink drops that are required to be printed are subjected to an electrostatic charge. This
occurs inside the charge electrode, which is situated at the point in the jet flight path where
the jet breaks up and the drops form. The electrostatic charge causes a flow of electrons
onto the drop as it is formed. The printing drop now possesses a negative electric charge.
This electrically-charged drop travels with the main stream of drops until it enters the area
between two deflector plates. The electrostatic field generated between the plates produces
a force on the drop, causing it to deflect from its original straight path and be attracted
towards the positive potential plate. The drop is deflected by an amount proportional to
the charge on the drop and the potential across the two deflector plates.
To ensure that the printing drops are receiving the optimum charge, a regular test of the
charging function is performed by measuring the drop charge at a sensor (phase sensor).
A measurement of jet speed is also carried out using both the phase sensor and the Time Of
Flight sensor to measure the time taken for drops to travel the set distance between the two
sensors. This time period provides an accurate evaluation of jet speed, which is then used
by the printer to vary the pressure at which the ink is forced from the nozzle and, in
conjunction with the pressure, to assess ink viscosity at the printhead.
3.5.2 Printhead Types

The Linx 4900 printer currently uses three types of Mk7 printheads. The basic design of
these is similar but with one important difference. Each type of printhead has a different
nozzle orifice size (jewel size—measured in micrometres), as follows:
• Mini: 50 µm
• Ultima: 62 µm
• Ultima plus: 75 µm
The Mini printhead is for 2-line printing of up to 14 High characters. The Ultima and
Ultima plus printheads are for 2-line printing of up to 16 High characters.
Refer to the Linx 4900 Ink Jet Printer Operating Manual for further information about the
different rasters that are available for each printhead and printer configuration, and related
speed/quality data.
MP65557–1 Amdt 01
Linx 4900 Maintenance Manual 3 — 11 Jan 2006
3.5.3 Modulation
The jet of ink from the nozzle is broken into evenly sized and spaced drops by a process
called modulation.
A jet of fluid will naturally break up into approximately equal sized droplets due to the
influence of aerodynamic drag and noise. The drop break-up, however, can be accurately
controlled by introducing a disturbance or excitation into the fluid. This is achieved in the
Linx printheads by oscillating a piezoelectric crystal in contact with the ink.
Ink feed line.

Ink delivered under
pressure from ink system
Piezoelectric Crystal oscillated

by the modulation signal 6245
Gun Chamber
Modulation Signal
Nozzle
Break-up of the ink jet occurs in the

charge electrode caused by excitation
from the piezoelectric crystal
Charge Electrode
NOTE: Charge Electrode
shown rotated through 90 degrees
for ease of representation
Figure 3-6. Modulation of the Ink Jet Using a Piezoelectric Crystal

If a voltage is applied to a piezoelectric crystal it flexes, and the degree of flexing depends
upon the amplitude of the voltage applied. Two opposite polarity bimorph piezoelectric
crystals are used in the printhead gun chamber, bonded together in such a way that they
distort in sympathy with a fixed-frequency sine wave. This gives a direct and very
controllable degree of modulation to the ink. As the edges are fixed, the crystal deflects and
thus displaces a small volume of ink. This displacement is transmitted through the ink,
introducing disturbance in the jet, and eventually it breaks up into uniform drops.
The frequency of the sine wave (modulation frequency) applied to the piezoelectric crystal
determines the rate of drop production. This is a fixed value for each printhead type:
• Mini: 96 kHz
• Ultima: 80 kHz
• Ultima plus: 64 kHz
Amdt 01 MP65557–1
The amplitude of the sine wave (modulation voltage) applied to the piezoelectric crystal
determines exactly where the ink jet forms into drops, and is dependent on:
• The type of printhead
• The individual characteristics of the particular printhead
• The type of ink being used
This modulation voltage is an in-house calibrated value between 0 and 255 volts a.c. and is
unique to every printhead. It is referred to as the Reference Modulation and forms part of the
printhead code, which is printed on each printhead conduit label.
As previously stated, the modulation amplitude determines the point at which the ink jet
forms into drops. This point varies depending on the viscosity of the ink; if the ink is
thicker, the drop break-off point occurs later than if the ink is thinner. The actual desired
point of drop breakoff is within the charge electrode slot where printing drops are required
to be charged.
6246
Jet Nozzle
Ink jet affected

by piezoelectric
crystal
Drop breakup
beginning to occur Charge
Electrode
Actual point of jet breakup. Strobe

This must occur within the LED
central region of the charge
electrode to achieve optimum
drop charging
Charged
drops
Figure 3-7. Correct Drop Breakoff Observed in the Charge Electrode
MP65557–1
Linx 4900 Maintenance Manual 3 — 13 Nov 2003
3.5.4 Drop Charge
In order to build a pattern, each drop has to be directed to a specific position on the
substrate. This is achieved by charging and deflecting each drop individually by a specified
amount.
Each printing drop receives an electric charge such that it can be deflected by the
electrostatic field between the deflector plates. The amount that the drop is charged is
dictated by the intended position of the drop on the substrate. The further the drop has to
be deflected, the higher 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) that it takes to form one complete
drop. Consequently, the drop becomes negatively charged. This is actually achieved by
capacitive coupling, whereby a flow of electrons is induced from the nozzle (which is at
earth potential), through the electrically-conductive ink onto the forming ink drop. When
the drop separates from the ink jet, the charging voltage is removed from the charge
electrode and the drop retains the charge it has been given.
The charge timing is such that the precise point of drop breakoff occurs at the end of the
charge pulse. Timing the end of the charge pulse to occur at the precise drop breakoff point
ensures that the drop has attained the full charge, and thus 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
appropriate level for the time period of the drop production. If the next drop is not to be
printed (and is, therefore, passed straight to the gutter), a small correction voltage of 12.5%
of the previous charge voltage is applied. This is known as historic correction (see below).
Strobe LED
A red light-emitting diode (LED) is located in the bottom centre of the charge electrode
slot, so that it is behind the jet break-up point when viewed from the front of the printhead.
The LED is pulsed at the same frequency as the modulation signal, and the stroboscopic
effect causes the ink jet to appear stationary in the charge electrode slot when viewed with
a suitable eyeglass. This feature allows the details of the jet break-up to be examined,
which can be useful for diagnostic purposes.
When viewing the ink jet break-up with an eyeglass of x10 or x20 magnification, the
example shown in Figure 3-7 should be observed.
The LED electrical supply is enabled when the printhead cover tube is removed, and
therefore can also be used as an indication that the Hall effect switch circuit is operating
correctly. However, in the interests of safety, it must be ensured that the deflector plates
and the charge electrode have been rendered safe before touching or working on them.
Refer to ‘Printhead Cover Sensor’ earlier in this chapter. Refer also to the descriptions of
the Cover Override link LK6 and Safety Override link LK4 in Electronics and Software >
IPM PCB > Test Points and Links later in this chapter.
MP65557–1
Nov 2003 3 — 14 Linx 4900 Maintenance Manual
3.5.5 Historic Correction
Historic correction is used to remove the positive charge induced in the non-printing drop
from the printing drop. The historic correction voltage ensures that the non-printing drops
have zero charge when they leave the charge electrode, and therefore pass straight to the
gutter.
A non-printing drop following a charged drop is susceptible to capacitive coupling from
the charged drop. This would place a small but significant positive charge on non-printing
drops. 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 of that drop’s production. The following drop is non-printing, and therefore must
pass to the gutter. To remove the positive charge that is now being induced in the non-
printing drop from the preceding printing drop, a voltage of 12.5 volts is applied to the
charge electrode, for the period of the non-printing drop’s production, to stabilize its
charge at zero.
3.5.6 Drop Deflection

Once drops are charged to the correct level, they continue along the flight path and pass
between the deflector (EHT) plates. These plates have a constant high voltage applied
across them of up to +8 kV, which establishes an electrostatic field. The negatively charged
(printing) drops are deflected in this field towards the positive plate by an amount
proportional to the field strength and the amount of charge on the individual drops.
The printing drops then exit through the slot in the printhead cover tube, and are laid
down on the substrate in rasters to form characters. The combination of the speed of the
drops travelling through the field and the charge given to them is accurately determined to
ensure that each drop is positioned correctly on the substrate.
Non-printing drops are given zero charge, which results in zero deflection, so they
continue on a straight flight path and enter the gutter. A vacuum acting on the gutter
draws the ink drops back through the system to the ink tank for reuse.
IMPORTANT: The deflector plates and mountings must remain clean and free from ink
deposits at all times, otherwise a deterioration in print quality may occur.
The 0 volts deflector plate mounting is black in colour, and therefore ink
deposits may not always be readily seen. The +8 kV deflector plate and
mounting are made from stainless steel and white plastic, respectively.
3.5.7 Phasing
The printhead has two sensors incorporated in the 0 volt deflector plate; this assembly is
called the Deflector and Phase Plate (DPP). These sensors are used to monitor the jet to
ensure that the printer is operating correctly. The first sensor is called the Phase Sensor; the
second sensor is called the Time Of Flight (TOF) Sensor. During startup and at intervals
between printing, the printer monitors the jet performance.
As previously mentioned, for correct charging of the drops to occur, the charge voltage
must remain on the charge electrode from the moment when the drop starts to form until
the drop breaks off from the modulated jet. The drop charging timing in relation to the
drop breakoff is critical; the charge voltage must neither occur too soon nor too late. For
correct timing to take place, it is necessary to have some form of feedback from the
printhead to inform the control circuits that the printing drops are being charged correctly.
This feedback process is called phasing. Phasing establishes that the point in time of drop
charge is synchronized with the point in time of drop breakoff. The point in time of drop
breakoff is determined by the modulation.
MP65557–1
An example of drops being charged at the correct and incorrect times is shown in the
following illustration. Note how the amplitude of the phase signal varies when the charge
signal is applied at different times in relation to the modulation signal.
68020
Phase position 0
MOD
CHG
Modulation and Charge

not in phase.
Drops charged too early.
Phase signal too small.
Phase position 4
MOD
CHG

not in phase.
Drops charged too early.
Phase position 8
MOD
CHG

in phase.
Drops charged correctly.
Phase signal correct.
Phase position 12
MOD
CHG

not in phase.
Drops charged too late.
Figure 3-8. Charge and Modulation Synchronization (Phasing)

Phasing is carried out by first charging a fixed number of eight drops by applying a fixed
10 volts to the charge electrode. These drops form a phase packet. The voltage is high
enough to charge the drops in the phase packet to a level sufficient to trigger the feedback
circuit, but not so high that the drops are deflected out of the gutter. The phase packet
travels past the phase sensor where it induces a current, known as the phase signal, in the
sensor. If the drops are charged at the correct point in time, the magnitude of the phase
signal is enough to trigger the phase electronics, and the print control is deemed to be in
phase.
MP65557–1
The phasing process synchronizes the charge and modulation to one of 16 positions (0–15)
in time. If the first phase position (0) shows the print control to be out-of-phase, the printer
software issues another phase packet, but on this occasion the drops are charged 1/16 of
the time period later in relation to the drop breakoff. Again the phase signal strength is
assessed. This process is repeated for each of the 16 phase positions until the maximum
phase signal is received (position 8). The phase position at that time is used for charging
drops during the printing process.
The phasing process is performed approximately every 25 ms during printing and between
patterns in order to maximize print quality.
3.5.8 Time Of Flight (TOF)

During printer operation, solvent evaporates from the ink. This causes the ink to become
thicker, i.e. the viscosity of the ink increases. If this were not controlled, a reduction in jet
speed would occur. This in turn would lead to a shift in the position of the printed drops
on the substrate due to the drops spending a longer time between the deflector plates. To
prevent this happening, and to maintain consistent print quality, the control function of the
printer monitors jet speed and alters the pressure to compensate for any variations.
This monitoring of the jet speed is known as Time of Flight (TOF) and is achieved initially in
the same way as the phase operation. That is, a number of TOF drops are charged by
applying 10 volts to the charge electrode. This packet of drops travels past the phase sensor
(situated in the DPP) where it induces a current in the sensor, which starts a counter. The
count increments until the same packet of TOF drops passes the TOF sensor (also situated
in the DPP). As the TOF packet passes the TOF sensor it induces a current, known as the
TOF signal, in the sensor, which stops the counter. The counter value is the Actual TOF.
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
constant jet speed, as follows:
• If Actual TOF is equal to Reference TOF (±0.5%)—system pressure is left unchanged
• 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
In practice, the process of obtaining the phase and TOF signals is identical. The difference
between the phase and TOF operations is in how the software manages the received signal.
3.5.9 Viscosity Control

As previously stated, the viscosity of the ink changes during printer operation. The
viscosity of the ink at the printhead is determined by the control system from the Set
Pressure required to maintain the actual TOF at the Reference TOF value. The Set Pressure
is varied in line with viscosity changes to maintain a constant TOF. When a predetermined
ink viscosity is reached, solvent is added to the ink tank from the solvent tank. This
predetermined viscosity is when the Set Pressure exceeds a value known as the Solvent Add
Pressure. Solvent Add Pressure is derived from a Reference Pressure, which is a calibrated
value unique to each printhead (and which forms part of the printhead code located on the
printhead conduit label). The Reference Pressure is also dependent on printhead
temperature.
See also: ‘Printhead Temperature Sensor’ earlier in this chapter.
For each of the printhead types, the Solvent Add Pressure is derived as follows:
• Ultima and Ultima plus: Solvent Add = Reference Pressure + 4 bits
MP65557–1
Solvent is added to the ink when all of the following conditions apply:
• Pressure check is OK (i.e. the pressure generation circuits functioned correctly at jet
startup and there is no System Warning “3.18 Low Pressure”)
• Set Pressure is greater than Solvent Add Pressure
• TOF within ±0.5% of Reference TOF
• Warm-up period expired
• Solvent level OK (i.e. the printer solvent level is above the minimum required and
there is no System Warning “3.04 Solvent Low”)
When solvent is added to the ink, the viscosity of the ink is lowered. Within 20 minutes (the
Viscosity Settle Time) this thinner ink arrives at the printhead, causing the Set Pressure to
decrease as the thinner ink flows from the nozzle. If, after 20 minutes, the Set Pressure
value is still above the Solvent Add Pressure value, more solvent is added to the ink tank.
To ensure that not too much solvent is inadvertently added to the ink, the printer allows
only 12 consecutive solvent additions (for ink type groups B and C) or 24 consecutive
solvent additions (for ink type groups A and D), where the Set Pressure has not fallen
below the Solvent Add Pressure. If after these solvent additions more solvent is still
required, the printer will fail with Print Failure “2.12 Viscosity”.
3.5.10 Guard Drops

Because all printing drops are negatively charged, they can interact with each other in the
flight path by repelling adjacent drops. This can cause a deterioration in print quality
generally, but is more apparent when printing large characters.
The most deflected drops in a raster carry a higher charge, and therefore have a greater
repelling effect on adjacent drops. In the case of large characters, this effect is amplified,
causing a greater degradation in print quality. However, where high quality print is
required (with printed drops touching on the substrate), it is necessary to separate the
drops in the flight path to eliminate the drop interaction. This is achieved by inserting
guard drops.
Guard drops are non-printing, low-charge drops inserted into each raster between printing
drops to effectively separate the drops in flight, thus reducing their interactive effect. When
printing large characters, more guard drops are inserted between the most deflected
(higher charged) drops to reduce their greater interactive effect.
6248
No Guard Drops; much

greater repulsion
Low charge, non-printing

Guard Drops inserted
to reduce repulsion
Gutter Gutter
Figure 3-9. Guard Drops
MP65557–1
3.5.11 Starting Up and Shutting Down
The principle of continuous ink jet printing has proved to be the most effective means of
printing with an ink that is required to dry almost instantly (within a second) on virtually
any surface. If ink is required to dry quickly on the product it will also have a tendency to
dry in the printhead, causing it to clog up.
The continuous ink jet printer overcomes this problem by constantly circulating the ink
through the printhead and ink system. Although the ink is still evaporating quickly during
this operation, it does not cause the nozzle to become blocked because there is a constant
replacement of ink in the nozzle.
A problem arises on shutdown when ink is left in the printhead nozzle; because it is fast
drying, it will soon cause a blockage in the nozzle. To overcome this, special functions to
clear the nozzle are necessary.
On shutdown, the ink is removed from the nozzle and the gun by suction through the feed
and purge lines. Just prior to final shutdown, solvent is introduced into the ink gun and is
circulated through the nozzle and gutter, thus clearing ink from these vital components.
This automatic procedure makes it unnecessary to clean the printhead manually after
shutdown.
On startup, a series of actions occur automatically:
• The electronic circuitry is checked
• The ink system feed valve, and the printhead feed and purge valves are opened to
allow the ink to circulate through the printhead
• The purge valve is closed, causing the ink jet to be established
• Pressure is increased to normal operating pressure and the ink jet is excited through
the modulation process to cause drop break-up
• The TOF is adjusted to be close to the reference TOF, i.e. drop velocity is corrected.
Only when these systems are operating correctly will the printer go to the ‘Printing’
state
• The phasing and modulation are checked automatically for optimum positioning
• On receiving a print trigger signal from the product sensor (e.g. photocell), the printer
prints the current message, which is automatically updated for dates, sequential
numbers, etc.
All these actions should operate automatically and it should not, under normal operating
conditions, be necessary to remove the printhead cover tube and carry out any
maintenance during startup or shutdown. However, under certain conditions it may be
necessary to remove the printhead cover tube and clean the printhead manually with
solvent at regular intervals.
IMPORTANT: It is essential that the correct solvent is used when cleaning the printhead,
i.e. MEK solvent for MEK based inks; Ethanol solvent for Ethanol based
inks; 3XXX for Mixed Base inks.
Summary tables of the startup and shutdown sequences are contained in the ‘Ink System’
section later in this chapter.
MP65557–1
3.5.12 Jet/Nozzle Alignment
The alignment of the jet is critical to the performance of the printhead. There are two
requirements:
• The jet must pass centrally through the charge electrode slot to ensure correct charging
• The undeflected drops must enter the gutter cleanly, i.e. without clipping the edges
It is not possible to adjust the position of the charge electrode, the DPP or the gutter. It is
possible to achieve a small amount of movement of the nozzle to correct jet misalignment.
3.5.13 Quality
During manufacture, each printer undergoes a series of performance and quality tests to
establish the individual characteristics of each printhead. These characteristics are related
to the printhead type and variant (e.g. type 62 µm; variant Ultima), and are:
• The Reference Pressure
• The Reference Modulation voltage
These parameters are established to give consistent print quality. The two parameters are
then grouped together with the fixed Charge Calibration Factor of 255 to form the
printhead code for the particular printhead. This code is identified on the printhead
conduit label, which is located near to the conduit entry point to the printer.
Refer to the Printhead Code option (Setup > Printhead Setup) in ‘Chapter 4: Setup Menu’
for details of how the code is created.
3.5.14 Printhead/Nozzle Replacement

Whenever a printhead is replaced, the code for the new printhead and the printhead type
must be entered in the Printhead Setup menu (Setup > Printhead Setup). In addition,
whenever a printhead or a nozzle is replaced, the new offset values, for all ink types except
3103, must be used from the supplied Reference Pressure and Reference Modulation Offset
Table. For the calibration procedure, refer to Section 5: Maintenance > Maintenance
Instructions > ‘Calibrated Nozzle Replacement (Offset Calibration)’ maintenance
instruction.
Prior to removing the printhead for replacement, the printer must be allowed to complete a
full normal shutdown. This removes any residual ink in the nozzle, feed, purge and gutter
lines.
MP65557–1
3.6 Ink System
3.6.1 General Description
The Ink System is contained in a stainless steel enclosure, which is integral to the base unit
of the cabinet. The cabinet top cover has two openings, through which the ink and solvent
tanks are filled via internal filler tubes. The filler tubes are sealed by removable protective
caps. Both the filler tubes and protective caps are colour coded—black for ink, and white
for solvent. Adhesive ink and solvent type identification labels are supplied with the
printer for attaching to the protective caps.
The ink system comprises the following main components (refer to ‘Figure 3-10. Static Ink
System’):
• Ink tank
• Ink pick-up tube incorporating a 40 µm stainless steel in-line filter
• Pump and motor assembly
• 10 µm (nominal) polypropylene disposable main ink filter
• Small ink manifold assembly, which includes the pressure transducer and venturi
• Damper
• Solvent tank
• Solvent pick-up tube incorporating a 20 µm stainless steel in-line filter
• Five solenoid-operated valves
• Interconnecting pipes
NOTE: The symbol ‘µm’ stands for micrometre, which is the SI unit of length and
formerly known as the micron.
The polyethylene ink and solvent tanks have nominal capacities of 1440 ml. Both tanks are
fitted with fluid level sensors (float switches) to detect when the level of ink or solvent falls
below a predetermined point. If either sensor detects a low fluid level, a System Warning
message is displayed (“3.03 Ink Low” or “3.04 Solvent Low”).
If, during a print run, the ink low condition is allowed to continue, after 8 hours for Mini
and Ultima printheads, and 6 hours for the Ultima plus printhead, the system reports the
Print Failure “2.05 Ink Tank Empty”. If, during a print run, the solvent low condition is
allowed to continue, after 12 hours (for all printheads), the system reports the Print Failure
“2.06 Solvent Tank Empty”. This is to prevent the ink or solvent from running out
completely.
The ink system pump has an internal system of gears, and is magnetically coupled to the
pump motor. The pump also has an integral pressure relief valve (PRV). Control of the
pump/motor assembly is achieved by a 0 to +5 volts (depending on the requested
pressure) drive signal supplied by the IPM PCB.
MP65557–1 Amdt 01
Operation
The pump draws up ink from the tank through the ink pick-up tube, which incorporates a
40 µm in-line filter. The ink then flows through the pump to the 10 µm main ink filter,
which provides the primary filtration within the ink system. The filter removes any
remaining foreign particles from the ink before it reaches the venturi manifold and the
printhead. From the main ink filter, the ink is fed through the venturi manifold to the
damper and the Feed valve, and then out to the printhead. The purpose of the damper is to
smooth any ink pressure fluctuations within the primary circuit and to isolate them from
the printhead.
Ink is fed to and from the printhead through the feed, purge and gutter lines, via a 3-way
fluid connector, which connects the printhead to the ink system. This connector is located
within the ink system enclosure and incorporates a 5 µm filter on Mini and Ultima
printheads, and a 35 µm filter on the Ultima plus printhead. The tubing to and from the
printhead is colour-coded: red stripe for the feed line, blue stripe for the purge line, and no
stripe for the gutter line.
The disposable ink pick-up tube and filter (all ink types), main ink filter (all ink types), and
3-way fluid connector filter (pigmented inks only) are replaced at every Scheduled
Maintenance. The damper is replaced annually. All these items are to be replaced in
accordance with the Scheduled Maintenance procedure provided in ‘Chapter 5:
Maintenance’.
The venturi in the manifold provides suction to draw back unused ink from the printhead
gutter to the ink tank via the Gutter valve, and to draw solvent from the solvent tank as
required.
During solvent addition and solvent flushing, the solvent is drawn from the tank via the
solvent pick-up tube, which incorporates a 20 µm in-line filter. It is then fed through the
Solvent Top-up (Solvent Add) valve and the venturi to the ink tank, or through the Solvent
Flush valve and the venturi manifold to the printhead.
Amdt 01 MP65557–1
Gun Printhead Printhead Feed Valve and Filter Assembly
Chamber Purge Valve (15 µm filter—Ultima and Midi 62 µm, and Mini 50 µm printheads;
35 µm filter—Ultima plus and Midi plus 75 µm printheads)
Purge Line
Gutter Restrictor
MP65557–1
Printhead OFF Feed Line
(2-metre printhead conduits only—Ultima and Midi 62 µm,
Gutter Line Mini 50 µm, and Ultima plus and Midi plus 75 µm printheads)
3-Way Fluid Connector and In-Line Feed Filter Assembly

10 µm Main Ink Damper (5 µm filter—Ultima and Midi 62 µm, and Mini 50 µm printheads;
Filter 35 µm filter—Ultima plus and Midi plus 75 µm printheads)
7 25 1 21 68146

19 20
Venturi
24
14 OFF 15 OFF 16 OFF 17 OFF 18 OFF
B C A 8
Pressure
3 — 23
Transducer
9 3 10 4 11 5 12 6 13
Feed Purge Gutter Solvent Solvent
Valve Valve Valve Add Flush
Valve Valve
Vent
Pump
22 20 µm
Vent
40 µm In-Line Filter
In-Line Filter fitted in
fitted in Solvent
Ink Pick-up Tube Pick-up Tube
INK SOLVENT
Amdt 01
Jan 2006
Figure 3-10. Static Ink System
3.6.2 Venturi Manifold Assembly
The venturi manifold assembly is the central part of the ink system. Its purpose is to
monitor the ink pressure, and to manage the ink and solvent distribution in the system.
Three components are used to achieve this—the manifold block, the pressure transducer,
and the vacuum venturi—each forming part of the complete manifold assembly. The main
component is the small manifold block, manufactured from white acetal, in which
interconnecting internal bores are drilled. These bores enter and exit the manifold block at
ports to which are connected the pressure transducer, vacuum venturi, and interconnecting
ink and solvent pipes.
The following illustration shows the venturi manifold assembly and the ink system valves:
Venturi
Manifold Block
Pressure
Solvent Flush
Transducer
Valve (5)
Gutter
Valve (3) Solvent Add 49165
Valve (4)
Feed
Valve (1) Purge
Valve (2)
Venturi
Festo Fitting
Vi
ole
t
Blu
e
Gree
Yell n
ow
Re
d
Ink System Cableform

Connector SK1
Figure 3-11. Venturi Manifold Assembly and Valves
Pressure Transducer
The actual pressure of the ink in the system is monitored by the pressure transducer, which
is fitted to a small manifold containing the venturi.
Vacuum Venturi
Ink flowing through the venturi creates a vacuum, which is tapped off and used for various
purposes. During normal operation the vacuum draws ink back into the system from the
printhead gutter. It is also used to draw solvent into the system for ink viscosity control,
and for flushing the printhead and ink lines. Finally, the vacuum is used to purge the ink
lines and to clear blockages and obstructions in the printhead. Refer to ‘Startup and
Shutdown Sequences’, and ‘Other Operating Sequences’ later in this section.
Amdt 01 MP65557–1
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 principle, but uses the turbulence caused by a high
pressure ink flow passing through a small bore directly into a larger bore. The turbulence
creates a vacuum around the ink flow, and this vacuum is tapped off through a bore drilled
at right angles to the ink flow. The following illustration is a sectional view of the venturi:
Ink flow from the pump

at Set Pressure
48004
Groove around circumference of

venturi to allow equalization of
Small bore
vacuum at both tappings
steel insert
Suction connected Suction connected

through the manifold to through the manifold
the Solvent Add valve to the Gutter valve
Large bore
drilling Area of low pressure
around the ink flow
due to turbulence
Venturi housing
Ink and air returned

to the ink tank
Figure 3-12. Section View of the Venturi
3.6.3 Valves
There are five solenoid-operated valves in the ink system enclosure, which are used to
control the flow of ink and solvent through the system. These valves are sealed and cannot
be disassembled. The valve types and designations are:
• 2-way Feed valve
• 3-way Purge valve
• 3-way Gutter valve
• 3-way Solvent Top-up (Solvent Add) valve
• 3-way Solvent Flush valve
The valves are mounted through the front wall of the ink system enclosure, allowing the
electrical and fluid connections to be isolated from each other; the fluid connections are
located on the inside of the enclosure, and the electrical connections on the outside.
MP65557–1
3.6.4 Ink System Connections
The pipe connections to the venturi manifold are made using Festo fittings or barb fittings.
The barbs are sealed by interference fit to the manifold and cannot be removed, and are
therefore not replaceable items.
The following illustration shows the venturi manifold and its components, the ink system
valves, and provides details of the ink system pipe connections:
22
21
20 19
VENTURI
MANIFOLD
18 17 16 15 14
1 25
7 8
C
A B
6 5 4 3 2
13 12 11 10 9
SOLVENT SOLVENT GUTTER PURGE FEED

24 FLUSH ADD (3) (2) (1)
(5) (4)
49199
INK SYSTEM PIPE CONNECTIONS
PIPE ROUTING PIPE LENGTHS
PORT 1 (VENTURI) TO DAMPER INLET (BLEED CAP END) 500 mm NATURAL PIPE (1/8 in. OD)
PORT 2 NOT USED —
PORT 3 (PURGE VALVE) TO 3-WAY FLUID CONNECTOR (PURGE) 450 mm BLUE STRIPE PIPE (1/8 in. OD)
PORT 4 (GUTTER VALVE) TO PORT 8 (VENTURI) 170 mm NATURAL PIPE (1/8 in. OD)
PORT 5 (SOLVENT ADD VALVE) TO PORT 6 (SOLVENT FLUSH VALVE) 120 mm NATURAL PIPE (1/8 in. OD)
PORT 9 (FEED VALVE) TO PORT A (VENTURI MANIFOLD) 250 mm NATURAL PIPE (1/8 in. OD)
PORT 10 (PURGE VALVE) TO INK TANK 330 mm NATURAL PIPE (1/8 in. OD)
PORT 12 (SOLVENT ADD VALVE) TO PORT 7 (VENTURI) 170 mm NATURAL PIPE (1/8 in. OD)
PORT 13 (SOLVENT FLUSH VALVE) TO PORT B (VENTURI MANIFOLD) 150 mm NATURAL PIPE (1/8 in. OD)
PORT 15 (PURGE VALVE) TO PORT 11 (GUTTER VALVE) 170 mm NATURAL PIPE (1/8 in. OD)
PORT 16 (GUTTER VALVE) TO 3-WAY FLUID CONNECTOR (GUTTER) 450 mm NATURAL PIPE (1/8 in. OD)
PORT 17 (SOLVENT ADD VALVE) TO 19 (Y-PIECE) 90 mm NATURAL PIPE (1/8 in. OD)
PORT 18 (SOLVENT FLUSH VALVE) TO 20 (Y-PIECE) 90 mm NATURAL PIPE (1/8 in. OD)
PORT 21 (Y-PIECE) TO 22 (SOLVENT TANK PICK-UP TUBE) 250 mm NATURAL PIPE (1/8 in. OD)
PORT 24 (VENTURI) TO INK TANK (INK RETURN LINE) 330 mm NATURAL PIPE (6 mm OD)
PORT C (VENTURI MANIFOLD) TO 3-WAY FLUID CONNECTOR (FEED) 450 mm RED STRIPE PIPE (1/8 in. OD)
DAMPER OUTLET TO PORT 14 (FEED VALVE) 330 mm NATURAL PIPE (1/8 in. OD)
MAIN INK FILTER OUTLET TO PORT 25 (PRESSURE TRANSDUCER) 90 mm NATURAL PIPE (6 mm OD)
INK PICK-UP TUBE TO PUMP INLET 300 mm NATURAL PIPE (6 mm OD)
PUMP OUTLET TO MAIN INK FILTER INLET 120 mm NATURAL PIPE (6 mm OD)
INK TANK TO SOLVENT TANK (VENT) 330 mm NATURAL PIPE (3/16 in. OD)
SOLVENT TANK TO INK TRAY (VENT) 330 mm NATURAL PIPE (3/16 in. OD)
Figure 3-13. 4900 Ink System Pipe Connections
MP65557–1
3.6.5 Ink and Solvent Flows
The ink and solvent flow descriptions that follow should be read in conjunction with the
ink and solvent flow diagrams, Figures 3-14, 3-15 and 3-16.
When the jet is running under normal operating conditions, there are two ink flow circuits
in operation: a primary circuit and a secondary circuit.
Primary Circuit (Figure 3-14)

The ink flow in the primary circuit is from the ink tank, up through the ink pick-up tube
and in-line filter to the pump, and then under pressure through the main ink filter to the
venturi manifold. Within the manifold, the pressurized ink passes the pressure transducer,
which sends an electrical feedback signal to the printer’s electronics system. This signal
gives the system an indication of the actual pressure at which the pump is operating, and
can thus be used to regulate the pump speed in order to achieve the desired pressure. After
passing the pressure transducer, the ink flows through the venturi, where the vacuum is
generated, and then flows back to the ink tank.
Secondary Circuit (Figures 3-15)

The secondary ink flow circuit comes into operation when the ink system Feed valve and
the printhead Feed valve are switched on. There is an internal manifold fluid connection
that feeds ink from the primary circuit at the venturi, through the damper, to the
switched-on Feed valve. This allows ink to be fed under pressure along the feed line and
through the in-line feed filter, located in the 3-way fluid connector.
The ink continues along the feed line to the printhead, where it is fed through the open
printhead Feed valve and then to the printhead nozzle, where it emerges as the jet. Drops
of ink not required for printing enter the gutter. The venturi vacuum acting on the gutter
draws the unprinted drops back into the system through the switched off Gutter valve, and
returns them to the ink tank via the venturi.
MP65557–1
Purge Line
Nov 2003
OFF Feed Line PIPE FLUID KEY
Printhead
Gutter Line Ink
Ink with Air Bubbles
10 µm Main Ink Damper

Filter
68147
Venturi
OFF OFF OFF OFF OFF
Pressure
Transducer
3 — 28
Valve Valve
Vent
Pump
Vent
INK SOLVENT

MP65557–1
Figure 3-14. Primary Circuit
Purge Line
ON Feed Line PIPE FLUID KEY
Printhead
MP65557–1
Gutter Line Ink
Discoloured Solvent
Filter
68148

Venturi
ON OFF OFF OFF OFF
Pressure
Transducer
3 — 29
Valve Valve
Vent
Pump
Vent
INK SOLVENT
Nov 2003
Figure 3-15. Secondary Circuit (Normal Running after Start Purge)
Solvent Addition (Figures 3-16)
Solvent is automatically added to the ink if the viscosity of the ink becomes too high. This
is indicated by the Set Pressure exceeding the predetermined Solvent Add Pressure (P1).
When this Solvent Add Pressure is exceeded, a solvent addition occurs only if all of the
following conditions apply:
• TOF is within ±0.5% of Reference TOF
• Warm-up period has expired
• Solvent level is OK (i.e. the printer solvent level is above the minimum required and
NOTE: No solvent is added if there is a “3.18 Low Pressure” System Warning, because
this means that there is a loss of pressure in the system, and therefore a higher
pressure will be required to attain the correct TOF, even though the ink viscosity
is probably acceptable.
The ink flow, when a solvent addition is performed, is as previously described for Normal
Operation, i.e. ink flow in both the primary and secondary ink circuits.
To add solvent, the Solvent Top-up (Solvent Add) valve is switched on. Vacuum from the
venturi now acts on the Solvent Top-up (Solvent Add) valve, as well as the normally
switched-off Gutter valve. The vacuum draws solvent from the tank, through the switched-
on Solvent Top-up (Solvent Add) valve—via the switched-off Solvent Flush valve—to the
venturi, where it is mixed with the ink in the primary circuit returning to the ink tank. The
resultant lower viscosity solvent/ink mixture in the ink tank is then fed to the printhead.
The Solvent Top-up (Solvent Add) valve is switched on for a predetermined time, which is
calculated to allow a fixed quantity of solvent to be added in a single ‘solvent add’
operation. This Solvent Add time is dependent on the ink and printhead type. Refer to the
‘Ink Type Dependent Parameters’ tables at the end of this ‘Ink System’ description.
After solvent is added, further solvent additions are inhibited for a predetermined period
of 20 minutes (the Viscosity Settle Time). This time allows the solvent to mix in the ink
tank, and for the effects of the solvent addition to be seen at the printhead.
MP65557–1
Purge Line
ON Feed Line PIPE FLUID KEY
Printhead
MP65557–1
Gutter Line Ink
Solvent
Filter
68149

Venturi
ON OFF OFF ON OFF
Pressure
Transducer
3 — 31
Valve Valve
Vent
Pump
Vent
INK SOLVENT
Nov 2003
Figure 3-16. Solvent Addition
3.6.6 Startup and Shutdown Sequences
There are three startup sequences:
• Normal Start
• Quick Start (only to be used by qualified service engineers for fault diagnostic
purposes)
• Restart
There are three shutdown sequences:
• Normal Shutdown
• Quick Stop (only to be used by qualified service engineers for fault diagnostic
purposes)
• Fault Shutdown
Fault Shutdown and Quick Stop are used in emergencies to shut off the jet as quickly as
possible.
Valve sequence summary tables are provided for each operating sequence. The valves are
identified in these tables as follows:
Feed F
Printhead Feed PF
Purge P
Gutter G
Solvent Top-up (Solvent Add) T
Solvent Flush L
A valve identification in bold type indicates that the valve is on; an identification in normal
type indicates that the valve is off. For example: F PF P G T L indicates that the Gutter and
Solvent Flush valves are on and the remainder are off.
Other operating sequences are detailed in this section after the Startup and Shutdown
Sequences using the same summary tables.
The timings quoted in the valve sequence summary tables are in seconds and the pressures
are quoted in bits.
NOTES:
1. The valve sequences and timings information given here is relevant to Version 1.0
software or later versions for the 4900 printer, unless otherwise stated.
2. The maximum pressure that the ink system can develop under normal operating
conditions is 65 p.s.i. (255 bits) and 90 p.s.i. under fault conditions.
MP65557–1
The various pressures and timings are printhead dependent. The following table lists the
pressures for the corresponding printhead types:
v1.5 49166
PRESSURES (BITS)
Condition Pressure Ultima Ultima plus Mini

Default Reference * P0 184 145 182
Solvent Add Offset ** – 4 4 4
Solvent Add P1 – – –
Test *** P3 235 235 235
Maximum Running P4 255 255 255
Solvent Jet P5 100 90 180
1st Solvent Add Offset 1 ** – 7 7 7
st
1 Solvent Add Offset 2 ** – 11 11 11
st
1 Solvent Add Offset 3 ** – 15 15 15
INK AND SOLVENT CONTROL
Condition Ultima Ultima plus Mini

Viscosity Settle Time (minutes) 20 20 20
Ink Low Time Out (hours) 8 6 8
Solvent Low Time Out (hours) 12 12 12
* The Default Reference Pressure (P0) is the normal running default pressure for the printhead
type, but this will actually be the Reference Pressure for each individual printhead, as specified in
the printhead code.
** The Solvent Add Offset is added to the Reference Pressure to produce the Solvent Add
Pressure (P1). The 1st Solvent Add Offset 1, 2 or 3 is added to the Solvent Add Pressure (P1) to
produce the 1st Solvent Add Pressure (P7, P8 or P9 respectively). This is where the printer adds
solvent at startup, if required.
*** The Test Pressure is used during the Pressure and Filter check, before a normal jet start.
Figure 3-17. Printhead Dependent Parameters Table
See also: ‘Ink Type Dependent Parameters’ tables at the end of this ‘Ink System’
subsection.
MP65557–1 Amdt 01
Normal Start Sequence
When the printer is first switched on and a message is selected for printing, all the valves
are switched off initially.
v1.5 49167
NORMAL START (2 m and 4 m conduits)
Action Description Ultima Ultima plus Mini

Valves F PF P G T L (all off)
Pressure Maximum Running (P4) 255 255 255
Wait Pressure response 1s 1s 1s
Valves F PF P G T L
Wait Clear feed line 10 s 10 s 10 s
Valves F PF P G T L
Wait Introduce small quantity of solvent 0.5 s 0.5 s 0.5 s
Valves F PF P G T L
Wait Balance pressure in purge line 1s 1s 1s
Valves F PF P G T L
Wait Start jet 5s 5s 5s
Valves F PF P G T L
Wait Purge gun 15 s 15 s 15 s
Valves F PF P G T L
Pressure Default Reference Pressure (P0) 184 145 182
Wait Wait for TOF
Figure 3-18. Normal Start Summary Table
Quick Start Sequence

This method of starting the printer is similar to the Normal Start, but the feed line purge is
omitted from the sequence. The Quick Start sequence is initiated by selecting the Quick
Start Jet option in the DIAGNOSTICS menu (Setup menu > Diagnostic Menu). For further
information about the Quick Start Jet option, refer to the ‘Diagnostic Menu’ section of
‘Chapter 5: Maintenance’.
When the printer is first switched on and a message is selected for printing, all the valves
are switched off initially.
v1.5 49168
QUICK START (2 m and 4 m conduits)

Pressure Constant 230 230 230
Wait Pressure/filter check 3s 3s 3s
Valves F PF P G T L
Valves F PF P G T L
Valves F PF P G T L
Valves F PF P G T L
Wait Continue jet 2s 2s 2s
Figure 3-19. Quick Start Summary Table
Amdt 01 MP65557–1
Restart Sequence
Before the jet starts, all the normal static checks are made such as, pressure/filter check, ink
and solvent levels, and time to the next Service. As the jet starts, the dynamic functional
checks and adjustments are carried out: ink in gutter check, pressure check, phasing and
TOF adjustments. The printer enters the Jet Running state only after all these functions
have been successfully completed. However, if any of the checks or adjustments are
invalid, the printer attempts a further three starts (four in total) using the Restart sequence.
If an invalid condition still exists, the printer provides an audible and on-screen warning,
or fails with a Print Failure message.
v1.5 49169
RESTART (2 m conduit; 4 m conduit figures in brackets)

Valves F PF P G T L
Wait Stop jet 1s 1s 1s
Valves F PF P G T L
Wait Depressurize feed line 1s 1s 1s
Valves F PF P G T L
Wait Clear feed and gutter lines 30 s (40 s) 30 s (40 s) 30 s (40 s)
Valves F PF P G T L
Wait Clear feed and purge lines 20 s (40 s) 20 s (40 s) 20 s (40 s)
Valves F PF P G T L
Wait Solvent to gun and purge line 13 s (10 s) 9.5 s (5 s) 11 s (10 s)
Wait Constant 30 s 30 s 30 s
Valves F PF P G T L
Wait Solvent to gun and purge line 13 s (10 s) 9.5 s (5 s) 11 s (10 s)
Pressure Solvent Jet Pressure (P5) 100 (50) 90 (50) 180 (180)
Wait Pre-solvent 2s 2s 2s
Valves F PF P G T L
Wait Start solvent jet/clean gutter pipe 14 s (40 s) 14 s (30 s ) 14 s (40 s)
Valves F PF P G T L
Valves F PF P G T L
Wait Constant 1s 1s 1s
Valves F PF P G T L
Wait Clear feed and gutter pipe 30 s 30 s 30 s
Restart
Valves F PF P G T L
Wait Clear feed line 10 s 10 s 10 s
Valves F PF P G T L
Wait Add small quantity of solvent 0.5 s 0.5 s 0.5 s
Valves F PF P G T L
Wait Balance pressure in purge line 1s 1s 1s
Valves F PF P G T L
Valves F PF P G T L
Valves F PF P G T L
Figure 3-20. Restart Summary Table
MP65557–1 Amdt 01
Normal Shutdown Sequence
The type of Normal Shutdown sequence depends on the length of the printhead conduit.
Valve sequence summary tables are shown for both the 2-metre and 4-metre printhead
conduit lengths. There are modifications to the 2-metre and 4-metre shutdown sequences in
v1.5 System Software to include an extra flushing (‘soak’) period. These additional
operations are shown in italics in the two summary tables.
Initially the Feed valves will be switched on and the jet will be running under normal
operating conditions, i.e. ink flow in both the primary and secondary circuits.
v1.5 49170
NORMAL SHUTDOWN (2 m conduit)

Mod Set modulation to zero
Valves F PF P G T L
Wait Vacuum to PF valve to stop jet 1s 1s 1s
Valves F PF P G T L
Valves F PF P G T L
Wait Clear feed line and gutter line 30 s 30 s 30 s
Valves F PF P G T L
Wait Clear feed line and purge line 20 s 20 s 20 s
Valves F PF P G T L
Wait Solvent to gun and purge line 13 s 9.5 s 11 s
Valve F PF P G T L (all off)

Wait Clear gutter line 30 s 30 s 30 s
Valve F PF P G T L
Wait Solvent to gun and purge line 13 s 9.5 s 11 s
Pressure Solvent Jet Pressure (P5) 100 90 180

Valves F PF P G T L
Wait Start solvent jet and clean gutter pipe 14 s 14 s 14 s
Valves F PF P G T L
Wait Stop solvent jet 1s 1s 1s
Valves F PF P G T L
Valves F PF P G T L
Valves F PF P G T L
Wait Clear gun and purge line 30 s 30 s 30 s
Pressure Set to zero 0 0 0
Figure 3-21. Normal Shutdown (2 m conduit) Summary Table
Amdt 01 MP65557–1
v1.5 49171
NORMAL SHUTDOWN (4 m conduit)

Valves F PF P G T L
Wait Vacuum to PF valve to stop jet 1s 1s 1s
Valves F PF P G T L
Wait Depressurize feed line 0.5 s 0.5 s 0.5 s
Valves F PF P G T L
Valves F PF P G T L
Wait Clear feed line/stop gutter vacuum 30 s 30 s 30 s
Valves F PF P G T L
Wait Clear purge line only 40 s 40 s 40 s
Valves F PF P G T L
Wait 1st solvent to gun and purge line 10 s 5s 10 s
Valve F PF P G T L (all off)

Valves F PF P G T L
Wait Clear feed line/stop gutter vacuum 20 s 20 s 20 s
Valves F PF P G T L
Wait Vacuum to purge line 10 s 10 s 10 s
Valves F PF P G T L
Wait 2nd solvent to gun and purge line 10 s 5s 10 s
Valves F PF P G T L
Pressure Solvent Jet Pressure (P5) 50 50 180
Valves F PF P G T L
Valves F PF P G T L
Wait Start solvent jet 40 s 30 s 40 s
Valves F PF P G T L
Wait Stop solvent jet 1s 1s 1s
Valves F PF P G T L
Valves F PF P G T L
Wait Clear gun and feed line 30 s 30 s 30 s
Valves F PF P G T L
Wait Clear gun and purge line 30 s 30 s 30 s
Figure 3-22. Normal Shutdown (4 m conduit) Summary Table
MP65557–1 Amdt 01
Purge Line
Amdt 01
Jan 2006
OFF Feed Line PIPE FLUID KEY
Printhead
Gutter Line Ink

Filter
68150
Venturi
OFF OFF OFF OFF OFF
Pressure
sequence has been successfully completed:
Transducer
3 — 38
Valve Valve
Vent
Pump
Vent
The following diagram shows the state of the ink system after a Normal Shutdown
INK SOLVENT

MP65557–1
Figure 3-23. Ink System after a Successful Normal Shutdown
Quick Stop Sequence
Quick Stop is a jet-stop facility for use by service engineers only.
The Quick Stop facility is initiated by pressing the [stop] key while pressing and holding
the [ctrl] key. Alternatively, select the Quick Stop Jet option in the DIAGNOSTICS menu
(Setup menu > Diagnostic Menu). The printer immediately aborts any other jet sequence
and performs this one. This is the quickest method of stopping the jet and should only be
used for fault diagnosis purposes.
NOTE: Auto Power Down is disabled if a Quick Stop occurs. Once the jet has shut down
after a Quick Stop, Auto Power Down remains disabled until the power is
switched off and then switched on again, or a jet start is performed.
Initially the Feed valves are switched on and the jet is running, i.e. ink flow in both the
primary and secondary circuits.
v1.5 49172
QUICK STOP (2 m and 4 m conduits)

Valves F PF P G T L
Valves F PF P G T L
Valves F PF P G T L
Wait Clear feed line 5s 5s 5s
Valves F PF P G T L
Wait Clear purge line 5s 5s 5s
Wait Clear gutter line 5s 5s 5s
Figure 3-24. Quick Stop Summary Table
Fault Shutdown Sequence

Fault Shutdown is initiated by the printer in response to a System Failure or Print Failure
condition. See also ‘Chapter 6: System Events’. On detection of a fault, the printer uses the
same shutdown sequence as the Quick Stop sequence described above.
MP65557–1 Amdt 01
3.6.7 Other Operating Sequences
Purge Dry Cycle Sequence
This is one of the valve drying sequences used in the System Flush option.
v1.5 49174
PURGE DRY CYCLE (2 m and 4 m conduits)

Valves F PF P G T L
Valves F PF P G T L
Valves F PF P G T L
Figure 3-25. Purge Dry Cycle Summary Table
Feed Dry Cycle Sequence

v1.5 49175
FEED DRY CYCLE (2 m and 4 m conduits)

Valves F PF P G T L
Valves F PF P G T L
Valves F PF P G T L
Figure 3-26. Feed Dry Cycle Summary Table
Amdt 01 MP65557–1
Nozzle Clear Sequence
This sequence can be used when there is a suspected blocked or obstructed nozzle. The
Nozzle Clear sequence is initiated from the DIAGNOSTICS menu (Setup menu >
Diagnostic Menu > Clear Nozzle), but the jet must be stopped before the item can be
selected. Refer to the ‘Nozzle Clear Sequence’ part of the ‘Jet Alignment and Nozzle
Cleaning’ maintenance instruction in Chapter 5 for details about how to carry out this
procedure.
All the valves will be switched off at the start of the sequence, and the pump will be
running with ink flowing in the primary circuit only. The system sets the pressure to the
Maximum Running value (P4) and, after a 5-second delay for the pressure to stabilize, the
Gutter valve is switched on for 15 seconds. This transfers the suction (vacuum) from the
gutter to the nozzle, via the Gutter valve and the Purge valve (off), and draws ink from the
nozzle chamber back along the purge line (through the Printhead Purge valve) to the tank.
This action attempts to clear the blocked nozzle by also sucking in air through the nozzle
aperture. Finally, the Gutter valve is switched off and the pump is stopped, reducing the
pressure to zero.
NOTE: It is recommended that a maximum of eight Nozzle Clear sequences are carried
out in an attempt to clear an obstruction or blockage, with an attempt made to
start the jet after each sequence.
Refer to Chapter 5: Maintenance > Diagnostics Menu > Clear Nozzle option, for more
details.
v1.5 49176
NOZZLE CLEAR (2 m and 4 m conduits)

Valves F PF P G T L
Figure 3-27. Nozzle Clear Summary Table
MP65557–1 Amdt 01
Flush Cycle Sequence
This is the main flush sequence used in the System Flush option.
v1.5 49177A
FLUSH CYCLE (2 m and 4 m conduits)

Valves F PF P G T L
Valves F PF P G T L
Valves F PF P G T L
Valves F PF P G T L
Valves F PF P G T L
Valves F PF P G T L
Valves F PF P G T L
(continued)
Figure 3-28. Flush Cycle Summary Table
Amdt 01 MP65557–1
v1.5 49177B
FLUSH CYCLE (2 m and 4 m conduits)

Valves F PF P G T L
Valves F PF P G T L
Valves F PF P G T L
Valves F PF P G T L
Valves F PF P G T L
Valves F PF P G T L
Figure 3-28. Flush Cycle Summary Table (continued)
Filter Purge Sequence

All the valves remain off and the pump is run at a fixed pressure of 120 bits. Ink is
circulated around the primary circuit for 5 minutes to purge a new replacement filter.
v1.5 49178
FILTER PURGE

Figure 3-29. Filter Purge Summary Table
MP65557–1 Amdt 01
Gutter Dry Cycle Sequence
v1.5 49179
GUTTER DRY CYCLE (2 m and 4 m conduits)

Figure 3-30. Gutter Dry Cycle Summary Table
Empty Tank Sequence

This sequence is one of the flush types used in the System Flush option.
v1.5 49180
EMPTY TANK

Figure 3-31. Empty Tank Summary Table
Solvent Drain Sequence

This sequence is one of the flush types used in the System Flush option.
v1.5 49181
SOLVENT DRAIN

Valves F PF P G T L
Figure 3-32. Solvent Drain Summary Table
Amdt 01 MP65557–1
Nozzle Flush Sequence
The Nozzle Flush sequence can be used as an alternative to, or in conjunction with, the
Nozzle Clear sequence when there is a suspected blocked or obstructed nozzle.
Unlike the Nozzle Clear sequence, where solvent is drawn in through the nozzle, the
Nozzle Flush sequence automatically fills the nozzle with solvent and then forces a jet of
solvent out of the nozzle and into the gutter to flush away any deposits.
IMPORTANT: The Nozzle Flush sequence attempts to establish a solvent jet, and if this
occurs the solvent is returned to the ink tank. Excessive use of the Nozzle
Flush sequence will, consequently, greatly reduce the viscosity of the ink,
causing the printer to fail. Therefore, the Nozzle Flush sequence must not
be used more than three times to clear a particular nozzle blockage.
The Nozzle Flush sequence is initiated from the DIAGNOSTICS menu (Setup menu >
Diagnostic Menu > Nozzle Flush), but the jet must be stopped before the item can be
selected. Refer to ‘Chapter 5: Maintenance’ > The Diagnostics Menu > Nozzle Flush, for
more details.
All the valves are switched off at the start of the sequence, and the pump is running with
ink flowing in the primary circuit only.
v1.5 49182
NOZZLE FLUSH (2 m and 4 m conduits)

Valves F PF P G T L
Valves F PF P G T L
Valves F PF P G T L
Wait Solvent uptake 30 s 30 s 30 s
Valves F PF P G T L
Valves F PF P G T L
Valves F PF P G T L
Valves F PF P G T L
Figure 3-33. Nozzle Flush Summary Table
MP65557–1 Amdt 01
Amdt 01
Jan 2006
INK TYPE DEPENDENT PARAMETERS (ULTIMA PRINTHEAD)
Ink Type
Parameters 3103 1010 1014 1016 1018 1035 1055 1056 1065 1070 1121 1240 1243 1270 1280 1290 1405 2030 2035 2250 3123 3124 3160 3240
Solvent type 3501 1505 1505 1506 1505 1535 1555 1555 1565 1560 1590 1512 1512 1540 1540 1540 1705 2500 2500 2750 3501 3501 3560 3710
Nominal Reference Pressure PREF
184 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
(bits)
Reference Pressure Offset * (bits) Adjusted manually according to published offset data table
Normal Solvent Add Pressure Offset
+4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4
from PREF (bits)
Maximum number of consecutive
12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 24 12 12 12 12 12 12 12
Solvent Adds
Reference Modulation Offset
Adjusted manually according to published offset data table
(VM + offset) (V)
3 — 46
Reference TOF (µs) 766 766 766 766 766 766 766 766 766 766 766 766 766 766 766 766 766 766 766 766 766 766 766 766
Normal Solvent Add Time tSA (s) 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10
Warm up tSA if PSET > PSA (s) 10 10 9 10 10 10 10 10 10 10 10 9 9 10 10 10 10 10 10 10 10 10 10 9
3.6.8 Ink Type Dependent Parameters
Scheduled Maintenance interval (hr) 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000
Scheduled Maintenance interval (mth) 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12
Modulation Tracking Slope (V/bit) 2.5 2.0 2.0 1.0 2.0 1.0 1.0 1.0 1.0 1.5 2.0 2.0 2.0 1.0 1.5 1.0 1.3 2.0 2.0 2.0 2.5 2.5 2.5 2.0
Ink Type B B B B B B B B B B B B B B B B A C C C B B B C
* Relative to 3103 ink.
Figure 3-34. Ink Type Dependent Parameters Table (Ultima Printhead)

MP65557–1
MP65557–1
INK TYPE DEPENDENT PARAMETERS (ULTIMA plus PRINTHEAD)
Ink Type
Parameters 3103 1009 1010 1014 1016 1018 1035 1039 1055 1056 1065 1070 1121 1240 1243 1270 1280 1290 1405 2030 2035 2250 3123 3124 3160 3240

Solvent type 3501 1505 1505 1505 1506 1505 1535 1505 1555 1555 1565 1560 1590 1512 1512 1540 1540 1540 1705 2500 2500 2750 3501 3501 3561 3710
Nominal Reference Pressure PREF
147 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
(bits)
Reference Pressure Offset * (bits) Adjusted manually according to published offset data table
Normal Solvent Add Pressure Offset
+4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4
from PREF (bits)
12 24 12 12 12 12 12 24 12 12 12 12 12 12 12 12 12 12 24 12 12 12 12 12 12 12
Solvent Adds
Reference Modulation Offset
3 — 47
Adjusted manually according to published offset data table
(VM + offset) (V)
Reference TOF (µs) 1330 1330 1330 1330 1330 1330 1330 1330 1950 1950 1950 1330 1330 1330 1330 1330 1950 1330 1330 1330 1330 1330 1330 1330 1330 1330
Normal Solvent Add Time tSA (s) 10 5 10 10 10 10 10 5 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10
Warm up tSA if PSET > PSA (s) 10 5 10 10 10 10 10 5 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10
Scheduled Maintenance interval (hr) 2000 1400 2000 2000 2000 2000 2000 1400 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000
Scheduled Maintenance interval (mth) 12 6 12 12 12 12 12 6 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12
Modulation Tracking Slope (V/bit) 1.0 2.2 2.5 2.0 1.0 1.2 2.0 3.0 1.6 1.6 2.0 1.6 1.6 2.5 2.5 1.9 2.0 1.6 1.0 1.5 1.5 1.5 2.0 2.0 2.0 2.5
Ink Type B D B B B B B D B B B B B B B B B B A C C C B B B C
* Relative to 3103 ink.
Figure 3-35. Ink Type Dependent Parameters Table (Ultima plus Printhead)
Amdt 01
Jan 2006
INK TYPE DEPENDENT PARAMETERS (MINI PRINTHEAD)
Ink Type
Parameters 1056 1240 1405
Solvent type 1555 1512 1705
Nominal Reference Pressure PREF 178 178
188
(bits) fixed fixed
Normal Solvent Add Pressure Offset +4 +4 +4
12 12 24
Solvent Adds
75 75
Reference Modulation VM (V) 50
fixed fixed
Reference TOF (µs) 565 565 565
Normal Solvent Add Time tSA (s) 10 10 10

Warm up tSA if PSET > PSA (s) 10 10 10
Scheduled Maintenance interval (hr) 2000 2000 2000
Scheduled Maintenance interval (mth) 12 12 12
Modulation Tracking Slope (V/bit) 0 1.5 1.7
Figure 3-36. Ink Type Dependent Parameters Table (Mini Printhead)
Amdt 01 MP65557–1
3.7 Electrical Components
3.7.1 Overview
The 4900 printer main electrical components comprise the following:
• Mains Power Cable
• Mains Power Supply Switch
• Power On Switch
• Mains Filter
• Mains Input Fuses
• Low Voltage Power Supply Unit (LVPSU)
• EHT Power Supply Unit (EHTPSU)
• Ink System Pump
• Ink System Valves
• Cooling Fan
• Printhead Positive Air Pump (optional)
3.7.2 Mains Power Cable

The mains input power cable connects to the printer on the rear right-hand side of the
base unit.
IMPORTANT: For the printer to comply with EN 60204-1:1997. Safety of machinery.
Electrical equipment of machines. Specification for general requirements, the
printer must be connected to the mains supply in one of the following two
ways:
• By using a plug and socket arrangement
• If the printer is hard wired to the mains supply, a mains disconnecting
device must be used between the printer and the mains supply
The design of the protection for the mains power cable connector changed in early
December 2005, from serial number BW763 onwards. Both designs are described below.
Mains Cable Connector Protection (printers pre-serial number BW763)

The cable connector is protected by an environmentally-sealed box cover, which must be
removed in order to disconnect the mains cable from the printer. This cover is secured to
the rear face of the base unit by four screws, and the cable is routed out of the cover via a
cable strain relief elbow.
Orientation of the elbow can be altered to point down, left or right. To achieve this, first
remove the connector cover and loosen the cable clamp nut inside. Turn the elbow through
90 or 180 degrees, as desired. Position the elbow in the new location slot and tighten the
cable clamp nut. Reconnect the power cable and refit the connector cover. Make sure the
cable connector is orientated correctly before refitting the cover so that the cable does not
have to be twisted to fit the connector.
Mains Cable Connector Protection (printers post-serial number BW763)

The cable connector is protected by an environmentally-sealed box with a hinged cover,
which must be opened in order to disconnect the mains cable from the printer. The cover is
secured by three screws, and the cable is routed out of the box via an opening in the
bottom. Orientation of the cable exit cannot be altered.
MP65557–1 Amdt 01
3.7.3 Mains Power Supply Switch
The Mains Power Supply Switch is mounted above the mains power input cable, on the
rear outside face of the base unit on the right-hand side.
It is a two-position, mains-rated rocker switch, protected by a splashproof cover, that
disconnects the printer from the mains supply. The on position is labelled ‘I’ and the off
position is labelled ‘0’.
3.7.4 Power On Switch

This switch is mounted on the right-hand front of the base unit.
It is a 2-pole, momentary-action ‘on’ switch, which, when pressed and released, connects
mains power to the LVPSU and thereby switches on the printer. Although it switches
mains power within the printer, it is not classified as a mains isolating switch, but is a mains
voltage-rated control device. To power down the printer, either the Auto Power Down feature
must be enabled, or the Mains Power Supply Switch on the rear of the printer must be
manually set to the ‘off’ position.
3.7.5 Mains Filter

The mains filter assembly is mounted on the rear inside face of the base unit on the right-
hand side, below the mains power supply switch.
The purpose of this unit is to isolate and filter the mains input, preventing electrical noise
and ‘spikes’ from interfering with the operation of the printer. It also prevents any
electrical noise from being transmitted from the printer to the mains supply wiring.
3.7.6 Mains Input Fuses

There are two mains input fuses housed in a dual fuse holder, which is part of the mains
filter. The fuses are located below the mains cable connector, on the rear right-hand side of
the base unit. To gain access to the fuses, the mains cable connector cover must be
removed/opened.
The fuses are 20 mm antisurge, ceramic, sand-filled, rated at 4 A for both 115 volts and 230
volts a.c. operation.
3.7.7 Low Voltage Power Supply Unit (LVPSU)

The LVPSU is mounted on a bracket, and this assembly is then mounted on the right-hand
outside wall of the ink system enclosure.
It is a switch mode unit that provides the necessary voltage rails to power various systems
within the printer.
The input voltage range of the unit is between 85 volts and 264 volts a.c., 50/60 Hz. A 10-way
Molex minifit junior connector receives the mains input as detailed in the following table:
48209
Input 10-way Molex pin number
Live 1, 6
Neutral 3, 8
Earth 5, 10
Figure 3-37. LVPSU Input Details
Amdt 01 MP65557–1
There are four outputs of +5.1 V, +12 V, –16 V and +24 V d.c. In addition, 6 outputs of 0
volts are provided (all commoned).
The following table provides details of the outputs on connector PL7, including pin
numbers:
48003
Output (V d.c.) Max. current (A) 16-way Molex pin number
+5.1 2.5 2, 10
+12.0 0.9 5, 13
–16.0 0.4 6, 14
+24.0 2.5 8, 16
0.0 N/A 3, 4, 7, 11, 12, 15
Reserved N/A 1, 9
Figure 3-38. LVPSU Output Details
3.7.8 EHT Power Supply Unit (EHTPSU)
WARNING: LETHAL VOLTAGE. THERE IS A POSSIBILITY THAT UNDER CERTAIN

FAULT CONDITIONS THE CHASSIS OF THE EHT 3000 POWER SUPPLY MAY
BECOME CONNECTED TO THE 300 V SUPPLY. SHOULD THIS OCCUR THE
CHASSIS IS PARTIALLY PROTECTED BY ITS INSULATING PAINT LAYER.
EXTREME CARE MUST BE TAKEN WHEN WORKING ON THE PRINTER WHILE
POWER IS APPLIED TO IT AND THE TOP COVER IS REMOVED. TEST THE
CHASSIS OF THE EHT POWER SUPPLY BEFORE TOUCHING IT.
FAILURE TO COMPLY WITH THIS SAFETY WARNING COULD RESULT IN
ELECTRIC SHOCK, WHICH MAY CAUSE INJURY OR DEATH.
There is a warning label attached to the top surface of the EHTPSU that bears the following
warning: “WARNING! CHASSIS MAY BE LIVE. TEST BEFORE TOUCHING.”
The EHT Power Supply Unit (EHTPSU) is secured to the top right-hand end of the air filter
housing.
The unit generates the high voltages required for the printhead positive deflector plate, and
modulation and charge generation circuits. It is powered by +24 volts d.c. from the LVPSU
via the IPM PCB.
A variable EHT output of 0 V to +10 kV (with an over current trip of 10 µA at any setting)
is provided, which is used to establish the +8 kV (maximum for all Mk7 printheads)
electrostatic field between the printhead deflector plates. The level of this output is
determined by the EHT Program Input, which is an analogue voltage of between 0 volts
and 10 volts d.c., with 10 volts equating to 10 kV. The value required to generate 8 kV
±1.7% is entered into the printer (refer to Chapter 5: Maintenance > Diagnostics Menu >
Calibration > EHT Cal Value).
The EHT output is routed from the unit to the printhead via a red cable to a white Highvol
style connector.
MP65557–1 Amdt 01
A further output of +300 volts, at a maximum current of 46 mA, is used to supply the
charge and modulation amplifiers on the IPM PCB. On detection of output over current
between 52 mA and 58 mA, the output voltage falls to 0 volts.
Apart from the EHT output, all other voltages and signals are routed to and from the unit
via a 12-way Molex minifit junior connector PL6.
The following table provides details of the inputs and outputs, including the connector pin
numbers:
68005
Input Output 12-way Molex pin number
+24 V Power 6
EHT Program Input (0–10 V) 3
/EHT Enable 4
/300 V Enable 9
0V 5, 12
Chassis 11
+300 V 1
/EHT Over Current 10
Not connected 2, 7, 8
Figure 3-39. EHTPSU Input/Output Details
3.7.9 Ink System Pump

This unit is a pump and brushless d.c. motor assembly mounted through an aperture in the
front wall of the ink system enclosure.
Its purpose is to pump ink around the ink system at various pressures as demanded by the
ink system control circuits. These pressure values depend on the various functions carried
out by the printer during startup, normal running, nozzle clearing, and shutdown. For
safety the pump also incorporates a pressure relief valve (PRV) set to 90 p.s.i.
The motor is powered by +24 volts d.c., and pressure control is achieved by a 0 volts to
5 volts d.c. drive signal supplied by the IPM PCB control circuits, via PL2.
Magnetic coupling from the motor to the pump ensures separation of the ink from the
electrical drive parts.
3.7.10 Ink System Valves and Cableform Assembly

The valves are mounted through the front wall of the ink system enclosure, allowing the
electrical and fluid connections to be isolated from each other; the fluid connections are
located on the inside of the enclosure, and the electrical connections on the outside.
Electrical connections to the valves are provided by the Valve Cableform Assembly from a
24-way Mini-Fit Junior connector (PL11) on the edge of the IPM PCB.
Amdt 01 MP65557–1
Colour-coding and pin number details of the Valve Cableform Assembly wiring to the
valves, pressure transducer, fluid level sensors (float switches) and ink spillage detection
are provided in the following table. The valves’ electrical connectors are numbered on their
top surfaces for easy valve identification to avoid incorrect connection, and this
information is also provided:
49183
VALVE CABLEFORM ASSEMBLY
Component Wire colours PL1 pin numbers
Feed Valve (1) Black; Purple 13; 14
(Red heatshrink)
Purge Valve (2) White/Yellow; Yellow/Brown 19; 20
(Yellow heatshrink)
Gutter Valve (3) Grey/Pink; Red/Blue 15; 16
(Green heatshrink)
Solvent Add Valve (4) White/Green; Brown/Green 17; 18
(Blue heatshrink)
Solvent Flush Valve (5) White/Grey; Grey/Brown 21; 22
(Violet heatshrink)
Pressure Transducer Brown; Green; Yellow; Grey 6; 7; 8; 9
(Black heatshrink)
Level Sensor—Ink Red; White/Pink 12; 24
Level Sensor—Solvent White; Blue 5; 11
Ink Spillage Detection Pink (Green/Yellow heatshrink) 10
Figure 3-40. Valve Cableform Details
3.7.11 Cooling Fan

The cooling fan is mounted on the top left-hand end of the air filter housing. It is a 24 volts
d.c. device rated at 2.4 watts, supplied directly from the LVPSU, and operates while the
printer is switched on. Air is drawn in by the fan through the base of the cabinet, through
the air filter, around the inside of the cabinet, and out through a mesh grill in the cabinet
base.
3.7.12 Printhead Positive Air Pump (optional)

The printhead positive air pump is mounted on the top of the air filter housing between the
cooling fan and the EHTPSU.
The pump is rated at 2.4 watts and is powered by +12 volts supplied from connector PL8
on the IPM PCB.
The purpose of the pump is to improve printer performance in dusty environments by
supplying a positive air pressure to the printhead to reduce the ingress of airborne
particles. The unit pumps filtered air from inside the printer cabinet, along the printhead
conduit to a stainless steel outlet fitting on the printhead. The air flow to the printhead is
greater than that through the gutter, thereby producing a positive air pressure inside the
printhead cover tube, which helps to keep the printhead free of dust and other airborne
debris.
The air supply pipe is fitted as standard to all Mk7 printheads. However, the pump is not
fitted as standard to the 4900 printer but is available as an option. (Refer to the Linx Ink Jet
Printers Parts and Prices manual, or contact your Linx distributor.)
MP65557–1 Amdt 01
3.8 Electronics and Software
3.8.1 Overview
The main electronics system in the 4900 printer is contained on one printed circuit board
(PCB), known as the Integrated Processor Module (IPM) PCB, which is mounted vertically
on the left-hand side of the cabinet.
The Keyboard and Display Assembly in the printer top cover contains the Display PCB.
The functions of the circuit boards are briefly described as follows.
IPM PCB
Contains the main Central Processing Unit, which controls printer operation. It also
contains the Unique Number Identification Chip (UNIC), and amplifiers for processing the
printhead control signals.
Display PCB
Processes the input from the keyboard and provides control of the display.
3.8.2 Circuit Diagrams

Service engineers involved in fault diagnosis and rectification at PCB level should ensure
that they use the appropriate revision of circuit diagram for the issue of PCB.
Circuit schematic and interconnecting diagrams of the 4900 electronic and electrical
functions are provided at the end of this manual. A detailed list of these drawings is
presented in the following table:
49184
Drawing title Drawing no. Sheet no. Circuits
4900 ELECTRICAL SYSTEM CD13008/1 Sheet 1 of 1
N/A
DIAGRAM
4900 IPM CIRCUIT SCHEMATIC: AS16080/4 Sheet 1 of 7
N/A
ROOT SHEET
4900 IPM CIRCUIT SCHEMATIC: AS16080/4 Sheet 2 of 7 Voltage References
AMPLIFIERS SHEET Charge Amplifier
Modulation Amplifier
4900 IPM CIRCUIT SCHEMATIC: AS16080/4 Sheet 3 of 7 CPU, Peripherals & Memory
CPU SHEET Memory Decode
Serial Number Chip (UNIC)
Battery Backup & Real Time Clock
4900 IPM CIRCUIT SCHEMATIC: AS16080/4 Sheet 4 of 7 Display Interface
DISPLAY INTERFACE SHEET Contrast Control
4900 IPM CIRCUIT SCHEMATIC: AS16080/4 Sheet 5 of 7 Gate Array & Charge/Sequencer
DROP GEN & DMA SHEET PROM
DMA Circuitry
4900 IPM CIRCUIT SCHEMATIC: AS16080/4 Sheet 6 of 7 Primary Trigger
HARDWARE SHEET Shaft Encoder & RS232 Buffers
Phase Amplifier
Auto Power Off
External Alarms
Positive Air Pump
4900 IPM CIRCUIT SCHEMATIC: AS16080/4 Sheet 7 of 7 Pressure Control
INK & PHEAD SHEET EHT/300V
Printhead Sensors
300V Detection
PCB Issue & Software Links
Pressure & Temperature ADCs
4900 DISPLAY CIRCUIT AS16081/2 Sheet 1 of 1 Display Buffers
SCHEMATIC Keyboard Controller
Figure 3-41. Circuit and Interconnecting Diagrams’ List
Amdt 01 MP65557–1
3.8.3 IPM PCB

MUST BE TAKEN WHEN WORKING ON THE IPM PCB, AS UP TO 300 VOLTS
D.C. IS PRESENT ON IT WHEN THE PRINTER IS SWITCHED ON. THE
CORRECT, STANDARD ELECTRICAL SAFETY PRECAUTIONS MUST BE
TAKEN. THERE IS A DANGER OF DEATH OR INJURY FROM ELECTRIC SHOCK
IF THE CORRECT ELECTRICAL SAFETY PRECAUTIONS ARE NOT TAKEN.
Test Points and Links

Test points and links are provided on the IPM PCB to aid fault diagnosis. Links are also
used to enable or disable various printer functions, and certain of the links must be fitted to
enable the printer to operate correctly.
Test points and links for the IPM PCB are listed below together with details of their
functions. Details are applicable to Issue 4 of the IPM PCB unless otherwise stated.
To make the test points and links easier to find, the board edges are marked with grid
square identifiers—A to D vertically, and 1 to 10 horizontally. A grid reference is provided
in brackets after each test point and link number in the following lists, which can be used to
locate it on the IPM PCB. A further aid to locating test points and links is provided after the
following lists in the form of an illustration of the IPM PCB with a reference grid
superimposed over it.
Test Points
TP1 (A10) MOD. Modulation amplifier output. A sine wave of between 0 volts and
255 volts a.c. should be observed with a frequency dependent on the type
of printhead fitted: 96 kHz (Mini 50 µm), 80 kHz (Ultima 62 µm), 64 kHz
(Ultima plus 75 µm). The signal should be a.c. coupled with the peaks of
the sine wave going positive and negative with respect to 0 volts.
TP3 (A7) PH_A. Amplified analogue signal from the phase detector in the range of
approximately +11 volts to –15 volts. There should be less than 1 volt peak-
to-peak noise during quiescent (non-printing) conditions. When printing,
this signal looks erratic as the amplifier is driven firmly into saturation by
the presence of charged printing drops.
TP4 (A7) PH_D. Digital representation of the phase signal. The quiescent (non-
printing) state for the signal is +12 V. When the phase signal is detected
(voltage at TP3 exceeds 4 V) the signal switches to –16 V. When phasing,
two negative-going pulses separated by a few milliseconds should be
observed.
TP5 (C7) RD_PRESS. This is the amplified output of the pressure transducer and is
a voltage representation of the pressure in the ink system of between
0 volts and +5 volts d.c. During normal operation, with link LK1 (OPEN
LOOP) fitted, the voltages measured at TP5 and TP6 are almost identical.
The Read Pressure and Set Pressure values observed in the MONITOR JET
screen (Diagnostics menu) are almost never the same due to tolerances in
the electronics.
TP6 (C8) SET_PRESS. This is the Set Pressure value and has a range of 0 volts to
+5 volts d.c. It represents the pressure set by the electronics to maintain the
required ink flow. During normal operation, with LK1 (OPEN LOOP)
fitted, the voltages measured at TP5 and TP6 are almost identical.
TP9 (B10) CHG. Charge amplifier output that is applied to the charge electrode. The
typical output range is 0 volts to +255 volts d.c.
MP65557–1 Amdt 01
TP13 (A9) 0V. Zero volts test point.
TP15 (C9) 0V. Zero volts test point.
TP17 (B9) 300/322V. EHTPSU output of 300 volts d.c.
TP21 (D5) 0V. Zero volts test point.
TP28 (C1) PRI (NOBJ). Primary trigger input. This is the opto-isolated primary
trigger signal. It is a 0 volts to 5 volts digital signal, with the falling or
rising edge indicating the presence of the object.
TP32 (C1) SHAFT-ENC. Single-ended shaft encoder input. This is the opto-isolated
shaft encoder signal, and is a 0 volts to 5 volts digital signal.
TP35 (D2) 0V. Zero volts test point.
TP40 (D5) 5V. A convenient point to test for the presence of the supply on the
+5.1 volts rail from the LVPSU.
TP44 (A1) 0V. Zero volts test point.
TP49 (B1) AUX_I/P. Secondary trigger input. This is the opto-isolated secondary
trigger signal, and is a 0 volts to 5 volts digital signal.
TP50 (C8/C9) CHG_LOW. Low voltage charge signal, before amplification, of between
0 volts and –8 volts.
TP51 (B8) MOD-LOW. Low voltage modulation signal, before amplification, of
between 0 volts and –8 volts. A sine wave should be observed with a
frequency dependent on the type of printhead fitted: 96 kHz (Mini 50 µm),
80 kHz (Ultima 62 µm), 64 kHz (Ultima plus 75 µm).
+24 volts rail from the LVPSU.
TP53 (D4) –15/16V. A convenient point to test for the presence of the supply on the –
16 volts rail from the LVPSU.
+12 volts rail from the LVPSU.
TP55 (C2) VBAT. The state of the NiMH battery can be monitored at this test point,
and should be a maximum of 2.9 V d.c. and a minimum of 2.2 V d.c.
TP56 (D6/D7) PRESST–. Pressure transducer output. A differential of 0 volts to 33 mV,
where 33 mV equates to 255 pressure bits. Measurement must be taken
between this test point and TP57.
TP57 (D7) PRESST+. Pressure transducer output. A differential of 0 volts to 33 mV,
where 33 mV equates to 255 pressure bits. Measurement must be taken
between this test point and TP56.
TP58 (A6) OVER_TEMP. Digital voltage of 0 volts or +5 volts d.c. relating to
printhead over temperature. 0 volts indicates an over temperature
condition above the threshold of 60 degrees C; +5 volts indicates a
temperature below the threshold of 60 degrees C.
TP59 (A7) PHEAD_TEMP. Analogue voltage of 0 volts to 11 volts d.c. relating to
printhead temperature.
TP60 (C8) GUTT_SEN. The gutter sense circuit detects the presence of ink flow in the
gutter during a Normal Start sequence (it is not detected during a Quick
Start sequence). If ink flow is not detected in the gutter for any reason (e.g.
a misaligned jet), the software will shut down the jet. The voltage
measured at this test point should be 5 volts d.c. if there is no jet detected,
and less than 4 volts d.c. if the jet is present in the gutter. These voltages
may vary with time.
Amdt 01 MP65557–1
TP61 (A8) 10VREF. This is the output of the +10 volts d.c. reference.
TP63 (A8) 5VREF. This is the output of the +5 volts d.c. reference.
TP64 (A8) –10REF. This is the output of the –10 volts d.c. reference.
TP65 (A8) EHT-PRO. The EHTPSU requires calibration to give a specific output of
8 kV by entering a calibration figure into the printer. An analogue voltage
of between 0 volts and 10 volts d.c. can be measured at this test point, with
10 volts equating to 10 kV.
TP67 (C8) VPOWERS. The energizing voltage rail for the printhead and ink system
valves can be checked at this test point. It is either the energizing voltage
of +24 volts d.c., or the valve hold-on voltage of +12 volts d.c.
TP68 (C2) QUADSE. Quadrature shaft encoder input. This is the opto-isolated
quadrature shaft encoder signal, and is a 0 volts to 5 volts digital signal.
TP69 (D3) VO. Display (LCD) contrast voltage of between –12.67 volts and 5 volts.
Links
LK1 (C7) OPEN LOOP. Removal of this link breaks the feedback loop that controls
the pump/pressure circuits. By removing the link it is possible to energize
the pump, even though there may be a fault in the pressure transducer
circuit or ink system. Because of the non-linearities in the control loop, the
scaling factors for the Set Pressure commands in the Service property sheet
do not apply when the link is removed. The Read Pressure command is
unaffected. This link should normally be fitted.
LK2 (C2) BATTERY. Connects the NiMH battery to the message store so that data is
retained when the printer is switched off. Removing this link deletes all
messages, datasets, downloaded fonts, logos and passwords from the NVR
(SRAM). In addition, various other parameters in flash memory are reset
to their default values, for example, Printhead Code, Ref Modulation,
Conduit Length, Ink Type, Head Height. These will all need to be re-
entered. The NiMH battery is also trickle charged when this link is fitted.
LK3 (C2) RESET. Momentarily fitting this link causes the microprocessor to reset. If
it is permanently fitted, the microprocessor is held in the reset state.
LK4 (A6) SAFE_O/R. (Safety Override). Software readable link.
WARNING: LETHAL VOLTAGE. WITH ‘PRINTHEAD OVER

TEMPERATURE’ OR ‘EHT TRIP’ FAULT CONDITIONS, AND
WITH LINK LK4 FITTED, THE 300 VOLTS D.C. WILL STILL BE
PRESENT AT THE PRINTHEAD.
THE CORRECT, STANDARD ELECTRICAL SAFETY
PRECAUTIONS MUST BE TAKEN WHILE WORKING ON THE
PRINTHEAD WITH LINK LK4 FITTED. LINK LK4 MUST NOT BE
FITTED PERMANENTLY AND THE PRINTER MUST NOT BE LEFT
UNATTENDED WHILE THE LINK IS FITTED. THERE IS A
DANGER OF DEATH OR INJURY FROM ELECTRIC SHOCK IF
THE CORRECT ELECTRICAL SAFETY PRECAUTIONS ARE NOT
TAKEN.
When this link is fitted, the printhead Over Temperature sense and the
EHT Trip sense signals will not disable the 300 V, ink system pump, feed
valves and EHT. However, the EHT Trip sense will disable the EHT
internally on the EHTPSU regardless of LK4 being fitted. The link may be
fitted with caution to aid fault diagnosis.
MP65557–1 Amdt 01
LK6 (A6) COVER.O/R. (Cover Override). Software readable link.
WARNING: LETHAL VOLTAGE. WHEN LINK LK6 IS FITTED,

AND UNDER NORMAL OPERATING CONDITIONS, THE EHT
WILL STILL BE PRESENT ON THE DEFLECTOR PLATES AND 300
VOLTS D.C. WILL BE PRESENT ON THE CHARGE ELECTRODE
AFTER THE PRINTHEAD COVER TUBE HAS BEEN REMOVED.
THE CORRECT, STANDARD ELECTRICAL SAFETY
PRECAUTIONS MUST BE TAKEN WHILE WORKING ON THE
PRINTHEAD WITH THE COVER TUBE REMOVED AND LINK LK6
FITTED. LINK LK6 MUST NOT BE FITTED PERMANENTLY AND
THE PRINTER MUST NOT BE LEFT UNATTENDED WHILE THE
LINK IS FITTED. THERE IS A DANGER OF DEATH OR INJURY
FROM ELECTRIC SHOCK IF THE CORRECT ELECTRICAL
SAFETY PRECAUTIONS ARE NOT TAKEN.
When this link is fitted and with the Cover Override option set to On
(Setup menu > Printhead Setup menu), the EHT and charge voltage
remain on while the printhead cover tube is removed (i.e. they are not
automatically disabled). This allows printing to continue for fault
diagnosis purposes. The red strobe LED also remains lit. See also System
Warnings “3.12 Printhead Cover Off” and “3.13 Cover Override Active”.
After removing the printhead cover tube and then fitting the link (or
refitting the printhead cover tube), a period of 6 seconds elapses before
printing recommences.
See also: Chapter 4: Setup Menu > Printhead Setup option > Cover
Override option.
LK8 (B9) VM. Connects the 300 volts d.c. stabilized supply to the modulation
amplifier. Selective removal of either LK8 or LK9 can be useful to isolate a
fault if a “2.04 300V Power Supply” fault is reported.
LK9 (B9) VC. Connects the 300 volts d.c. stabilized supply to the charge amplifier.
Selective removal of either LK8 or LK9 can be useful to isolate a fault if a
“2.04 300V Power Supply” fault is reported.
LK10 (A8) SW LKS. Links LK10A, LK10B, LK10C, LK10D and LK10E are software-
readable links, and as such should not be moved or interfered with.
LK11 (A7) BIST. (Built In Self Test). Software-readable link. When fitted it places the
gate array in test mode, which generates a staircase waveform with
historic correction.
LK12 (A7) GUTT_O/R. (Gutter Sense Override). The purpose of the gutter sense is to
detect the presence of ink flow in the gutter. If ink flow is not detected in
the gutter for any reason (e.g. a misaligned jet), the software will shut
down the jet. Absence of ink in the gutter is detected within approximately
10 seconds. With this link fitted, the software starts and maintains the jet
regardless of the gutter sense status.
LK13 (A6) POW_O/R. (Power Off Override). Software readable link. When this link is
fitted the auto power down mains on/off switch cannot be switched off by
the software.
NOTE: Changing the printhead Type (Setup menu > Printhead Setup
menu) or the configuration Code (Setup menu > Change
Configuration menu) causes the printer to switch off
automatically, and it must be switched on again for these new
parameters to take effect. If link LK13 is fitted when either of these
parameters is changed, the printer will not be able to switch off
automatically.
Amdt 01 MP65557–1
LK14 (C1) 24V/5V. Selects the appropriate supply voltage for a single-ended shaft
encoder—either 5 volts d.c. (pins 1 and 2) or 24 volts d.c. (pins 2 and 3).
LK20 (D6/D7) BUZZER. This link, when removed, inhibits the internal warning buzzer,
and may be removed when fault finding to relieve personal irritation! It
should normally be fitted.
LK21 (C1) 24V/5V. Selects the appropriate supply voltage for a quadrature shaft
encoder, either 5 volts d.c. (pins 1 and 2) or 24 volts d.c. (pins 2 and 3). This
link must be fitted for the same supply rail as LK14.
LK24 (C2) MED. When this link is fitted in position B (between pins 2 and 3), and
LK25 is fitted in position A (between pins 1 and 2), MEDIUM debounce of
approximately 1 ms is set on the primary trigger input. The default position
for this link and link LK25 is position A (between pins 1 and 2), which both
together give FAST or ‘normal’ debounce of approximately 50 µs.
LK25 (C2) SLOW. When this link is fitted in position B (between pins 2 and 3), and
LK24 is fitted in position A (between pins 1 and 2), SLOW debounce of
approximately 25 ms is set on the primary trigger input, which filters out
multiple primary trigger edges to give one genuine pulse. This is
particularly useful when a relay contact is used as a trigger source. The
default position for this link and link LK24 is position A (between pins 1
and 2), which both together give FAST or ‘normal’ debounce of
approximately 50 µs.
LK26 (C1) PNP. When all four links are fitted on this eight-pin link, the circuitry to
accept a PNP type of primary trigger is selected.
LK27 (B1) NPN. When all four links are fitted on this eight-pin link, the circuitry to
accept an NPN type of primary trigger is selected (the default setting).
IMPORTANT: All four links must be fitted to either LK26 or LK27. Do not mix the links.
LK28 (B2) MED. When this link is fitted in position B (between pins 2 and 3), and
LK29 is fitted in position A (between pins 1 and 2), MEDIUM debounce of
approximately 1 ms is set on the secondary trigger input. The default
position for this link and link LK29 is position A (between pins 1 and 2),
which both together give FAST or ‘normal’ debounce of approximately
50 µs.
LK29 (B2) SLOW. When this link is fitted in position B (between pins 2 and 3), and
LK28 is fitted in position A (between pins 1 and 2), SLOW debounce of
approximately 25 ms is set on the secondary trigger input, which filters out
multiple secondary trigger edges to give one genuine pulse. This is
particularly useful when a relay contact is used as a trigger source. The
default position for this link and link LK28 is position A (between pins 1
and 2), which both together give FAST or ‘normal’ debounce of
approximately 50 µs.
LK30 (B1) PNP. When all four links are fitted on this eight-pin link, the circuitry to
accept a PNP type of secondary trigger is selected.
LK31 (B1) NPN. When all four links are fitted on this eight-pin link, the circuitry to
accept an NPN type of secondary trigger is selected (the default setting).
IMPORTANT: All four links must be fitted to either LK30 or LK31. Do not mix the links.
MP65557–1 Amdt 01
The following table lists the IPM PCB links, their functions and default settings:
49192
Link Function Default setting
LK1 OPEN LOOP Fitted
LK2 BATTERY Fitted
LK3 RESET Not fitted
LK4 SAFE O/R Not fitted
LK6 COVER O/R Not fitted
LK8 VM Fitted
LK9 VC Fitted
LK10 SW LKS Not fitted
LK11 BIST Not fitted
LK12 GUTT O/R Not fitted
LK13 POW O/R Not fitted
LK14 24V/5V (single-ended S/E) 5V (pins 1 and 2)
LK20 BUZZER Fitted
LK21 24V/5V (quadrature S/E) 5V (pins 1 and 2)
LK24 MED (primary trigger) Fitted (pins 1 and 2)
LK25 SLOW (primary trigger) Fitted (pins 1 and 2)
LK26 PNP (primary trigger) All four not fitted
LK27 NPN (primary trigger) All four fitted
LK28 MED (secondary trigger) Fitted (pins 1 and 2)
LK29 SLOW (secondary trigger) Fitted (pins 1 and 2)
LK30 PNP (secondary trigger) All four not fitted
LK31 NPN (secondary trigger) All four fitted
Figure 3-42. IPM PCB Link Default Settings
Safety Functions
Detection and safety lock-out hardware guards against hazardous situations arising as a
result of fault conditions, according to the following table:
68002
Fault condition Action
Switch Switch Switch Switch Switch
EHT Off 300 V Off Ink Feed P’head Feed Pump Off
Valve Off Valve Off
EHT Over Current ✔ ✔ ✔ ✔ ✔
Printhead Over Temp. ✔ ✔ ✔ ✔ ✔
Printhead Cover Off ✔ ✘ ✘ ✘ ✘
Figure 3-43. Fault Conditions and Actions

NOTES:
1. Links enable the actions to be overridden resulting in unsafe conditions.
2. Cover Override link LK6 defeats the Printhead Cover Off detector.
3. Safety Override link LK4 defeats all safety detectors.
4. All override links are readable by the software.
Amdt 01 MP65557–1
MP65557–1
49265
3 — 61
Test Point Link
Figure 3-44. IPM PCB Test Points and Links Locations
Amdt 01
Jan 2006
Replacement and Calibration
If the IPM PCB is replaced, or if the software is upgraded, the electronics system will
require recalibrating. Also, the NVR will have been reinitialized, causing the printer line
configuration settings to be reset to the default values. Therefore, the original settings will
need to be re-entered.
The printer’s UNIC is located on the IPM PCB and this must also be removed and fitted to
the replacement PCB. The Printer Configuration Code must then be re-entered in order for
the printer to access the required options (Chapter 4: Setup menu > Configuration sub-
menu > Code option).
If recalibration is required, refer to the ‘IPM PCB Calibration’ Maintenance Instruction in
‘Chapter 5: Maintenance’.
3.8.4 Display PCB

The user interface consists of a full QWERTY membrane keypad (see Figure 3-2), a 256 x
64-pixel back lit LCD, and a Display PCB.
The Display PCB is fitted to the rear of the LCD, and the combined assembly is fitted inside
the printer top cover.
Test Points and Links

There are no test points or links on the Display PCB.
3.8.5 Software
The system software program for the 4900 printer is stored in the PROGRAM PROM IC41
on the IPM PCB. The software version number can be viewed in the SYSTEM
CONFIGURATION menu (in the Setup menu). Alternatively, pressing the [V] accelerator
key in the CURRENT MESSAGE screen displays the system software version number in
the status line.
All parameters for configuring the printer are contained in three PROMs on the IPM PCB:
• PROGRAM PROM IC41
• CHG/SEQ PROM IC65
• LOGO PROM IC43 (not fitted as standard)
The printer variant (Standard Speed, High Speed, Super High Speed or DC), message types
(rasters), and any additional software options (for example, DDE Printer Driver, LogoJet)
are configured/enabled from the data stored in these PROMs, using the Printer
Configuration Code. For more information refer to Chapter 4: Setup Menu > Change
Configuration option > Code option.
The printhead type (Mini, Ultima or Ultima plus) is selected in the Printhead Setup menu
(Setup menu > Printhead Setup menu > Type option).
Up to eight languages are stored in the PROGRAM PROM IC41. Depending on the
language required, it may be necessary to change the PROGRAM PROM. For details of the
different language group PROMs available, refer to the Linx Ink Jet Printers Parts and Prices
manual.
Amdt 01 MP65557–1
3.9 External Signals
The following external signal information contains descriptions of the Primary Trigger,
Secondary Trigger, Shaft Encoders, Alarm Output and the RS232 Interface.
3.9.1 Primary Trigger

The primary trigger input can be from a photocell, a contact switch, a relay contact, a signal
from a PLC, or many other sources.
A photocell would normally be used to detect the presence of the product on the
production line as it approaches the printhead, and to supply a ‘next object’ signal to the
printer firmware. This initiates a print delay, after which a message is printed. By correctly
positioning the photocell and programming a suitable delay, the position of the message on
the product (print registration) can be controlled. The primary trigger can also perform the
same function as the secondary trigger.
The input is connected to either SK1 or SK2 on the IPM PCB. These two connectors are
located through the printer rear panel, and identified as PRIMARY TRIGGER/SHAFT
ENCODER and SECONDARY TRIGGER/SHAFT ENCODER. The two connectors are
wired in parallel so either may be used for a primary trigger device. The hardware input
circuit is separate from, but identical to, that of the secondary trigger.
Signal conditions for the primary 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.
The primary trigger source should be an open collector device, of either NPN or PNP type,
capable of using a 24 volts supply, or it can be a volt-free relay contact. The choice of
photocell type is determined by fitting the four part link LK26 (on the IPM PCB) for PNP
operation, or the four part link LK27 for NPN operation.
Typical configurations for NPN and PNP photocells used as primary triggers are shown in
the following two simplified illustrations:
49026
Iss 7
SK1/SK2 4900 PRINTER
NPN PHOTOCELL LK27
1 24VF
1 2
IC88 Internal
3 x 750R signal
PRIMARY LK26
TRIGGER 6 3 x 750R
1 2
2 0VF
Figure 3-45. Primary Trigger—NPN Configuration
MP65557–1 Amdt 01
49027
Iss 7
PNP PHOTOCELL
1 24VF
IC88 Internal
3 x 750R signal
PRIMARY
TRIGGER 6 LK26 3 x 750R
1 2
LK26
2 0VF
7 8
Figure 3-46. Primary Trigger—PNP Configuration

The software determines from which edge of the input signal (leading or trailing edge) the
‘next object’ triggers are being generated. SLOW debounce of approximately 25 ms can be
set on the primary trigger input by fitting link LK24 in position A (between pins 1 and 2),
and link LK25 in position B (between pins 2 and 3), which filters out multiple primary
trigger edges to give one genuine pulse. This is particularly useful when a relay contact is
used as a trigger source.
When link LK24 is fitted in position B (between pins 2 and 3), and link LK25 in position A
(between pins 1 and 2), MEDIUM debounce of approximately 1 ms is set on the primary
trigger input. The default position for links LK24 and LK25 is position A (between pins 1
and 2), which both together give FAST or ‘normal’ debounce of approximately 50 µs.
The following table summarizes the different amounts of debounce filtering that can be
selected for the primary trigger:
49218
Debounce type LK24 position LK25 position Debounce timing
Slow Between pins 1 and 2 Between pins 2 and 3 23.9 ms ±20%
Medium Between pins 2 and 3 Between pins 1 and 2 1.1 ms ±20%
Fast Between pins 1 and 2 Between pins 1 and 2 49.2 µs ±20%
Figure 3-47. Primary Trigger Debounce Timings
3.9.2 Secondary Trigger

The secondary trigger input can be from a photocell, a contact switch, a relay contact, a
signal from a PLC, or many other sources. The secondary trigger would normally be used
to increment or reset sequential numbers or messages, to change the orientation of a
message, or to change from printing one message to another. The secondary trigger can
also perform the same function as the primary trigger.
The input is connected to either SK1 or SK2 on the IPM PCB. These two connectors are
located through the printer rear panel, and identified as PRIMARY TRIGGER/SHAFT
ENCODER and SECONDARY TRIGGER/SHAFT ENCODER, respectively. The two
connectors are wired in parallel so either may be used for a secondary trigger device. The
hardware input circuit is separate from, but identical to, that of the primary trigger.
Signal conditions for the secondary 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.
Amdt 01 MP65557–1
The secondary trigger source should be an open collector device, of either NPN or PNP
type, capable of using a 24 volts supply, or it can be a volt-free relay contact. The choice of
trigger device type is determined by fitting the four part link LK30 (on the IPM PCB) for
PNP operation, or the four part link LK31 for NPN operation.
Typical configurations for NPN and PNP photocells used as secondary triggers are shown
in the following two simplified illustrations:
49204
Iss 7
NPN PHOTOCELL LK31
1 24VF
1 2
IC90 Internal
3 x 750R signal
SECONDARY LK30
TRIGGER 4 3 x 750R
1 2
2 0VF
Figure 3-48. Secondary Trigger—NPN Configuration

49205
Iss 7
PNP PHOTOCELL
1 24VF
IC90 Internal
3 x 750R signal
SECONDARY
TRIGGER 4 LK30 3 x 750R
1 2
LK30
2 0VF
7 8
Figure 3-49. Secondary Trigger—PNP Configuration

The software determines from which edge of the input signal (leading or trailing edge) the
secondary triggers are being generated. SLOW debounce of approximately 25 ms can be set
on the secondary trigger input by fitting link LK28 in position A (between pins 1 and 2), and
link LK29 in position B (between pins 2 and 3), which filters out multiple secondary trigger
edges to give one genuine pulse. This is particularly useful when a relay contact is used as
a trigger source.
When link LK28 is fitted in position B (between pins 2 and 3), and link LK29 in position A
(between pins 1 and 2), MEDIUM debounce of approximately 1 ms is set on the secondary
trigger input. The default position for links LK28 and LK29 is position A (between pins 1
and 2), which both together give FAST or ‘normal’ debounce of approximately 50 µs.
The following table summarizes the different amounts of debounce filtering that can be
selected for the secondary trigger:
49363
Debounce type LK28 position LK29 position Debounce timing
Slow Between pins 1 and 2 Between pins 2 and 3 23.9 ms ±20%
Medium Between pins 2 and 3 Between pins 1 and 2 1.1 ms ±20%
Fast Between pins 1 and 2 Between pins 1 and 2 49.2 µs ±20%
Figure 3-50. Secondary Trigger Debounce Timings
MP65557–1 Amdt 01
3.9.3 Shaft Encoders
Either a 5-volt or a 24-volt, single-ended or quadrature shaft encoder can be used. The
input circuit of the single-ended shaft encoder has a maximum frequency response of 80
kHz.
The shaft encoder is connected to either SK1 or SK2 on the IPM PCB—these two connectors
are located through the printer rear panel, and identified as TRIGGER/SHAFT ENCODER.
The two connectors are wired in parallel so either may be used for a shaft encoder.
The shaft encoder supply voltage selection is determined by fitting link LK14 (single-ended
shaft encoder) or link LK21 (quadrature shaft encoder) in one of two positions. Pins 1 and 2
are linked for a 5-volt shaft encoder, and pins 2 and 3 are linked for a 24-volt shaft encoder.
The position of link LK14 or link LK21 is irrelevant when using an open-collector type of
shaft encoder. Regardless of the supply voltage setting, the shaft encoder must be capable
of sinking 10 mA per printer.
NOTE: If a quadrature shaft encoder is used, the printer counts two pulses per encoder
revolution. For example, a 2500 p.p.r. encoder is seen as 5000 pulses per
revolution.
The following two illustrations show the input connections for a 5-volt and a 24-volt single-
ended shaft encoder, respectively:
49193
5 V SINGLE-ENDED SK1/SK2 4900 PRINTER
SHAFT ENCODER 3 5VF
24VF
1
SE INPUT 8
470R
4 x 910R
NOTE:
2
Connections and LK14
LK14 shown for a 3 1
5 V Shaft Encoder
1
ANODE
IC87A 7
OUTPUT
2
CATHODE
2 0VF
Figure 3-51. 5 V Single-Ended Shaft Encoder Connections
49219
24 V SINGLE-ENDED SK1/SK2 4900 PRINTER
SHAFT ENCODER 3 5VF
1 24VF
SE INPUT 8
470R
4 x 910R
NOTE:
2
24 V Shaft Encoder
1
ANODE
IC87A 7
OUTPUT
2
CATHODE
2 0VF
Figure 3-52. 24 V Single-Ended Shaft Encoder Connections
Amdt 01 MP65557–1
The following two illustrations show the input connections for a 5-volt and a 24-volt
quadrature shaft encoder, respectively:
49220
5 V QUADRATURE SK1/SK2 4900 PRINTER
SHAFT ENCODER 3 5VF
24VF
1
QSE INPUT 9
470R
4 x 910R
NOTE:
2
5 V Shaft Encoder
4
ANODE
IC87B 6
OUTPUT
3
CATHODE
2 0VF
Figure 3-53. 5 V Quadrature Shaft Encoder Connections
49221
24 V QUADRATURE SK1/SK2 4900 PRINTER
SHAFT ENCODER 3 5VF
1 24VF
QSE INPUT 9
470R
4 x 910R
NOTE:
2
24 V Shaft Encoder
4
ANODE
IC87B 6
OUTPUT
3
CATHODE
2 0VF
Figure 3-54. 24 V Quadrature Shaft Encoder Connections
Width Adjuster Unit

A Width Adjuster Unit (WAU) is available, which can be connected between the shaft
encoder and the printer to intercept the shaft encoder signal. The WAU enables the printed
length of a message to be more finely adjusted to suit the application than is possible with
the printer’s Print Width setting alone. Alternative values for print width are generated by
the WAU to provide precise positioning of the code within a restricted space on a product.
Refer to the Width Adjuster Unit User Guide for details of how to set up and use the unit.
MP65557–1 Amdt 01
3.9.4 Primary Trigger and Shaft Encoder Configurations
There are three configurations for connecting product sensors and shaft encoders to the
4900 printer:
• One product sensor and one shaft encoder to trigger a single printer
• One product sensor and one shaft encoder to trigger a group of between two and four
printers
• One product sensor to trigger a group of between two and eight printers
NOTE: Operation with non-Linx supplied product sensors and shaft encoders cannot be
guaranteed.
Configuration 1
One product sensor and one shaft encoder can be connected to either or both of the
‘Trigger/Shaft Encoder’ sockets on the rear panel of the printer:
49194
Sensor and/ Sensor and/

or
or Encoder or Encoder
Figure 3-55. Two Devices Triggering a Single Printer
Configuration 2
When up to four printers are required to be triggered together, they are connected in series
using the ‘PDEM Cableform 2M D-D IP67’ connected to either of the ‘Trigger/Shaft
Encoder’ sockets of each adjacent pair of printers. A single product sensor is connected to
the first printer in the series, and a single shaft encoder is connected to the vacant ‘Trigger/
Shaft Encoder’ socket of the last printer:
49195
PDEM Cableform
Sensor 2M D-D IP67 Encoder
Figure 3-56. Two Devices Triggering Four Printers
Amdt 01 MP65557–1
Configuration 3
When up to eight printers are required to be triggered together, they are connected in
series using the ‘PDEM Cableform 2M D-D IP67’ connected to either of the ‘Trigger/Shaft
Encoder’ sockets of each adjacent pair of printers. A single product sensor is connected to
the first printer in the series:
49196
PDEM Cableform
Sensor 2M D-D IP67
PDEM Cableform
2M D-D IP67
Figure 3-57. One Sensor Triggering up to Eight Printers

NOTES:
1. The maximum numbers of printers that can used with a shaft encoder is four.
2. The maximum numbers of printers that can used with a product sensor is eight.
MP65557–1 Amdt 01
3.9.5 Alarm Output
The alarm internal switching signal can be used to operate either a 24 volts external alarm,
or a mains powered external alarm via volt-free contacts (VFC).
The printer is shipped in the 24 volts alarm operation configuration, but the mains
powered external alarm capability is available as an option.
24 Volts External Alarm

CAUTION: The printer ALARM OUTPUT connector must not be connected to the
mains or any other power source. Doing so could severely damage the printer.
The 24 volts external alarm output circuit is protected by a 200 mA, self-resetting fuse (F2)
on the IPM PCB. The alarm output is routed from connector PL9 on the IPM PCB to the
ALARM OUTPUT connector on the printer’s rear panel via the Alarm PCB, which is fitted
to the back of the ALARM OUTPUT connector.
68651
24 VOLTS ‘ALARM OUTPUT’ CONNECTOR
Signal Pins used
24 V L
Return N
Figure 3-58. 24 Volts External Alarm Pin Connections
Mains (VFC) External Alarm

For a mains powered external alarm, the alarm switching signal is used to operate a volt-
free contacts (VFC) relay (RLA1) on the IPM PCB.
WARNING. LETHAL VOLTAGE. IF A MAINS POWERED EXTERNAL ALARM

IS CONNECTED TO THE PRINTER, THERE MAY BE MAINS VOLTAGE ON
THE PCB ATTACHED TO THE ALARM CONNECTOR AND ON THE IPM PCB
IN THE AREA OF THE EXTERNAL ALARM RELAY, EVEN IF THE PRINTER IS
ISOLATED FROM ITS OWN MAINS POWER SUPPLY. WHEN THE PRINTER
TOP COVER IS REMOVED, DO NOT TOUCH THE ALARM CONNECTOR PCB
OR THE IPM PCB IN THE AREA OF THE EXTERNAL ALARM RELAY.
FAILURE TO OBSERVE THIS SAFETY WARNING COULD RESULT IN
ELECTRIC SHOCK, WHICH MAY CAUSE INJURY OR DEATH.
The alarm relay is protected by a 1 A, sand-filled, ceramic, slow-blow fuse (F1). The output
is routed from connector PL10 on the IPM PCB to the ALARM OUTPUT connector on the
printer’s rear panel via the Alarm PCB, which is fitted to the back of the ALARM OUTPUT
connector.
Either ‘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 should have its wiring connected in accordance with the following table:
68652
MAINS (VFC) ‘ALARM OUTPUT’ CONNECTOR
Signal Pins used
Common L
Normally Closed (NC) N
Normally Open (NO) E
Figure 3-59. Mains External Alarm (Volt-free) Pin Connections
Amdt 01 MP65557–1
VFC Relay Operation with Invert Option Set to ‘No’
In the following descriptions of the VFC relay contact operation, it is assumed that the
ALARM menu options are set to their default settings of: Mode—Pulsed; Failure and
Warning—Yes; Print Disabled, Ink and Solvent, and Invert—No.
Normally Closed (NC)

Before power is applied to the printer, the NC relay contact is closed. When power is
applied to the printer, the NC relay contact state is determined by whether or not any
failures or warnings are present. If no failures or warnings are detected, the alarm relay is
not energized and therefore the NC relay contact remains closed. When any failures or
warnings are detected, the alarm relay is energized and the NC relay contact opens. Note
that with the Mode option set to its default of Pulsed, the relay contact is pulsed twice for
warnings, and remains open continuously for failures.
Normally Open (NO)

Before power is applied to the printer, the NO relay contact is open. When power is
applied to the printer, the NO relay contact state is determined by whether or not any
not energized and therefore the NO relay contact remains open. When any failures or
warnings are detected, the alarm relay is energized and the NO relay contact closes. Note
that with the Mode option set to its default of Pulsed, the relay contact is pulsed twice for
warnings, and remains closed continuously for failures.
VFC Relay Operation with Invert Option Set to ‘Yes’

In the following descriptions of the VFC relay contact operation, it is assumed that the
ALARM menu options are set to their default settings except for Invert, which is set to Yes.
That is: Mode—Pulsed; Failure and Warning—Yes; Print Disabled, and Ink and Solvent—
No; Invert—Yes.
Normally Closed (NC)

Before power is applied to the printer, the NC relay contact is closed. When power is
applied to the printer, the NC relay contact state is determined by whether or not any
energized and the NC relay contact opens. When any failures or warnings are detected, the
alarm relay is de-energized and the NC relay contact closes. Note that with the Mode option
set to its default of Pulsed, the relay contact is pulsed twice for warnings, and remains
closed continuously for failures.
Normally Open (NO)

Before power is applied to the printer, the NO relay contact is open. When power is applied
to the printer, the NO relay contact state is determined by whether or not any failures or
warnings are present. If no failures or warnings are detected, the alarm relay is energized
and the NO relay contact closes. When any failures or warnings are detected, the alarm
relay is de-energized and the NO relay contact opens. Note that with the Mode option set to
its default of Pulsed, the relay contact is pulsed twice for warnings, and remains open
continuously for failures.
The above descriptions are summarized in the following table:
MP65557–1 Amdt 01
v1.5 49198
‘NC’ RELAY CONTACT OPERATION
INVERT OPTION—NO
VFC relay contact state
Printer power No event detected Event detected
Off Closed Closed
On Closed Open
‘NO’ RELAY CONTACT OPERATION

INVERT OPTION—NO
Off Open Open
On Open Closed
‘NC’ RELAY CONTACT OPERATION

INVERT OPTION—YES
Off Closed Closed
On Open Closed
‘NO’ RELAY CONTACT OPERATION

INVERT OPTION—YES
Off Open Open
On Closed Open
Figure 3-60. Summary of the VFC Relay Operation
Amdt 01 MP65557–1
3.9.6 Serial Interface
The 4900 printer has a Serial Interface, which provides a means of controlling all the printer
functions through a remote device such as a PC or PLC. The printer is a ‘slave’ that receives
commands from a remote host, and sends back status information and data as requested.
The printer uses RS232 as standard, which gives point to point communications.
Cable Connections
Connection for the RS232 interface is via the RS232 connector on the printer’s rear panel,
and is a 9-way, D-type connector with numeric pin-out designations. Pin connections for
the RS232 interface cable are detailed in the following illustration:
COMPUTER 48202 PRINTER

PL4
TxD TxD 3
3
RxD RxD 2
2
RTS RTS 7
7
DCD DCD 1
1
6 6 (not connected)
DTR DTR 4
4
CTS CTS 8
8
Gnd Gnd 5
5
9 9 (not connected)
Figure 3-61. RS232 Interface Cable Pin Connections
MP65557–1 Amdt 01
3.9.7 D-Type Connector Assembly
Correct assembly of the D-type connector used for trigger devices, Shaft Encoder and
RS232 connections to the printer, is shown in the following illustration:
Cable screen to be terminated by removing the

outer sheath and folding braid back on itself by
approximately 10 mm. Braid is to be secured
6321 by cable clamp over exposed braid.
6
7
5 8
9 (see NOTE 1)
4
10 2 1
3
1. Cable 6. Rubber gasket

2. Locking screw 7. Main body of hood
3. Holding cap 8. Cable clamp
4. Top part of hood 9. D-type connector
5. Hood screw 10. Contact plate–internal (only for shielded version)
NOTES: 1. For RS232 and RS485 cables Item 9 is a female connector.

2. Test all cable connections for continuity and short circuits before use.
3. 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 3-62. Correct Assembly of the IP67 D-Type Connector
Amdt 01 MP65557–1
CHAPTER 4: SETUP MENU
4.1 Introduction
This chapter explains the options that are available in the Linx 4900 printer’s SETUP menu.
The detailed information given in this chapter refers to printers with Version 1.0 System
Software installed unless otherwise stated.
Refer to the Linx 4900 Ink Jet Printer Operating Manual for details of message editing and
other functions available from the 4900 user interface.
4.2 Current Message Screen

The CURRENT MESSAGE screen is the first user screen displayed, after the startup screen,
when the printer is switched on (the system carries out the automatic self-tests while the
startup screen is displayed).
The last used message is shown in the message area of the display. For example, the
following screen shows one of the standard test patterns:
49077
CURRENT MESSAGE : Test16 Quality
F1 : Change Message F2 : Check Status

F3 : New Message F4 : Change Setup
Figure 4-1. Current Message Screen

Pressing the function key [F4] selects the SETUP menu, provided that the Password option
in the SETUP menu has previously been set to Off (see Password Access below).
MP65557–1 Amdt 01
4.3 Password Access
If the Password option in the SETUP menu has been set to On, the PASSWORD screen is
displayed after the CURRENT MESSAGE screen and before the SETUP menu. This ensures
that only personnel who know the current password are able to enter the SETUP menu,
and thereby switch off the Password option or, furthermore, change the password. Setting
the Password option to Off allows the user to exit and re-enter the SETUP menu without
having to use the password each time. This setting is remembered when the printer is
switched off.
49300
PASSWORD
Enter Password > _
Figure 4-2. Password Screen

The correct Service Level password must be entered in the Password screen before the full
range of SETUP menu options can be accessed.
Four security access levels are used: Level A (Base Level), Level B (User Level 1), Level C
(User Level 2) and Level D (Service Level). For the purposes of this maintenance manual,
only the Service access level is relevant and discussed in detail in this chapter. Access
levels are referred to by name rather than level letter for clarity.
Each access level has its own factory-set default password but the Service Level default
password is not published in this manual. This is because not all personnel who have
access to this manual will have received adequate training to use the full DIAGNOSTICS
menu options, which are only available with the Service Level password. The Service Level
default password is suppled to Linx-authorized personnel and to those who have attended
a Linx-approved maintenance course. This password should be written against the access
level shown on the separate (unnumbered) page at the end of this chapter. The page
should then be removed from the manual and kept in a safe place.
To enter the SETUP menu press [F4], type in the password and press [enter]. Note that
passwords are not sensitive to upper-case or lower-case letters, so entering “ABC”, “abc”
or “Abc” has the same effect.
Amdt 01 MP65557–1
4.4 Total Menu Options
When the SETUP menu is displayed it lists the first four options, and the down arrow key
can be used to reveal the remaining options:
v1.5 49208
SETUP
> Password : Off
Print Height : Normal
Normalise Message Type : 0
Print Width : 0
Print Delay : 16
Print Count : 9
Reverse Message : Off
Message Orientation (see Note below)
Bold Ratio : 2
Set Time : 17:15
Set Date : 11:11:05
Julian Date Format : European
Primary Trigger : Leading Edge
Shaft Encoder : On
Auto Power Down
Ink Type Selection : A
Mod. Tracking Slope : 1.0
Head Height : 0.5m
Printhead Setup
Alarm
Change Password
Change Language
Change Configuration
Remote Setup Menu
Diagnostic Menu
Solv Add Time : 0
Figure 4-3. Setup Menu

NOTE: In v1.5 System Software the Reverse Message option is replaced by the Message
Orientation option when the 4900 DC configuration code is used.
Refer to the ‘Password’ option later in this chapter for the passwords/user levels required
to gain access to the Diagnostics options. Also refer to ‘Chapter 5: Maintenance’ for more
detailed information about the availability of the various Diagnostics options.
4.5 Option Availability

The printer has three main states: Jet Off, Jet Running, and Ready to Print (printing or
awaiting a print trigger signal). The SETUP menu changes to reflect these states, which
may affect the availability of some options and also the ability to select an option or change
its parameters. Options that are displayed and can be selected and changed are identified
with a solid circle (●), while options that are for display only and cannot be selected are
identified with an unfilled or open circle ( ).
Options are only displayed if they are valid for the password used and the current state of
the printer. For example, the Head Height option is only displayed when the User Level 2
or Service Level passwords are used, and it can only be selected (and changed) when the
printer is in the Jet Off state. When the printer is in the Jet Running or Ready to Print states,
the Head Height option is displayed, but cannot be selected and changed.
MP65557–1 Amdt 01
The following table shows the validity of each option in relation to the printer state and
level of password used. The convention for the validity of the options in the table is the
same as that displayed on the printer, that is, solid and open circles. Options that are not
available are identified with a dash (–).
v1.5 49209
USER LEVEL 1 USER LEVEL 2 SERVICE LEVEL

PASSWORD PASSWORD PASSWORD
Setup menu options Jet Jet R’dy Jet Jet R’dy Jet Jet R’dy
Off Run to Off Run to Off Run to
Print Print Print
Password ● ● ● ● ● ● ● ● ●
Print Height ● ● ● ● ● ● ● ● ●
Normalise Message Type – – – – – – ● ● ●
Print Width ● ● ● ● ● ● ● ● ●
Print Delay ● ● ● ● ● ● ● ● ●
Print Count ● ● ● ● ● ● ● ● ●
Reverse Message (non-DC) ● ● ● ● ● ●
Message Orientation (DC): ● ● ● ● ● ● ● ● ●
sub-options ● ● ● ● ● ●
Bold Ratio ● ● ● ● ● ●
Set Time ● ● ● ● ● ●
Set Date ● ● ● ● ● ●
Julian Date Format ● ● ● ● ● ●
Primary Trigger ● ● ● ● ● ●
Shaft Encoder – – – ● ● ● ●
Auto Power Down – – – ● ● ● ● ● ●
Ink Type Selection – – – ●
Mod. Tracking Slope – – – – – – ● ● ●
Head Height – – – ● ●
Printhead Setup: – – – – – – ● ● ●
sub-options – – – – – – ●
Alarm: – – – ● ● ● ● ● ●
sub-options – – – ● ●
Change Password – – – ● ● ● ● ● ●
Change Language: – – – ● ● ● ● ● ●
sub-options – – – ● ● ● ●
Change Configuration: – – – – – – ● ● ●
UNIC – – –
Code – – – – – – ●
Remote Setup Menu – – – ● ● ● ● ● ●
Diagnostic Menu (refer to – – – ● ● ● ● ● ●

Chapter 5: Maintenance)
Solv Add Time – – –
Figure 4-4. Setup Menu Option AvailabilityTable
Amdt 01 MP65557–1
4.6 Selecting and Changing Menu Options
Use the up and down arrow keys to the right of the display to move the cursor to the
required menu option. An arrowhead symbol (>) indicates the menu option at which the
cursor is currently positioned. When the arrowhead is pointing at the required menu
option, press [enter] to select the option. This may select a further menu screen, or the
cursor may move across to the field at the right of the screen, ready for alteration of the
particular menu option setting.
How the settings are changed is dependent on the type of menu option selected. Some
options have a range of settings that can be stepped through using the left and right arrow
keys (for example, the range of Print Height values; or Password : On/Off). Other options
allow a value to be typed in (for example, Set Time : 10:16). When the option setting has
been changed, press [enter] again to return the cursor to the left side of the screen (the
menu list). To return to the CURRENT MESSAGE screen from the SETUP menu, press the
[esc] key.
Note that not all menu options can be changed. Some options are for display purposes
only, while others cannot be accessed due to the current status of the printer.
4.7 Option Description

4.7.1 Password
This option allows the user to switch the password function on or off, which has the effect
of either displaying the PASSWORD screen before access to the SETUP menu and other
options, or not. Set this option to On for the password screen to be displayed, or to Off if
password entry is not required.
To switch the Password option on or off:
1. Scroll to the Password option.
2. Select the On or Off setting by pressing [enter].
3. Change the setting to On or Off by pressing the left or right arrow key.
4. Press [enter] again.
The ability to access the DIAGNOSTICS menu from the SETUP menu is dependent on the
password entered, as follows:
• If the User Level 1 password is entered, only a limited list of options is displayed in
the SETUP menu, and no access is permitted to Diagnostics
• If the User Level 2 password is entered, access is permitted to a restricted selection of
the Diagnostics options
• If the Service Level password is entered, access is permitted to all the Diagnostics
options
Password operation can be switched off and on by any level of user who has access to the
SETUP menu. However, the printer remains in the access condition that corresponds to the
level of the last password that was entered. For example, if a user enters the User Level 2
password to gain access to the SETUP menu, and then switches off the Password function,
ANY user is then able to access the User Level 2 functions, but NO users (including service
personnel) are able to access the additional ‘service only’ Diagnostics options. To gain
access to these service diagnostics options, it is necessary to switch the Password function
on again, exit from the SETUP menu, and re-enter using the Service Level password.
MP65557–1 Amdt 01
4.7.2 Print Height
The Print Height option is used to increase or decrease the height of the current message
only, in 5% increments. The range within which the print height can be adjusted is
dependent on the message type, as shown in the following table:
v1.5 49222
MESSAGE TYPE PRINT HEIGHT RANGES
Message type Ultima Ultima plus Mini

5 Linear Wide 0% to –5% 0% to –5% N/A
7 Linear Speed 0% to –5% 0% to –5% N/A
7 Linear Quality +10% to –5% +10% to –5% N/A
7 Linear Flexible +50% to –20% N/A N/A
16 Linear Speed 0 0% to –5% N/A
16 Linear Quality +10% to –5% +10% to –5% N/A
16 Linear Flexible +10% to 0% N/A N/A
2x7 Stitched Quality (1.36m/s) N/A +10% to –5% N/A
2x7 Stitched Quality (1.34m/s) +10% to –5% N/A N/A
4T 1x5 WIDE 6.83m/s N/A N/A +15% to –10%
8T 1x5 WIDE 6.83m/s N/A N/A +15% to –10%
4T 1x7 Quality 1.95m/s N/A N/A +15% to –10%
4T 1x7 Speed 2.27m/s N/A N/A +15% to –10%
4T 1x7 WIDE 5.12m/s N/A N/A +15% to –10%
8T 1x7 WIDE 5.12m/s N/A N/A +15% to –10%
Figure 4-5. Table of Message Type Print Height Ranges

‘Normal’ is displayed against this option for the ‘0’ setting.
A new message acquires the print delay and print width from the last selected message,
but the print height always returns to zero.
Amdt 01 MP65557–1
4.7.3 Normalise Message Type
Used in conjunction with the Print Height setting (print height of the current message), the
Normalise Message Type option can be used to further increase the print height of the
current message type. This enables a greater print height range and can be adjusted between
–10% and +10%.
NOTE: Using this option normalises all stored and new messages of the same current
message type.
The print height setting operates in a small part of the actual print range available from the
printhead. By using the Normalise Message Type option, the print height setting can be
adjusted to operate in different areas of the print range, away from the nominal character
height default setting. The following illustration shows an example of a Normalise
Message Type adjustment using the 7 Linear Flexible message type, which has a print
height range of –20% to +50%:
49223
Maximum extent of the print height range
where drops might clip the deflector plate and the gutter
7 Linear Flexible Print Height setting range
–20% –10% N +50%
Minimum Maximum
(gutter (deflector
clipping) plate
clipping)
–20% N +50%
By using the Normalise Message Type option at the adjusted Print

Height setting of -10%, the print size has been reduced and the
normal position (N) is now equal to nominal -10%.
Figure 4-6. Normalise Message Type Adjustment

The above example shows the Normalise Message Type option being used to increase the
print range, which allows smaller print. To obtain larger print, Normalise Message Type
can be used when a positive (+) print height setting is selected.
NOTE: If the entered setting exceeds –10% or +10%, one of the following advisory
messages is displayed in the status line:
“Value Not Set : Too Large”
“Value Not Set : Too Small”
MP65557–1 Amdt 01
The maximum and minimum limits of the print range occur when the drops clip the
deflector plate or the gutter (this may occur at high printing speeds with large drop sizes).
Both conditions give poor print quality, which usually deteriorates as ink builds up on the
deflector plate or gutter. To avoid this condition, make sure that the combination of
Normalise Message Type and the maximum or minimum Print Height setting does not
allow clipping to occur. Therefore, carry out a test by selecting +10% or –10%—depending
on whether the print height is being increased or decreased—to determine if clipping will
occur. The following illustration shows deflector plate and gutter clipping:
49210
Gutter
Nozzle +8 kV
Deflector Plate
Figure 4-7. Deflector Plate and Gutter Clipping

NOTE: The Normalise Message Type option is only available with the Service Level
password.
4.7.4 Print Width

The Print Width option is used to increase or decrease the width of the current message.
The width is controlled by setting a number in the range 0 to 65535. The higher the
number, the greater the width, therefore, the minimum width setting is 0, which is the
fastest rate at which the printer can print.
Print width is a timing delay between rasters, which is measured by inserting a number of
non-printing drops between each raster. A Print Width setting of 0 means no drops into the
gutter before the next raster is printed; a Print Width setting of 500 means 500 drops into
the gutter before the next raster is printed.
When used in conjunction with the Shaft Encoder option set to On, the width is equal to the
divide ratio required for the shaft encoder setup. See also the Shaft Encoder option
described later in this section.
NOTES:
1. Altering the message width affects the Print Delay setting (see Print Delay
below).
2. A new message acquires the print delay and print width from the last selected
message.
Amdt 01 MP65557–1
4.7.5 Print Delay
The Print Delay option is used to control the delay between the print trigger signal and the
start of printing (if the Primary Trigger option is set to Triggered), or the delay between
prints (if the Primary Trigger option is set to Off or Enable). The delay is controlled by
setting a number in the range 0 to 65534 (the higher the number, the longer the delay).
Print delay is the distance from the end of one message to the start of the next. It is counted
in rasters and is the total number of drops in a raster plus any width setting.
NOTE: The size of the delay increases or decreases if the shaft encoder setting is
anything other than ideal pitch.
Too small a delay may result in the System Warning “3.05 Over Speed (Print Trigger)”
error message being reported. There are minimum delay settings for each message type,
necessary for the printer to carry out Phasing and TOF checks between prints. Too small a
delay may result in the printer being unable to complete these checks. This could result in
printer performance problems because the ink viscosity may move out of range. The
minimum delay for each message type and printhead combination is shown in the
following table, and these are the values that the printer defaults to if no other value is
entered:
v1.5 49211
MINIMUM PRINT DELAY DEFAULT VALUES

5 Linear Wide 92 113 N/A
7 Linear Speed 69 71 N/A
7 Linear Quality 40 34 N/A
7 Linear Flexible 33 N/A N/A
16 Linear Speed 15 17 N/A
16 Linear Quality 12 12 N/A
16 Linear Flexible 11 N/A N/A
2x7 Stitched Quality (1.36m/s) N/A 29 N/A
2x7 Stitched Quality (1.34m/s) 27 N/A N/A
4T 1x5 WIDE 6.83m/s N/A N/A 96
4T 1x7 Quality 1.95m/s N/A N/A 42
4T 1x7 Speed 2.27m/s N/A N/A 48
Figure 4-8. Message Type Minimum Delay Default Values
MP65557–1 Amdt 01
The minimum delay values in the above table assume a Print Width setting of 0 and that
the next print trigger will occur after the last message has completed printing. They do not
take account of print triggers overlapping printing.
The Print Delay setting can be affected by the Print Width setting of the current message.
For this reason, the recommended method for setting up the Print Width and the Print
Delay for a production line is as follows:
1. Adjust the Print Delay setting to position the message on the product.
2. Adjust the Print Width setting for the required message width.
3. Make a further adjustment to the Print Delay setting to achieve the precise print
registration.
Entering a Print Delay value that is less than the recommended minimum results in the
advisory message “Value Not Set : Too Small” being displayed in the status line. However,
if the Service Level password is used, this restriction can be overridden allowing delays
smaller than the recommended minimum to be entered.
4.7.6 Print Count

Print Count shows the cumulative number of messages printed. It is also displayed against
Count in the PRINT STATUS screen, which is accessed by pressing the [F2] (Check Status)
key from the CURRENT MESSAGE screen. The value can be reset to zero or altered by
typing in a number up to a maximum of 999,999,999.
4.7.7 Reverse Message (non-DC Configuration)

The Reverse Message option allows the orientation of the current message to be changed to
print in reverse. Printing must be stopped before this option can be changed.
For the purposes of this explanation, it is assumed that a normally-orientated printhead
has the printhead cover tube securing screw facing the approaching product on the
production line.
The two settings are Off and On:
Off
With the option set to Off, the message is printed from left to right (as displayed in the
CURRENT MESSAGE screen).
6109
Figure 4-9. Message Printed with ‘Reverse Message’ Off
On
With the option set to On, the message is printed in reverse.
6110
Figure 4-10. Message Printed with ‘Reverse Message’ On
Amdt 01 MP65557–1
4.7.8 Message Orientation (v1.5 S/W & DC Configuration)
In v1.5 System Software the Reverse Message option is replaced by the Message
Orientation option when the 4900 DC configuration code is used.
Message Orientation operates in two modes—Static or Secondary Trigger (dynamic),
which are described in the following sections.
Access to the Message Orientation menu is available during printing. However, during
printing, all menu options are disabled and cannot be changed.
On entry to the MESSAGE ORIENTATION menu, the following options are displayed:
v1.5 49025
MESSAGE ORIENTATION
> Mode : Static
State 1 : Normal
Figure 4-11. Message Orientation Menu (Static Mode)
Static Mode
Mode
The Mode option sets the mode of operation to either Static or Secondary Trigger.
State 1
In Static mode, the orientation of the message is fixed in one of the following four
orientations and is selected using the State 1 option:
• Normal
• Reverse
• Invert
• Reverse and Invert
These orientations are illustrated in the following four figures:
6109
Figure 4-12. ‘Normal’ Message Orientation
6110
Figure 4-13. ‘Reverse’ Message Orientation
6111
Figure 4-14. ‘Invert’ Message Orientation
6113
Figure 4-15. ‘Reverse and Invert’ Message Orientation
MP65557–1 Amdt 01
Secondary Trigger (Dynamic) Mode
Changing the setting of the Mode option displays the Secondary Trigger function menu:
v1.5 49028
MESSAGE ORIENTATION
> Mode : Secondary Trigger
State 1 : Normal
State 2 : Normal
Active : State 2
Sync Error : Off

Figure 4-16. Message Orientation Menu (Secondary Trigger Mode)
NOTE: The options State 1, State 2, and Sync Error are shown in their default settings.
In this mode, the current message orientation alternates between two states (State 1 and
State 2) under the control of a secondary trigger device. One of the four orientations
described in ‘Static’ mode above can be assigned to each of the two states. These states are
associated with the high and low levels of the secondary trigger input. The orientation
remains in a particular state while the secondary trigger remains at that level.
The current level of the secondary trigger is sampled just before printing commences and
the orientation of the message is set to the orientation associated with that state.
Active
This option is for display purposes only and shows the currently ‘active’ state (State 1 or
State 2) based on the level of the secondary trigger (high or low).
Sync Error
The number of times the state of the secondary trigger changes between print triggers is
irrelevant. However, the ‘Synchronisation Error’ System Warning can be enabled by setting
this option to On to warn the operator that a state change has occurred during a print. This
does not affect the print. The System Warning is reported as “Error 3.33 Synchronisation”,
and is cleared at the start of printing.
NOTE: Changing modes does not affect the settings for each option, although Sync Error
is ignored in Static mode.
4.7.9 Bold Ratio

The Bold Ratio option is used to adjust the density of the characters to be printed. To alter
the bold ratio prior to creating a message, the ratio figure is entered in the range 1 to 9.
A bold ratio of 1 is equivalent to standard print, that is, one vertical line of drops (raster)
per vertical in a 7 High character, or two vertical lines of drops per vertical in a 16 High
character. Selecting a bold ratio greater than 1 produces a repeat print of each raster by the
factor of the bold ratio figure. For example, using a bold ratio of 2 with a 7 High character
makes the character the same height but twice as wide (see the following figure).
4006
BOLD RATIO BOLD RATIO

x1 x2
Figure 4-17. Bold Ratio Setting

NOTE: For very porous substrates a bold ratio of 5 or more can be used, and over-
printing each raster by typically 40% or 50% using a fast print rate and a slow
product line speed.
Amdt 01 MP65557–1
4.7.10 Set Time
This option displays the current time, which can be altered if required.
Using the 24 hour format, enter two digits for the hours followed by a colon, and two digits
for the minutes (for example, 10:16).
4.7.11 Set Date

This option displays the current date, which can be altered if required.
Using the numeric European date format, enter two digits for the day followed by a colon,
two digits for the month followed by a colon, and two digits for the year (for example,
16:07:97).
4.7.12 Julian Date Format

This option provides the choice of two conventions (European or American) for the day
number in the year, as shown in the following table:
6016
EUROPEAN AMERICAN
Non-Leap Year 1 Jan = Day 001 1 Jan = Day 001
28 Feb = Day 059 28 Feb = Day 059
1 Mar = Day 060 1 Mar = Day 060
31 Dec = Day 365 31 Dec = Day 365
Leap Year 1 Jan = Day 001 1 Jan = Day 001
28 Feb = Day 059 28 Feb = Day 059
29 Feb = Day 366 29 Feb = Day 60
1 Mar = Day 060 1 Mar = Day 061
31 Dec = Day 365 31 Dec = Day 366
Figure 4-18. Julian Date Format
4.7.13 Primary Trigger

The printer can be set up to print on receipt of an external primary trigger signal. A photocell
is normally used as the primary trigger to detect the presence of the product on the
production line as it approaches the printhead.
The photocell supplies a ‘next object’ signal to the printer to print a single message for each
trigger signal. This is known as an ‘edge trigger’.
Other types of product sensor can be used to print continuously for the duration that the
presence of the product is being detected. This method uses a ‘level trigger’.
The Primary Trigger option is used to configure the printer to accept the different trigger
signals of different types of product sensor used. For example, this option can be used to
allow a photocell, which would normally trigger the print on detection of the leading edge of
a product, to trigger the print on detection of the trailing edge of a product, and vice versa.
The Primary Trigger option provides six modes: Leading Edge (the default setting), Trailing
Edge, High Level, Low Level, Remote, and Off.
Leading Edge
With Leading Edge selected, the trigger signal is used to trigger the printing of each
message on detection (by the trigger device) of the leading edge of the product. A single
message is printed for each primary trigger signal.
The Print Delay option specifies the number of blank rasters between the signal and the
actual start of printing.
MP65557–1 Amdt 01
Trailing Edge
With Trailing Edge selected, the trigger signal is used to trigger the printing of each
message on detection (by the trigger device) of the trailing edge of the product. A single
message is printed for each primary trigger signal.
The Print Delay option specifies the number of blank rasters between the signal and the
actual start of printing.
High Level
With High Level selected, printing is started and is continuous as long as the trigger signal
is present (HIGH). Printing is stopped when the end of the product is detected by the
trigger signal going LOW, and restarts at the next HIGH signal. If a print has already
started when the signal goes LOW, the message will be finished and not restarted until the
signal goes HIGH again. The Print Delay option specifies the number of blank rasters
between individual messages—the larger the delay, the longer the blank space between
messages.
Low Level
With Low Level selected, printing is started and is continuous as long as the trigger signal
is LOW. Printing is stopped when the end of the product is detected by the trigger signal
going HIGH, and restarts at the next LOW signal. If a print has already started when the
signal goes HIGH, the message will be finished and not restarted until the signal goes
LOW again. The Print Delay option specifies the number of blank rasters between
individual messages—the larger the delay, the longer the blank space between messages.
Remote
Printing is started on receipt of a trigger signal from a remote computer, via the RS232 link.
Off
When set to this mode the primary trigger input to the printer is switched off, and printing
is continuous at a rate dictated by the Print Width and Print Delay settings. The Print Delay
option specifies the number of blank rasters between individual messages—the larger the
delay, the longer the blank space between messages.
NOTES:
1. The setting of the Primary Trigger option is retained when the printer is off.
2. If the Shaft Encoder option is enabled (set to On), pulses must be present for
printing to occur.
Amdt 01 MP65557–1
4.7.14 Shaft Encoder
This option is used to set up the operation of the shaft encoder (if fitted). Shaft encoders are
recommended to be fitted to production lines where variable speed is likely.
A shaft encoder generates a number of pulses per revolution. When connected to a
production line (typically via a friction wheel) the encoder produces a pulse per distance
travelled by the production line. These pulses are used to trigger the rasters being printed,
thereby maintaining equal distance between rasters irrespective of the speed of the
production line. This feature can be used to compensate for variations in production line
speed to produce a constant width of print. Linx recommend that a shaft encoder
producing a minimum of 2500 pulses per revolution is used.
When Shaft Encoder operation is selected, the appropriate shaft encoder divide ratio (Print
Width) must be specified to ensure the correct width of the printed message.
Shaft Encoder Divide Ratio (Print Width)

The Shaft Encoder Divide Ratio is a value used by the system to adjust the rate at which
rasters are printed, in relation to the production line speed. The divide ratio is known as
the ‘print width’, which is entered using the Print Width option described earlier in this
section.
The shaft encoder indicates the speed of the product passing the printhead by the rate at
which it delivers pulses to the printer. This incoming signal is then divided by a calculated
‘divide ratio’ and the result is used to trigger the generation of each raster. Consequently,
the distance between each printed raster remains constant, and the width of each printed
message also stays constant irrespective of the production line speed.
A divide ratio of 1 means that one raster is triggered for each shaft encoder pulse. A divide
ratio of 5 means that one raster is triggered for every five shaft encoder pulses.
Calculating the Print Width

NOTE: It is important that the divide ratio is calculated from the geometry of the
production line setup. If guessed at, errors in reproducible print width are likely;
rasters will be printed too close together or too far apart.
The ideal divide ratio (Print Width) is arrived at as follows:
Print Width = (N x PI) – 1
where:
N = number of shaft encoder pulses per millimetre of line movement
PI = Ideal Pitch*
Subtracting 1 from the calculated Print Width is a requirement of the software and is
compatible with other Linx printers. This is the value to be entered in the Print Width
option.
N can be calculated as:
shaft encoder pulses per revolution x revolutions per metre
1000
* The Ideal Pitch between rasters is dependent on the message type and printhead type, as
shown in the following table:
MP65557–1 Amdt 01
v1.5 49212
MESSAGE TYPE IDEAL PITCH VALUES (mm)

5 Linear Wide 0.469 0.569 N/A
7 Linear Speed 0.353 0.428 N/A
7 Linear Quality 0.353 0.428 N/A
7 Linear Flexible 0.423 N/A N/A
16 Linear Speed 0.400 0.428 N/A
16 Linear Quality 0.353 0.428 N/A
16 Linear Flexible 0.423 N/A N/A
2x7 Stitched Quality (1.36m/s) N/A 0.428 N/A
2x7 Stitched Quality (1.34m/s) 0.353 N/A N/A
4T 1x5 WIDE 6.83m/s N/A N/A 0.428
8T 1x5 WIDE 6.83m/s N/A N/A 0.428
4T 1x7 Quality 1.95m/s N/A N/A 0.285
4T 1x7 Speed 2.27m/s N/A N/A 0.285
8T 1x7 Speed 1.95m/s N/A N/A 0.285
4T 1x7 Speed 3.41m/s N/A N/A 0.285
4T 1x7 WIDE 5.12m/s N/A N/A 0.428
8T 1x7 WIDE 5.12m/s N/A N/A 0.428
4T 2x7 Speed 0.97m/s N/A N/A 0.285
4T 2x7 Speed 1.30m/s N/A N/A 0.285
Figure 4-19. Message Type Ideal Pitch Values
Example Calculation
To illustrate this calculation, the following information is assumed:
Printhead: Ultima 62 µm
Message type: 16 Linear Speed
Line speed: Variable speed up to 0.4 m/s (which is less than
the maximum speed at which this raster will
operate with ideal pitch)
Ideal Pitch (PI): 0.4 mm for an Ultima 62 µm printhead (16 Linear
Speed message type—from the table above)
The following information about the shaft encoder is required:
Pulses per revolution: 2500 pulses/rev.
Wheel diameter: 49.0 mm (d)
Revolutions per metre: 6.5 rev/m (1/πd)
Amdt 01 MP65557–1
Firstly, to calculate N:
N = (pulses/rev) x (rev/m) = number of pulses/mm of line movement
1000
N = 2500 x 6.5 = 16.25 pulses/mm
1000
This value is now multiplied by the ideal pitch for the raster to establish the ideal divide
ratio:
Ideal divide ratio = 16.25 x 0.4 = 6.5
Although the ideal divide ratio would be 6.5, this must be rounded up to the nearest whole
number (in this case 7), which is the actual divide ratio, as the printer can accept only whole
numbers.
The software requires that the actual value to be entered in the Print Width option must be
1 less than the calculated value. Therefore, the Print Width entered is 6.
In this example, rounding up from 6.25 to 7 would create an increase in the drop pitch
from the ideal pitch. To calculate the actual pitch between rasters:
actual divide ratio x PI = actual pitch
ideal divide ratio
7.00 x 0.4 = 0.431 mm
6.50
NOTES:
1. If the width of the printed message decreases when the line speed is decreased,
or if the width of the printed message increases as the line speed is increased,
this means that the Print Width value is too low.
2. If the line is running at a constant speed and the width of the message increases
when the value of Print Width has been decreased, this is also an indication that
the Print Width value is too low.
Width Adjuster Unit

A Width Adjuster Unit (WAU) is available, which can be connected between the shaft
encoder and the printer to intercept the shaft encoder signal. The WAU enables the printed
length of a message to be more finely adjusted to suit the application than is possible with
the printer’s Print Width setting alone. Non-integer values for print width are generated by
the WAU to provide precise positioning of the code within a restricted space on a product.
Refer to the Width Adjuster Unit User Guide for details of how to set up and use the unit.
Shaft Encoder Modes

The two modes available for the Shaft Encoder option are Off and On.
Off
This mode is selected when a shaft encoder is not in use. The Print Width option setting is
used to determine the width of each message. The minimum width setting in this mode is
1, which gives the fastest rate at which messages can be printed.
On
Pulses direct from the shaft encoder are used to control print speed, and a value for print
width must be calculated and entered in the Print Width option.
MP65557–1 Amdt 01
4.7.15 Auto Power Down
The electrical supply is switched to the printer by the Mains Power Supply Switch located
on the rear panel. The printer is powered up by first setting this rocker switch from the ‘0’
(off) position to the ‘I’ (on) position, then pressing and holding (for 2 seconds) the Power
On push button switch on the front of the printer.
The printer can be switched off by any of the following methods:
• Using the power saving functions in the Auto Power Down menu
• Pressing the red [stop] key when the jet is not running (Idle mode)
• Using the Mains Power Supply Switch on the rear panel (as a last resort—this is not a
recommended method for switching off the printer and should be used only in an
emergency)
A latching relay is fitted to the 4900 printer, which enables the printer to switch off
automatically under predefined conditions.
IMPORTANT: The Auto Power Down function on the 4900 printer removes electrical
power from the main control electronics within the printer, and thereby
safely disables the printer functionality. However, when auto power down
is completed, power is still present in the internal wiring from the rear
panel Mains Power Supply Switch to the front panel Power On button and
the relay on the IPM PCB. During normal day-to-day use, for example,
whilst washing down, there is no need to switch off the printer at the rear.
An Auto Mains Power Off Bypass Kit is available for the 4900 printer. The purpose of this
kit is to remove the auto power off facility from the printer to allow it to be integrated into
OEM applications. When the kit is fitted, the power control for the printer is provided
solely by the mains power supply switch on the printer’s rear panel.
The power saving options can be configured by selecting the Auto Power Down option,
which displays the following menu (the options are shown with their default settings):
49021
AUTO POWER DOWN

> Auto Power Down : On
Printer Idle : Off
Idle Time (mins) : 60
Figure 4-20. Auto Power Down Menu

IMPORTANT: Although the Auto Power Down functions allow the printer to switch off
automatically, it is still the responsibility of the operator to make sure that
the printer does actually switch off. This facility should be regarded as a
convenience, NOT a safety device.
Auto Power Down

IMPORTANT: Auto Power Down is disabled if the Power Off Override link LK13 is
fitted, that is to say, the Auto Power Down option is no longer displayed in
the SETUP menu so it cannot be activated.
Auto Power Down is also disabled during Filter Purge.
The two Auto Power Down option settings are On and Off, as follows.
Amdt 01 MP65557–1
On
When this option is set to On, the printer switches off automatically after a successful jet
shutdown has been completed, followed by the power down delay of 10 seconds. After jet
shutdown, the CURRENT MESSAGE screen changes to the AUTO POWER DOWN
message screen:
49023
AUTO POWER DOWN
About to power down in:

10 seconds
Press any key to resume
Figure 4-21. Auto Power Down Message Screen

This alerts the user to the power down delay, after which the printer switches off. The
automatic power down action can be cancelled while this message screen is being
displayed by pressing any key, which returns the user to the CURRENT MESSAGE screen.
Off
When this option is set to Off, the printer does not switch off automatically (unless the
Printer Idle option is set to On—see below). The printer must be switched off manually
using one of the following two methods:
• By pressing the red [stop] key at any screen when the printer is Idle
NOTE: Regardless of whether the Auto Power Down options are configured On or
Off, the printer can be switched off manually by pressing the red [stop] key
at any screen when the printer is in Idle mode.
When the red [stop] key is pressed, a message screen is displayed asking if the user
wants to switch off the power:
49024
POWER DOWN
Switch off power?
F1 : Yes F2 : No
Figure 4-22. Power Down Message Screen

If the Power Off Override link LK13 is fitted, the above screen is not displayed, and
therefore the second method described below must be used to switch off the printer.
If [F1] Yes is selected, the power is switched off without any delay time.
• By setting the Mains Power Supply Switch on the rear panel from the ‘I’ (on) position
to the ‘0’ (off) position (as a last resort)
MP65557–1 Amdt 01
Printer Idle
The two settings available are Off and On.
Off
When this option is set to Off, the Printer Idle facility is disabled.
On
When this option is set to On, the printer switches off automatically (regardless of the Auto
Power Down setting) after a successful jet shutdown has been completed, followed by the
elapse of the Idle Time setting (see below), plus the power down delay of 10 seconds.
After the Idle Time setting has elapsed, the CURRENT MESSAGE screen changes to the
same AUTO POWER DOWN message screen as shown above.
Idle Time (mins)

This setting is only used in conjunction with the Printer Idle option, not the Auto Power
Down option.
The Idle Time can be set between 1 and 300 minutes; the default is 60 minutes.
For the purposes of this function, the printer is defined as ‘Idle’ if the following criteria are
met:
• The jet is NOT running
• No key presses have been detected
• The remote interface is enabled and no characters have been received or transmitted
during the idle time
4.7.16 Ink Type Selection

The ink type being used in the printer is selected with this option. A choice of four ink type
groups is available—A, B, C, or D— and the default ink type is group B. Unless directed
otherwise by Linx, this option should be set for the particular ink type used, as detailed in
the Ink Type Dependent Parameters tables at the end of the ‘Ink System’ section of
‘Chapter 3: Technical Description’.
4.7.17 Mod. Tracking Slope

The Modulation Tracking Slope (measured in V/bit of pressure) is normally set as a
default that is dependent on the printhead type and ink type being used.
This option allows the service engineer to alter the Modulation Tracking Slope to fine-tune
the setting to suit the ink type and individual printhead combination. The setting is
variable from 0.0 V/bit to 5.0 V/bit in 0.1 increments. For example, a setting of 1.0 equates
to an increase in modulation voltage of 1.0 V for every 1 bit of pressure change; a setting of
5.0 equates to an increase in modulation voltage of 5.0 V for every 1 bit of pressure change.
When the printhead type or ink type is changed (and therefore the Type option in the
Printhead Setup menu, or the Ink Type Selection option are changed), the default
Modulation Tracking Slope value for the new printhead and ink type combination is used.
See also: Chapter 5: Maintenance > Modulation Tracking option.
Amdt 01 MP65557–1
4.7.18 Head Height
The ink system pressure must be compensated for when the printhead is mounted above or
below the height of the printer. Pressure is altered by 2.5 pressure points (bits) for every
half metre that the printhead is above or below the printer.
For practical purposes, the measurement should be made vertically from the keyboard
space bar to the printhead nozzle (in reality, the vertical distance is from the printer
pressure transducer to the printhead nozzle).
The vertical distance is entered in half or whole metres. If a measurement other than a
multiple of 0.5 metre is entered, the software rounds the value down to the nearest whole
0.5 metre. For example, entering a value of ‘1.3m’ or ‘–1.3m results in a value of ‘1.0m’
being set.
If the printhead is mounted below the printer, the distance is entered in the format ‘–X.Xm’.
If the printhead is mounted above the printer, it is not necessary to enter a ‘+’ prefix; the
value is entered simply as ‘X.Xm’.
The maximum distance accepted by the software is ±2 metres for a 2-metre printhead
conduit, and ±4 metres for a 4-metre printhead conduit. If a greater distance is entered, the
following advisory message is displayed in the status line:
“Head Height Exceeds Conduit Length”
NOTE: Only a maximum distance of ±2 metres should be entered, as the 4-metre
printhead conduit has not been tested beyond 2 metres.
Changing the Head Height setting automatically changes the printhead Reference
Pressure, from which the Solvent Add Pressure value is calculated. Therefore, the
MONITOR JET screen (Diagnostics sub-menu) displays different Solvent Add pressures
depending on the Head Height setting.
IMPORTANT: Care must be exercised with this option, otherwise poor printer
performance will result if incorrectly set.
4.7.19 Printhead Setup

Although this menu can be accessed when the jet is running, the options can be changed
only when the jet is stopped. Selecting the Printhead Setup option displays a menu
containing four printhead-related parameters:
49214
PRINTHEAD SETUP
> Type : Ultima
Conduit Length : 2m
Printhead Code : 184-090-255
Cover Override : Off
Figure 4-23. Printhead Setup Menu
MP65557–1 Amdt 01
Type
The printhead type fitted to the printer is selected using this option. The 4900 printer
currently supports three printhead types—Ultima, Ultima plus and Mini; the default
printhead type is Ultima. The Mini printhead option is only available when the DC
configuration code is used.
Once a printhead type is specified, a default printhead code is used by the printer—see
Printhead Code below for more details.
Changing the printhead type causes the NVR data to be cleared, which resets the printer’s
parameter settings to their default values. The following data will be lost:
• All messages
• System time and date
• All printer setup information (except for the printhead type)
• All data accumulated by the printer during operation, for example, System Times,
Event List
As a warning to the operator that the NVR data will be deleted, when a new printhead
type is specified and [enter] is pressed, the following advisory message screen is displayed:
49215
PRINTHEAD SETUP
This action will cause all NVR to be deleted.
Do you wish to continue?
F1 : Yes F2 : No
Figure 4-24. “Deleting NVR” Advisory Message Screen

The printer must then be switched off and then on again for the new printhead type to take
effect. Selecting F1 : Yes in response to the above screen message automatically switches off
the printer. When the printer is switched on again, the system parameters are set for the
new printhead type.
If F2 : No is selected, the printer is not switched off, data is not lost, and the printer returns
to the SETUP menu.
IMPORTANT: If the Power Off Override link LK13 is fitted, the printer does not switch off
automatically when F1 : Yes is selected. It must be switched off and then
on again manually using the Mains Power Supply Switch on the rear
panel.
Conduit Length
This option identifies which of the two standard lengths of printhead conduit is fitted to
the printer, which ensures that the correct startup and shutdown sequence timings are
used. The printhead conduit lengths available are 2 metres and 4 metres, therefore, this
option has only two settings of 2m and 4m. The default conduit length is 2m.
Amdt 01 MP65557–1
Printhead Code
A code number is printed on all Mk7 printhead conduit labels. This code contains
important calibration information, which must be entered in the Printhead Code option in
any of the following circumstances:
• Whenever a new or replacement printhead is fitted
• When the software Program PROM is changed
• When the IPM PCB is replaced
The default printhead codes are 184-090-255 for the Ultima printhead, 147-120-255 for the
Ultima plus printhead, and 178-050-255 for the Mini printhead, which are used by the
printer until the correct code for the individual printhead is entered. The relevant code
must be entered correctly, making sure that every digit is exactly as specified on the
printhead conduit label and the dashes are placed in the correct positions. The composition
of the nine-digit code is as follows:
49349
Reference Pressure Charge Calibration

000 – 255 bits Factor
050 – 300
P P P MMM C C C
Reference Modulation
Voltage
010 – 255 volts
Figure 4-25. Printhead Code Composition

• Digits 1 to 3 (PPP) specify the Reference Pressure value. The normal operating range is
000 to 255 pressure bits
• Digits 4 to 6 (MMM) specify the Reference Modulation voltage, in the range 010 to 255
volts
• Digits 7 to 9 (CCC) specify the Charge Calibration Factor, in the range 050 to 300,
which is fixed at 255 for the 4900 printer
These calibration parameters are used by the printer to optimize performance.
IMPORTANT: Care must be exercised with this option, otherwise poor printer
performance will result if incorrectly set.
Cover Override
Setting this option to On enables the Cover Override link LK6 on the IPM PCB. To print
with the printhead cover tube removed, link LK6 must be fitted and the Cover Override
option must be set to On. In other words, unless this option is set to On, if link LK6 is fitted it
is ignored and the printer continues to isolate the printhead when it detects that the
printhead cover tube has been removed.
The System Warning “3.13 Cover Override Active” is displayed in the status line only
when both link LK6 is fitted and the Cover Override option is set to On.
This option is enabled only when the Cover Override link LK6 is fitted. In the event that
link LK6 remains inadvertently fitted, as a safety feature the Cover Override option is reset
to Off when the printer is next switched on.
See also: Chapter 3: Technical Description > Electronics and Software > IPM PCB > Test
Points and Links > LK6 (Cover Override).
Chapter 6: System Events > System Warnings > 3.13 Cover Override Active.
MP65557–1 Amdt 01
4.7.20 Alarm
When a printer failure or warning occurs, the system activates an internal alarm tone
(beeper) and an LED on the user interface. In a warning condition the alarm tone is pulsed
twice, whereas in a failure condition the alarm tone sounds continuously.
The 4900 printer also has the facility of outputs to an external alarm. The output is taken
from a 2-pin or 3-pin socket (ALARM OUTPUT) located on the rear panel of the printer,
and can be for either a 24 volts external alarm or a mains-rated external alarm.
The 24 volts external alarm output is fitted as standard and is for use with an alarm beacon
powered by the printer. The mains-rated external alarm output is available as an option
and is for use with an externally-powered alarm beacon, production line interlock, or some
other similar device.
A relay with volt-free contacts (VFC) is fitted to the IPM PCB and is used in conjunction
with the optional VFC Alarm Upgrade to provide a mains-rated external alarm output. The
relay contacts are a ‘single pole changeover’ type rated at 240 V AC, 1 A. Three pins are
available at the ALARM OUTPUT connector on the printer rear panel when the VFC
Alarm Upgrade has been installed. The operation of the relay contacts—‘normally open’
(NO) or ‘normally closed’ (NC)—can be selected by wiring the alarm device connector in
accordance with the appropriate pins of the ALARM OUTPUT connector (see to Chapter 3:
Technical Description > External Signals > Alarm Output > Mains (VFC) External Alarm).
The Alarm option allows different combinations of events to be selected to trigger the
external alarm (simultaneously with the internal alarm tone and user interface LED).
Selecting the Alarm option displays the following menu:
v1.5 49224
ALARM
> Mode : Pulsed
Failure : Yes
Warning : Yes
Print Disabled : No
Ink and Solvent : No

Invert : No
Figure 4-26. Alarm Menu
The options in the above menu are shown with their default settings. Any combination of
the event options can be configured by setting them to on (Yes) or off (No).
Mode
This option allows the alarm output to be changed to activate the external alarm
continuously for System Warning event conditions. When all System Warning events have
been cleared, the alarm output is automatically deactivated. The Mode option can be set to
either Pulsed or Continuous.
Pulsed
In the Pulsed mode the alarm output operates as normal, that is, if a System Warning event
occurs, the alarm output is switched to pulse the external alarm on and off twice. (If a
System Failure or Print Failure occurs, the external alarm is still continuous.)
Continuous
In the Continuous mode, the alarm output is switched to activate the external alarm
continuously while a System Warning event is present.
Amdt 01 MP65557–1
Failure
When this option is set to Yes (on), the alarm output is switched to activate the external
alarm continuously only when a Print Failure event occurs, not in a System Warning event
condition.
Warning
When this option is set to Yes (on), the alarm output is switched to pulse the external alarm
on and off twice each time a System Warning event occurs, or switched to activate the
external alarm continuously while a System Warning event is present, depending on the
Mode setting.
Print Disabled
When this option is set to Yes (on), the alarm output is switched to activate the external
alarm continuously while the printer cannot print for whatever reason, for example, when
the printhead cover tube is removed. As soon as the printer enters the ‘Ready to Print’ state
or is printing, the alarm output is deactivated.
NOTE: The ‘Ready to Print’ state is defined as: power on; jet running; message selected
ready to print; and the printer is waiting for a print trigger (‘print go’).
Ink and Solvent

When this option is set to Yes (on), the alarm is switched to activate the external alarm only
when the “3.03 Ink Low” or “3.04 Solvent Low” System Warning events are present. The
alarm is either pulsed on and off twice or is continuous, depending on the Mode setting.
NOTES:
1. Setting the options ‘Warning’ and ‘Ink and Solvent’ to Yes has the same effect as
setting only ‘Warning’ to Yes.
2. In the Ink and Solvent mode, Print Failures do not produce an alarm output.
Invert
This is an additional option that was introduced in v1.5 System Software.
When this option is set to Yes (on), the alarm output action is inverted. That is, the external
alarm device is activated when the printer is in the ‘Ready to Print’ state, or is printing, and
there is no alarm present in the printer.
This setting is intended to be used in conjunction with the volt-free contacts (VFC) relay
function and the Print Disabled option.
To use the printer to control a production line, set only the Print Disabled and Invert
options to Yes. Also, connect the live supply for the production line controller to the
equivalent of pin L on the ALARM OUTPUT connector, and drive the production line from
the equivalent of pin E. In this arrangement, the VFC relay connection is in one state when
the printer is able to print, and the production line runs. The VFC relay connection is in the
other state, and the production line is stopped, when the printer is unable to print because
of a fault or warning condition, or the printer is switched off, or the alarm output
connection on the rear of the printer is not made.
The following table summarizes the Invert option operation:
MP65557–1 Amdt 01
v1.5 49197
PRINTER CONFIGURATION EXTERNAL ALARM CONNECTOR PINS
AND STATE
Invert Printer Configured NC—normally closed relay NO—normally open relay
option power event contact (pin N) contact (pin E)
setting detected *
Off — Connects to Common (pin L) Open circuit
No On No Connects to Common (pin L) Open circuit
On Yes Open circuit Connects to Common (pin L)
Off — Connects to Common (pin L) Open circuit
Yes On Yes Connects to Common (pin L) Open circuit
On No Open circuit Connects to Common (pin L)
* A configured event is any of the Failure, Warning, Print Disabled, or Ink and Solvent options set
to Yes.
Figure 4-27. Alarm Invert Operation
For more information, refer to Chapter 3: Technical Description > External Signals > Alarm
Output > Mains (VFC) External Alarm.
4.7.21 Change Password

This option can be used to change the system passwords for User Level 1 and User Level 2;
the Service Level password cannot be changed. On every occasion that this option is
selected, even if the password function has been switched off, the PASSWORD screen is
displayed first and a password is required to gain access to the Change Password function.
If the User Level 1 password is entered here, only the current User Level 1 (Level B)
password is displayed in the CHANGE PASSWORD screen. If the User Level 2 or the
Service Level passwords are entered, both the User Level 1 (Level B) and User Level 2
(Level C) passwords are displayed:
49018
CHANGE PASSWORD
> Level B : LINX1
Level C : LINX2
Figure 4-28. Change Password Menu

Any new password entered must consist of between four and 10 characters, and is not
sensitive to upper-case or lower-case letters (for example, a password of ‘SECURE’ would
be valid if entered as ‘secure’ or ‘Secure’).
NOTE: The Change Password option is not available in the SETUP menu at User Level 1.
Amdt 01 MP65557–1
4.7.22 Change Language
Selecting this option displays the CHANGE LANGUAGE menu, where the language and
associated parameters used by the printer can be set up. The following menu shows the
Euro 1 language group:
49188
CHANGE LANGUAGE
> English
French
German
Italian
Spanish
Portuguese
Dutch
Indonesian
Figure 4-29. Change Language Menu
There are 10 language builds available for the 4900 printer, each with its own language
group: Euro 1, Euro 2, Euro 3, Russian, Greek, Arabic, Farsi, Hebrew, Japanese and
Chinese. Up to eight language options per group are contained in the 4900 software, but
only for those printers that have the Latin character set. If any other character set is used,
the printer contains only that language and English. The default language is English.
There is only ever one character set and keyboard driver available for a particular language
group on a 4900 printer.
Selecting a language changes the language in which menus are displayed, and also
automatically selects the default date format for that language. The date format cannot be
changed from the default for that language.
The following table lists the different defaults for a given language:
v1.4 49216
Language Keyboard Driver Character Set Date Format
English Latin Latin English
Arabic Arabic Arabic Arabic
Chinese (Simplified) Chinese Chinese Chinese
Croatian Latin Latin Croatian
Czech Latin Latin Czech
Danish Latin Latin Danish
Dutch Latin Latin Dutch
Farsi Farsi Farsi Arabic
Finnish Latin Latin Finnish
French Latin Latin French
German Latin Latin German
Greek Greek Greek Greek
Hebrew Hebrew Hebrew Hebrew (mths only)
Hungarian Latin Latin Hungarian
Indonesian Latin Latin Indonesian
Italian Latin Latin Italian
Japanese Katakana Japanese Japanese English
Norwegian Latin Latin Norwegian
Polish Latin Latin Polish
Portuguese Latin Latin Portuguese
Russian Russian Russian Russian
Slovenian Latin Latin Slovenian
Spanish Latin Latin Spanish
Swedish Latin Latin Swedish
Turkish Latin Latin Turkish
Figure 4-30. Change Language Option Default Settings
MP65557–1 Amdt 01
4.7.23 Change Configuration
The Configuration menu allows the printer to be configured to a customer’s requirements
by using Linx-supplied codes:
49217
CONFIGURATION
> UNIC : 000002B7D892
Code : 123456-123456-123456-123456
Figure 4-31. Configuration Menu
UNIC
The UNIC (Unique Number Identification Chip) option displays the 12-character serial
number used to identify the individual printer. It is obtained from the removable UNIC on
the IPM PCB (the chip looks like a circular metal battery) and is the same as that printed on
the chip, for example, ‘000002B7D892’. The system software detects the presence of the
UNIC on power-up and displays the serial number next to the (view only) UNIC option.
If a UNIC is not found on power-up, the printer displays the System Failure “1.35 No
UNIC Chip”, and then stops. It is then necessary to switch off the printer and fit a valid
UNIC before proceeding.
If the IPM PCB is replaced, the UNIC must be removed from the old PCB and fitted to the
replacement one. If this is not done, any configuration codes (see below) will not work with
the replacement PCB.
Code
The Code item is a 24-character code, which tells the software what the printer
configuration is (for example, High Speed), what message types (rasters) are available, and
what software options are enabled to the customer. This Printer Configuration Code is
unique to, and supplied with, each printer. It is generated at Linx using the serial number
from the UNIC in combination with the printer configuration and software option
information.
Printer software options are pre-programmed into the software, but only those options that
a customer has requested are enabled by using an appropriate configuration code.
During manufacture the printer serial number, the printer UNIC serial number, and the
Printer Configuration Code are associated and held on the Configuration Database. Linx
Order Administration can resupply the code should it be lost, or a new code can be
purchased to enable additional printer options.
NOTE: Neither the printhead type nor the ink type are configured through the Printer
Configuration Code. These are selected separately in the Printhead Setup menu
and the Ink Type Selection option, respectively.
The Printer Configuration Code is entered in four groups of six characters each, separated
by hyphens. If a printer has not been configured, it defaults to a Standard Speed (SS)
printer but the default code for this is not displayed. Only a valid alternative code to the
default code can be entered and remain displayed, for example, when a customer requests
a change to the configuration. If an invalid code is entered, the following advisory message
is displayed in the status line:
“Invalid Configuration Code”
If three invalid codes are entered, the following advisory message is displayed in the status
line and the code is ignored:
“Please Wait”
Amdt 01 MP65557–1
After 1 minute has elapsed, the code can be validated again. The time doubles each time
another invalid code is entered.
When the Printer Configuration Code has been changed, if it changes the printer type from
an SS to an HS, all existing stored messages are deleted. This is because, if the message
types (rasters) were retained, they would be invalid for the different printer type.
As a warning to the operator that the messages will be deleted, when the new Printer
Configuration Code is specified and [enter] is pressed, the following advisory message
screen is displayed:
49225
CLEAR MESSAGE AREA

This action will delete all messages.
Do you wish to continue?
F1 : Yes F2 : No
Figure 4-32. “Deleting Messages” Advisory Message Screen

The printer must then be switched off and then on again for the new Printer Configuration
Code to take effect. Selecting F1 : Yes in response to the above screen message
automatically switches off the printer. When the printer is switched on again, the new
Printer Configuration Code is incorporated.
If F2 : No is selected, the printer is not switched off and messages are not lost. The printer
returns to the CONFIGURATION menu and the old Printer Configuration Code is displayed.
IMPORTANT: If the Power Off Override link LK13 is fitted, the printer does not switch off
automatically when F1 : Yes is selected. It must be switched off and then on
again manually using the Mains Power Supply Switch on the rear panel.
NOTE: If changing the Printer Configuration Code enables a communications option but
the printer type is not changed, the messages are not deleted and the above
message screen is not displayed, but the printer is still automatically switched off.
4.7.24 Remote Setup Menu (RS232)

The RS232 interface provides the facility for a remote computer to be used to control a
majority of a Linx printer’s functions. Additional functions are included to allow the
transfer of the various data set types and messages to and from the printer. The formats of
these data sets and messages, plus the full list of ASCII Control Characters, are described
in the Linx Remote Communications Interface Reference Manual.
The following subsections describe the Remote Setup menu structure and explain how to
use the menus to set up the printer for remote operation.
Selecting the Remote Setup Menu option (or pressing the [R] key from the SETUP menu)
displays the following menu, which allows access to a further six sub-menus:
49316
REMOTE SETUP
> Transfer Parameters
Serial Parameters
Flow Control
Message Delimiters
Print Control
Print Mode
Figure 4-33. Remote Setup Menu (RS232)
NOTE: All the following Remote Setup sub-menus are shown with their default settings.
MP65557–1 Amdt 01
Transfer Parameters
The Transfer Parameters option defines the general parameters for the RS232 link:
49266
TRANSFER PARAMETERS
> Mode : RS232
Escape Char : ESC (27)
Checksum Disabled : No
Buffer Threshold : 128
4800 Translation : No
Figure 4-34. Transfer Parameters Menu
Mode
This is always RS232 as the 4900 does not support any other protocol.
Escape Char
Escape Char defines the character that is used by the RS232 communications protocol to
identify the delimiting characters for the start and end of data transferred to and from the
printer. Any value between 01 and 31 can be set. It is also used to identify other ‘special’
data characters. This is described in further detail in the Linx Remote Communications
Interface Reference Manual.
NOTE: Special characters are used for various tasks in the interface and, as with the
escape character, can be set to any value between 01 and 31 (ASCII control
characters SOH to US). No two special characters can have the same value. If an
attempt is made to set two special characters to the same value, a warning
message is displayed in the status line.
Checksum Disabled
Checksum Disabled allows the user to disable the insertion of checksums at the end of
data transmitted from the printer, by setting the option from No to Yes. The printer also
does not look for checksums on the end of received data. It is recommended that the Yes
setting is not used continuously. This is because, without the checksum there is no check
on the basic integrity of the transferred data, and corrupted data may cause problems in
both the printer and remote computer.
Buffer Threshold
Buffer Threshold defines the number of characters to receive in the printer receive buffer
before the printer disables data flow using either hardware or software flow control. This is
used to ensure that no characters are lost, as there is a finite time between the receiver
telling the transmitter to stop sending and the transmitter actually stopping. The Buffer
Threshold allows the receiver to receive those additional characters without running out of
buffer space.
This option can be set to any value between 1 and 254.
Amdt 01 MP65557–1
4800 Translation
This option enables translation of 4900 printer data so that the 4900 printer can be used in
applications that communicate with other types of Linx printers, typically alongside 4800
or 6200 printers.
When the 4800 Translation option is set to No (the default setting), the 4900 uses its own
naming conventions for printer data and parameter values during data transfer. The
printer is therefore not compatible with applications that communicate with other types of
Linx printers.
When this option is set to Yes, the 4900 printer is compatible with applications that
communicate with other types of Linx printers (4800 or 6200). The names of various data
and parameter values that are used during data transfer are translated from the 4900
convention to the 4800 convention. For example, when the 4900 message type name ‘5 FH
(Caps)’ is used, it is translated to the 4800 message type name ‘5 High Caps’. In addition,
parameter values that are recognised as bit sets are also translated internally.
NOTE: There is a limitation on translating data when messages are transferred from a
4900 printer to other types of Linx printers. Messages created on a 4900 printer
and then transferred via a PC to another Linx printer (4800 or 6200) are not
translated. Character sets are also not translated.
Messages created on other Linx printers (4800 or 6200) and then transferred via
a PC to a 4900 printer will be successfully translated.
Details of the 4900 to 4800 translations are provided in the Linx Remote Communications
Interface Reference Manual.
Serial Parameters
This sub-menu defines the communications parameters used by the serial hardware, and
determines the format and speed of the transferred data. Both the transmitter and receiver
should use the same serial parameters to allow successful transmission and reception to
take place.
49317
SERIAL PARAMETERS
> Baud Rate : 9600
Stop Bits : 1
Parity : None
Data Bits : 8
Figure 4-35. Serial Parameters Menu
Baud Rate
This determines the speed of the transferred data and can be set to 9600 or 19200.
Stop Bits
This determines the number of stop bits used: 1, 1.5 or 2.
Parity
This determines the type of parity bit to be used. The settings are None, Odd or Even.
Data Bits
This shows the number of data bits used. It is for display purposes only and cannot be
changed.
MP65557–1 Amdt 01
Flow Control
Both the printer and the remote computer use areas of memory called ‘buffers’ to receive
incoming characters. These areas of memory are limited in size, and to ensure that they do
not overflow and lose characters, flow control is implemented at regular intervals to stop
reception of characters.
49318
FLOW CONTROL
> Flow Control : Cts/Dtr (H/w)
Xon Char : DC1 (17)
Xoff Char : DC3 (19)
Figure 4-36. Flow Control Menu
Flow Control
Flow control can be implemented either by using hardware lines (Cts and Dtr) in the RS232
cable or by sending special characters called Xon and Xoff over the link. These special
characters are identified in the data stream by the escape character preceding them.
The two settings for the Flow Control option are Cts/Dtr (H/w) and Xon/Xoff (S/w).
Xon Char
The Xon Char option can be set to any value between 01 and 31 (ASCII control characters
SOH to US).
Xoff Char
The Xoff Char option can be set to any value between 01 and 31 (ASCII control characters
SOH to US).
Message Delimiters
The characters used to delimit transmitted and received data over the interface are
specified in this sub-menu. All the characters are identified in the data stream by the
escape character preceding them.
49319
MESSAGE DELIMITERS
> Start Char : STX (02)
Alternate Start Char : SOH (01)
End Char : ETX (03)
Ack Char : ACK (06)
Nak Char : NAK (21)
Figure 4-37. Message Delimiters Menu

All the options in the MESSAGE DELIMITERS menu can be set to any value between 01
and 31 (ASCII control characters SOH to US).
Amdt 01 MP65557–1
Print Control
In most circumstances the remote computer initiates communications, and the printer only
replies to a received command. The Print Control option allows certain ASCII control
characters to be transmitted and received by the printer without the normal
communications being initiated by the computer.
49320
PRINT CONTROL
> Print Trigger Char
Print Delay Char
Print Go Char
Print End Char
Figure 4-38. Print Control Menu

These control characters indicate the following:
• ENQ (05)—the computer is triggering a ‘print go’
• BS (08)—the printer has started the print delay
• SI (15)—the printer has started to generate rasters
• EM (25)—the printer has completed a print sequence
Each character is preceded by the escape character so that it can be distinguished from
normal data.
Each of the following characters can be enabled or disabled (On or Off state) as
appropriate, and each character can be set in the range 1 to 31.
Print Trigger Char

The Print Trigger character can be issued by the host computer to start a print. The printer
treats this character in the same way as a photocell trigger and starts the print delay. The
Photocell option should be set to Remote for the Print Trigger character to be actioned.
Print Delay Char

The Print Delay character is issued by the printer when a photocell trigger occurs, just
before the print delay starts. If the Photocell option is set to Off, this character is not sent, as
under these circumstances a photocell trigger never occurs.
Print Go Char
The Print Go character is issued by the printer at the end of the print delay when printing is
about to commence.
Print End Char

The Print End character is issued by the printer when printing stops, that is, when a ‘stop
print’ command is issued, or the message print count reaches 0 with no other message
pending.
MP65557–1 Amdt 01
Print Mode
In addition to the static printing process where data is downloaded for printing beforehand
and then printing is started, the printer can be set up to receive data during printing using
the PRINT MODE sub-menu.
49321
PRINT MODE
> Mode : Continuous
Print Go/No Data : Warn/Ignore PG
Print Go/Pixel RAM : Warn/Ignore PG
Clear Remote Buffer : On
Number Of Buffers : 2
Figure 4-39. Print Mode Menu

Using the Print Mode option it is possible to control the following:
• Circumstances under which printing takes place
• Field data download during printing
• Failure conditions
• Issuing of print control characters
• Size and amount of data received
Mode
The Mode option can be set to either Continuous or Single print.
Continuous
In Continuous print mode, printing always takes place regardless of whether or not any
remote data has been received. Therefore, if one set of remote data is received, it is
continuously printed until more remote data is received.
Single
In Single print mode, printing takes place once for each set of remote data received. If no
more data is received, any print triggers that occur are dealt with according to how the
failure condition has been set up.
For normal printing where no remote data is expected, the Mode option should always be
set to Continuous. Single print mode should be used exclusively with messages expecting
remote data.
The two commands that should be used to download the remote data are 28 (download
field data) and 29 (download remote field data). The former is used to download complete
static field structures, and the latter is used to download text characters to be inserted in
predefined remote fields in the message. Both are described in the Linx Remote
Communications Interface Reference Manual.
Amdt 01 MP65557–1
Print Go/No Data
This is one of the two failure conditions that can be configured, and is implemented when a
‘print go’ occurs and no remote data has been received.
The Print Go/No Data option can be set to carry out one of the following three actions:
• Do nothing and ignore the ‘print go’ (Ignore Prn Go)
• Report the error and ignore the ‘print go’ (Warn/Ignore PG)
• Report the error and stop printing, but not stop the jet (Fail/Stop Prn)
If the print mode has been set to Continuous print, the Print Go/No Data error does not
occur. This is regardless of whether any remote data has been received or not. In
Continuous print mode, printing always take place.
Print Go/Pixel RAM

This is the second of the two failure conditions that can be configured, and is implemented
when a ‘print go’ occurs and the printer is still generating the pixel pattern.
The Print Go/Pixel RAM option can be set to carry out one of the same three actions as
Print Go/No Data above.
Clear Remote Buffer

The remote print buffer is used to store any remote data that has been downloaded to the
printer using commands 28 and 29.
The Clear Remote Buffer option is available to clear the buffer when printing stops.
If it is set to Yes, once printing stops the buffer is cleared. This does not affect the data that
has already been loaded into the message.
If it is set to No, any data in the remote buffer when printing stops remains there.
Therefore, if printing is restarted, it continues with the data already in the buffer.
Number Of Buffers
The remote buffer is 1024 bytes long and can be divided into 1, 2, 4, 8, 16, 32, 64 or 128
blocks by changing the setting of this option. For example, if the buffer is divided into eight
blocks, each block is 128 (1024 ÷ 8) bytes long. The minimum value for the remote buffer
divisor is 1 in Single print mode and 2 in Continuous print mode.
As data is downloaded, using commands 28 or 29, it is loaded into each of these blocks—
one command per block. Therefore, all the commands must be smaller than the current size
of each block.
For each print, the printer checks whether any data exists in the remote buffer. If there is
data, it is taken from the next occupied block and loaded into the message for printing.
4.7.25 Diagnostics Menu

For full details of the diagnostic options refer to ‘Diagnostics Menu’ in ‘Chapter 5:
Maintenance’.
4.7.26 Solv Add Time

This option indicates the total time (in multiples of 10 seconds) that the solvent add valve
has been operated since the printer has been switched on. The time figure is only reset to
zero when the power is switched off; it is not reset when the jet is stopped. It is also for
display purposes only and cannot be changed.
NOTE: The Solvent Add Time for each solvent addition is ink type dependent; refer to
the Ink Type Dependent Parameters tables in the ‘Ink System’ section of ‘Chapter
3: Technical Description’.
MP65557–1 Amdt 01
Amdt 01 MP65557–1
4.8 Passwords
User Level 1 (Level B): “LINX1”
User Level 2 (Level C): “LINX2”
Service Level (Level D): “………”
MP65557–1
4900 Maintenance Manual Nov 2003
MP65557–1
Nov 2003 4900 Maintenance Manual
CHAPTER 5: MAINTENANCE
5.1 Introduction
This chapter is divided into two sections. The first section describes the options that are
available in the DIAGNOSTICS menu. The second section contains Maintenance
Instructions for carrying out specific tasks on the 4900 printer.
The detailed information given in this chapter refers to printers with Version 1.0 software
installed, unless otherwise stated.
5.2 Diagnostics Menu

5.2.1 Password Access
Access to the SETUP menu is by password as described in ‘Chapter 4: Setup Menu’; four
levels of password are used. The first three levels are intended for operators and have
limited or no access to the DIAGNOSTICS menu; the fourth level has full access to the
diagnostics.
NOTE: The passwords are not given here because not all personnel who have access to
this manual will have received adequate training to use the full DIAGNOSTICS
menu, which is only available with the Service Level password. The last page of
‘Chapter 4: Setup Menu’ contains the passwords. The page can be removed for
security if desired and filed in a safe place.
If User Level 2 or Service Level passwords have been used on entry to the SETUP menu,
access to the DIAGNOSTICS menu can be made by scrolling through the SETUP menu
using the down arrow key until the cursor is next to the Diagnostic Menu option, then
pressing [enter]. Alternatively, immediate access can be made by pressing the letter [D]
key. The first four diagnostic options are then displayed and the up and down arrow keys
can be used to scroll through the full menu.
MP65557–1
5.2.2 Total Menu Options
The DIAGNOSTICS menu shown below covers the full range of options that are available
with the Service Level password. All options are shown, irrespective of jet state, for
illustration purposes only:
49226
DIAGNOSTICS
> Start Jet
Stop Jet
Quick Start Jet
Start Print
Stop Print
Test Print
Clear Nozzle : 1
Nozzle Flush
Monitor Jet
System Times
System Configuration
Phase : 0
Phase Offset : 8
Ref Pressures
Pressure Tracking : Off
Set Pressure : 0
Modulation Tracking : Off
Set Modulation : 0
Filter Purge : Off
Phase Fault : On
Phase Period : 30
Auto Phase : On
TOF Correction : On
TOF Warm Up : On
Calibration
Alarm Test : Off
Generate Test Pattern
System Flush
Valve Test
Figure 5-1. Diagnostics Menu
5.2.3 Option Availability

The following paragraphs identify the Service Level password options together with the
restricted list of options available with the User Level 2 password.
The printer has three main states: Jet Off, Jet Running and Ready to Print (printing or
awaiting a ‘print go’ signal). The DIAGNOSTICS menu changes to reflect these states,
which may affect the availability of some options and also the ability to select an option or
change its parameters. Options that are displayed and can be selected and changed are
identified with a solid circle (●), while options that are for display only and cannot be
selected are identified with an unfilled or open circle ( ).
Options are only displayed if they are valid for the password used and the current state of
the printer. For example, the Start Jet option is not displayed when the printer is in the Jet
Running state, as it is not applicable. This keeps the menu list to a minimum at all times.
MP65557–1
The following table shows the validity of each option in relation to the printer state and
level of password used. The convention for the validity of the options in the table is the
same as that displayed on the printer, i.e. solid and open circles. Options that are not
available are identified with a dash (–).
49227
USER LEVEL 2 PASSWORD SERVICE LEVEL PASSWORD
Diagnostic options Jet Off Jet Ready to Jet Off Jet Ready to
Running Print Running Print
Start Jet – – – ● – –
Stop Jet – – – – ● –
Quick Start Jet – – – ● – –
Start Print – – – – ● –
Stop Print – – – – – ●
Test Print – – – – – ●
Clear Nozzle ● – – ● – –
Nozzle Flush ● – – ● – –
Monitor Jet ● ● ● ● ● ●
System Times: ● ● ● ● ● ●
Power On
Jet Running
Service (Hours) ● ● ●
System Configuration: ● ● ● ● ● ●
sub-options
Phase – – – ● ● ●
Phase Offset – – – ● ● ●
Ref Pressures ● ● ● ● ● ●
Pressure Tracking – – – ● ● ●
Set Pressure ● ● ●
Modulation Tracking – – – ● ● ●
Set Modulation ● ● ●
Filter Purge – – – ● – –
Phase Fault – – – ● ●
Phase Period – – – ● ●
Auto Phase – – – ● ●
TOF Correction – – – ● ●
TOF Warm Up – – – – ●
Calibration – – – ● – –
Alarm Test – – – ● – –
Generate Test Pattern ● ● – ● ● –
System Flush – – – ● – –
Valve Test – – – ● ● ●
Figure 5-2. Diagnostics Menu Option Availability
MP65557–1
5.2.4 Selecting and Changing Menu Options
Use the up and down arrow keys on the keypad to move the cursor to the required menu
option. An arrowhead symbol (>) indicates the menu option at which the cursor is
currently positioned. When the arrowhead is pointing at the required menu option, press
[enter] to select the option. This may access a further menu screen, or the cursor may move
across to the field at the right of the screen ready for alteration of the particular menu
option setting.
How the settings are changed is dependent on the type of menu option selected. Some
options have a choice of settings that can be selected using the left and right arrow keys
(e.g. Alarm Test : On/Off). Other options allow a value to be typed in (e.g. Set Pressure :
255). When the option setting has been changed, press [enter] again to return the cursor to
the left side of the screen (the menu list). To return to the CURRENT MESSAGE screen
(via the SETUP menu), press the [esc] key twice.
Note that not all menu options can be changed. Some options are for display purposes
only while others cannot be accessed due to the current status of the printer.
MP65557–1
5.3 Option Description
The following subsections describe the full list of options available with the Service Level
password.
5.3.1 Start Jet

This option mimics the [start] key to start the printer but without enabling print, thus
giving a printer state of Jet Running. While the jet is starting, the following status line
message is displayed:
“Starting Jet : Please Wait”
Before the jet starts, all the normal static checks are made, for example, pressure/filter
check, ink and solvent levels, and Service and Filter times. During the jet starting
sequence, the dynamic functional checks and adjustments are carried out: pressure check,
TOF and phasing. Only after all these checks have been completed will the printer enter
the Jet Running state.
As with a normal start, if any of the checks or adjustments are invalid the printer attempts
a further three starts (four in total). If an invalid condition still exists, the printer will
provide an audible and on-screen warning, or will fail with a fault code.
If the Phase Fault option is set to Off, the printer will continue to run after the third restart,
but under the conditions described in Phase Fault later in this section.
See also: Start Print option; Quick Start Jet option; Phase Fault option.
Chapter 3: Technical Description > Ink System > Startup and Shutdown
Sequences.
Chapter 6: System Events.
5.3.2 Stop Jet

This option stops the jet. While the jet is stopping, the following status line message is
displayed:
“Stopping Jet : Please Wait”
When the jet has stopped, the following status line message is displayed:
“Jet Stopped : Press Stop to Power Down”
Quick Stop
Pressing the [stop] key while holding the [ctrl] key provides a quick stop. This stops the jet,
clears the feed line for 5 seconds, clears the purge line for 5 seconds, and clears the gutter
line for 5 seconds only. The use of this stop method is for fault diagnosis ONLY and must
not be used prior to a period of non-use, as this will not adequately prepare the printer for
restart.
MP65557–1
5.3.3 Quick Start Jet
This option starts the jet using a shorter method than a Normal Start, to assist with fault
diagnosis. The important differences between a Normal Start sequence and a Quick Start
Jet sequence are described below.
Firstly, there is a change to the sequence of operations on startup. Normally the sequence
is as follows:
1. Check pressure.
2. Establish jet.
3. Check if jet is in the gutter.
4. Set pressure to Pressure Reference.
5. Apply a ‘block’ charge to all the drops.
6. Measure Time Of Flight.
7. Adjust pressure if Time Of Flight is out of range.
8. Repeat 5 to 7 until Time Of Flight is in range.
9. Find phase position.
10. Printer state Jet Running.
When the Quick Start Jet option is used, the sequence is shorter and rearranged as follows:
1. Check pressure.
2. Establish jet.
3. Set pressure to Pressure Reference.
4. Printer state Jet Running.
5. Attempt to phase the jet.
6. Measure Time Of Flight.
7. Adjust pressure if Time Of Flight is out of range.
8. Repeat 5 to 7 until Time Of Flight is in range.
It can be seen from the above Quick Start Jet sequence that 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 overridden, and the jet is established using the
printhead reference pressure and reference modulation values. The printer enters the Jet
Running state and then adjusts the pressure to obtain the correct TOF.
If the Monitor Jet option is used to check the jet control values soon after the jet is started,
the readings may be incorrect. A few minutes must elapse to allow TOF corrections to be
completed.
The system can only implement TOF correction if all the feedback signals are present,
otherwise the printer will continue to operate at the printhead reference values. In this
case the MONITOR JET screen would show TOF : 0.
A second important difference is that the Phase Fault error detection function is
automatically disabled (set to Off). Therefore, should there be a phase or TOF feedback
signal fault, the jet will continue to run (allowing fault diagnosis) instead of shutting down
as would happen under normal running conditions (see Phase Fault later in this section).
When using Quick Start Jet, and after the fault has been rectified, it is advisable to stop the
jet and power down the printer, then power up and start the printer normally using the
[start] key. This is necessary because it is possible that the fault has not, in fact, been
rectified when the jet is started with the normal routine.
CAUTION: The Quick Start Jet option will start the jet even if the ink level is low. The
pump will be damaged if it is run without ink.
See also: Phase Fault option; Monitor Jet option; Start Jet option; TOF Correction option.
Sequences.
MP65557–1
5.3.4 Start Print
This option changes the printer state from Jet Running to Printing, but will only happen if a
message is currently displayed in the CURRENT MESSAGE screen. Refer to the 4900 User
Manual for descriptions of how to select and edit messages.
Using the Start Print option will not re-enable the Phase Fault option, and therefore should
only be used to start printing during fault diagnosis when the printer is in a fault condition.
Note that the Phase Fault detection function will be automatically re-enabled after the
warm-up time (see Phase Fault later in this section).
The [start] and [F1] keys can also be used to start printing and these will re-enable the
Phase Fault option.
NOTE: The Start Print command has a lower level function than the main [start] key,
which sets, for example, Phase Fault to On when pressed. Using Start Print
leaves the Phase Fault option in its current state.
See also: Start Jet option; Stop Print option; Quick Start Jet option; Test Print option; Phase
Fault option.
5.3.5 Stop Print

This option changes the printer state from Printing to Jet Running. That is, it disables
printing but maintains the jet. This allows certain diagnostic functions to be displayed and
selected, which is not possible in the Printing state.
Pressing the [F1] key when the CURRENT MESSAGE screen is displayed also changes the
printer state from Printing to Jet Running.
See also: Start Jet option; Quick Start Jet option; Start Print option.
5.3.6 Test Print

The Test Print option is only available in the Printing state.
This option simulates a single ‘print trigger’ to print a single message manually from the
keyboard instead of using a trigger signal. The printed message is the one displayed in the
CURRENT MESSAGE screen. The Print Delay and Print Width settings selected in the
SETUP menu apply as with a normal trigger. The Test Print function has the same effect as
the external trigger in updating software options, sequential numbers and print counters.
This function operates only if the Primary Trigger option in the SETUP menu is set to
Leading Edge or Trailing Edge, and the printhead cover tube is fitted. If either of these
conditions are incorrect, one of the following status line messages will be displayed:
“Test Print : Invalid Trigger Mode”
“Test Print : Cover Off”
If the Shaft Encoder option in the SETUP menu is set to Direct, printing will commence
only when shaft encoder pulses are received, as would normally be the case when a
production line is running. The Shaft Encoder option is disabled by selecting Off, and then
printing is at a speed determined by the Print Width setting in the SETUP menu.
Operation of the printer is as normal in every other respect; checks for printhead cover tube
off and overspeed are made, and any associated error messages are displayed. When Test
Print is selected, one of the following status line messages is displayed:
“Test Print : Print Started”
“Test Print : Already Printing”
See also: Chapter 4: Setup Menu > Primary Trigger and Shaft Encoder options.
MP65557–1
5.3.7 Clear Nozzle
WARNING: HAZARDOUS INKS AND SOLVENTS. SAFETY GLASSES AND

SOLVENT-RESISTANT PROTECTIVE GLOVES MUST BE WORN
THROUGHOUT THE FOLLOWING PROCEDURE. FAILURE TO COMPLY WITH
THIS SAFETY WARNING COULD RESULT IN IRRITATION AND REVERSIBLE
LOCAL DAMAGE TO THE EYES, AND NON-ALLERGIC CONTACT
DERMATITIS.
The jet must be stopped before this option can be selected.
The Clear Nozzle option can be used as an alternative to, or in conjunction with, the Nozzle
Flush option (described later in this section) when there is a suspected blocked or
obstructed printhead nozzle.
CAUTION: The solvent applied to the nozzle during this sequence must be the correct
type for the ink used in the printer. Use of the wrong solvent is likely to result in print
failure.
This option initiates a nozzle clearing sequence to clear an obstruction or blockage by
applying vacuum to the nozzle. While the printer is performing the Clear Nozzle
sequence, the printhead should be inverted 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.
A single Clear Nozzle sequence lasts 20 seconds. The pump is run at the maximum
pressure of 255 bits and, after 5 seconds, the gutter valve is energized (opened). This
transfers the vacuum from the gutter to the nozzle assembly for a further 15 seconds. The
gutter valve is then closed and the pump is stopped, reducing the pressure to zero.
It is recommended that a maximum of eight Clear Nozzle sequences are carried out in an
attempt to clear an obstruction or blockage, with an attempt to start the jet carried out after
each sequence.
If after this procedure the nozzle is still blocked, carry out the necessary nozzle soaking
and washing procedures detailed in the ‘Jet Alignment and Nozzle Cleaning’ maintenance
instruction. If these procedures still do not clear the nozzle blockage, the nozzle assembly
or complete printhead should be replaced.
While the Clear Nozzle sequence is being performed, the following status line message is
displayed:
“Clearing Nozzle : Please Wait”
See also: Set Pressure option.
Chapter 2: Safety.
Chapter 3: Technical Description > Ink System > Other Operating Sequences >
Nozzle Clear Sequence, for a summary of the valve sequences for this item.
MP65557–1
5.3.8 Nozzle Flush

DERMATITIS.
WARNING: SOLVENT JET HAZARD. THE USE OF THE NOZZLE FLUSH

FUNCTION MUST NOT BE CONFUSED WITH THE NOZZLE CLEAR FUNCTION.
WHEN THE NOZZLE FLUSH SEQUENCE IS IN OPERATION THE PRINTHEAD
MUST BE DIRECTED DOWN INTO A SUITABLE RECEPTACLE IN ORDER TO
CONTAIN THE SOLVENT.
The jet must be stopped before this option can be selected.
The previously mentioned Clear Nozzle sequence removes particulates from the jewel and
nozzle area, but can leave them in suspension within the gun chamber where they may be
redeposited on the jewel. This could lead to the jet alignment or nozzle blockage problem
reappearing in the future, if not immediately.
Unlike the Clear Nozzle sequence, where solvent is drawn in through the nozzle, the
Nozzle Flush sequence automatically fills the nozzle with solvent and then forces a jet of
solvent out of the nozzle and into the gutter to flush away any deposits. Therefore, the
Nozzle Flush sequence can be used as an alternative to, or in conjunction with, the Clear
Nozzle sequence when there is a suspected blocked or obstructed nozzle.
The duration of the Nozzle Flush sequence is 145 seconds (2 min 25 s) for a 2-metre and a
4-metre printhead conduit.
IMPORTANT: The Nozzle Flush sequence attempts to establish a solvent jet and, if this
occurs, the solvent is returned to the ink tank. Excessive use of the Nozzle
Flush sequence will, consequently, greatly reduce the viscosity of the ink
causing the printer to fail. Therefore, the Nozzle Flush sequence must
not be used more than three times to clear a particular nozzle blockage.
Chapter 2: Safety.
Chapter 3: Technical Description > Ink System > Other Operating Sequences >
Nozzle Flush Sequence, for a summary of the valve sequences for this item.
MP65557–1
5.3.9 Monitor Jet
The MONITOR JET screen displays the printer’s main jet control parameters in a single
screen:
49228
MONITOR JET
Press : 185 (186) Add Press : 188
TOF : 7862 Ref TOF : 7843
Modln : 92 Ref Modln : 90
Phase : 14 Phd Temp : 25
Figure 5-3. Monitor Jet Screen

The example shown above is for a Mk7 Ultima printhead with the jet running, and the
parameter values are typical of what would normally be seen. The parameters are for
display only and cannot be changed.
This screen can be quickly accessed from the CURRENT MESSAGE screen by pressing the
[M] accelerator key. It can also be quickly accessed from the SETUP menu by pressing the
[D] accelerator key, and then from the DIAGNOSTICS menu by pressing the [M]
accelerator key, regardless of the current position of the menu cursor (>).
The following paragraphs describe each of the parameters in the MONITOR JET screen,
line-by-line, reading from left to right:
Press (Pressure)
Two parameters are displayed for ‘Press’. The first is the Set Pressure value and the
second, in brackets, is the Read Pressure value.
Set Pressure
The Set Pressure value is displayed in pressure bits. When the printer is in a jet state, i.e.
Jet Running or Ready to Print, this pressure value is set and adjusted by the microprocessor
to maintain the Time Of Flight (TOF) within the control parameters. Alternatively, the
value reflects the different pressures required by the software for other sequences, for
example, startup and shutdown.
This pressure value is the same as the one set/displayed in the Set Pressure option,
described later in this section.
See also: Set Pressure option; Ref Pressures option; Read Pressure (Monitor Jet screen).
Read Pressure
This is the actual pressure (in pressure bits) measured by the ink system pressure
transducer. The value would normally reflect the Set Pressure value (see above) with only
a small difference of typically 3 to 5 bits. During the pressure/filter check part of the
Normal Start sequence, if the Read Pressure is more than 5 bits below the Set Pressure, the
System Warning message “3.18 Low Pressure” will be displayed.
See also: Set Pressure option; Set Pressure (Monitor Jet screen).
Chapter 6: System Events > System Warnings > 3.18 Low Pressure.
MP65557–1
Add Press (Pressure)
This is the Solvent Add Pressure reference and is the same as the Solvent Add value in the
PRESSURE REFS menu. When the pressure exceeds this value the printer allows a solvent
addition if all of the solvent add criteria have been met.
When the Head Height option (SETUP menu) is used to compensate for differences
between the printer and printhead heights, the printhead Reference Pressure is
automatically adjusted. The Solvent Add Pressure is calculated from the printhead
Reference Pressure and therefore is also adjusted.
See also: Solvent Add (Ref Pressures menu).
Chapter 3: Technical Description > Ink System > Ink and Solvent Flows > Solvent
Addition.
Chapter 4: Setup Menu > Head Height.
TOF
This is the measured TOF displayed as an averaged reading. The displayed value
represents the jet speed—the higher the reading, the slower the jet; the lower the reading,
the faster the jet.
Time of Flight (TOF) values are obtained by measuring the time taken for a special ‘packet’
of low charged drops to pass between two datum points—the phase sensor and the TOF
sensor located in the printhead Deflector and Phase Plate (DPP). The software obtains a
number of TOF measurements and averages only those values that fall within a
predetermined tolerance of the last averaged reading. A specified minimum number of
values must be within the tolerance before the averaged TOF value is used to control the
system pressure. If the displayed value is zero, this means that less than the specified
minimum number of values are within the tolerance, and therefore the TOF measurement
is invalid.
An asterisk (*) appended to the TOF reading indicates that a TOF reading is late, probably
due to noise. Such a TOF value is still used by the jet control software as a valid value.
Control is achieved by using the averaged value to increase or decrease the pressure, as
necessary, to maintain the TOF at the Reference TOF (with a small tolerance of ±0.5%).
The Print Failure message “2.03 Time Of Flight Failure” is displayed if there are no valid
TOF readings for a period of 40 minutes.
See also: Chapter 6: System Events > Print Failures > 2.03 Time Of Flight Failure.
Ref TOF
This is the TOF reference value displayed as a normalized reading, which effectively is the
jet velocity reference. The microprocessor uses this value, in conjunction with the
measured TOF value, to maintain the correct TOF.
Modln (Modulation)
This is the modulation voltage currently used by the printer to control drop break-up. It is
also the same value as the one that is set and displayed in the Set Modulation option
described later in this chapter.
Under normal operating conditions, there is usually a small difference between this value
and the Ref Modln (Reference Modulation) value described below. These values should be
the same when the Modulation Tracking option (see later in this chapter) is disabled.
MP65557–1 Amdt 01
Ref Modln (Reference Modulation)
This is the Reference Modulation used by the printer.
Under normal operating conditions there is usually a small difference between this value
and the Modln (Modulation) value described above. These values should be the same
when the Modulation Tracking option (see later in this chapter) is disabled.
The Reference Modulation value displayed here is the same value as the one given as part
of the Printhead Code displayed in the PRINTHEAD SETUP menu (Setup menu). It
should also be the same value as that printed on the printhead conduit label. If the
Reference Modulation part of the Printhead Code is different from that on the printhead
conduit label, it must be re-entered.
See also: Chapter 4: Setup Menu > Printhead Setup menu > Printhead Code option.
Phase
This shows the current phase position that the printer is using to charge the drops for
printing, and is the same as the value displayed separately in the Phase option, described
later in this section.
See also: Phase option.
Phd Temp
This simply displays the printhead temperature. If the temperature exceeds 60 °C, the
Print Failure message ”2.00 Printhead Over Temperature” will be displayed.
WARNING: HIGH TEMPERATURE. WHEN THIS FAULT IS REPORTED THE

PRINTHEAD AND COVER MAY BE VERY HOT. EXTREME CARE MUST BE
TAKEN TO AVOID SKIN BURNS AND INCREASING THE RISK OF A FIRE. DO
NOT TOUCH THE PRINTHEAD OR ATTEMPT TO REMOVE THE PRINTHEAD
COVER UNTIL IT HAS BEEN ALLOWED TO COOL DOWN NATURALLY.
REMOVING THE PRINTHEAD COVER BEFORE IT HAS COOLED DOWN MAY
RESULT IN SEVERE BURNS TO THE HANDS AND THE POSSIBILITY OF FIRE
DUE TO THE SUDDEN INCREASE IN OXYGEN AROUND THE PRINTHEAD.
See also: Chapter 3: Technical Description > Printhead Components > Printhead
Temperature Sensor.
See also: Chapter 6: System Events > Print Failures > 2.00 Printhead Over Temperature.
5.3.10 System Times

This option displays the operating times of the printer, in three categories:
49229
SYSTEM TIMES
> Power On : 75
Jet Running : 50
Service (Hours) : 1350
Figure 5-4. System Times Screen
Amdt 01 MP65557–1
For User Level 2 Diagnostics, the System Times parameters are for display only and cannot
be altered. With the Service Level password the Power On and Jet Running times are for
display only and cannot be altered, whereas the Service (Hours) time can be reset by the
service engineer.
NOTES:
1. The cumulative (total) Power On and Jet Running stored values are reset to zero
if the battery link LK2 on the IPM PCB is removed.
2. It is important that a note is made of the Service (Hours) time when carrying out
maintenance on the printer involving a change of software, removal of the
battery link LK2, or replacing the IPM PCB. Software change or link LK2
removal initializes the memory and resets the time to its default setting.
Power On
This displays the total cumulative time, in hours, that the printer has been switched on. It is
updated while the printer is powered up and is for display purposes only.
Jet Running
This displays the total cumulative time, in hours, that the jet has been running, that is, in Jet
Running or Ready to Print states. It is for display purposes only and cannot be altered.
Service (Hours)
This displays the time remaining, in hours, until the next scheduled maintenance of the
printer is due. The time decrements (only when the jet is running) from a manually set,
recommended maximum scheduled maintenance interval.
The scheduled maintenance interval is ink type dependent, as shown in the following table:
49282
Ink type group Basic (maximum) maintenance

interval
A 2000 hours
B 2000 hours
C 2000 hours
D 1400 hours
Figure 5-5. Scheduled Maintenance Intervals

When the Service interval reaches zero hours, the System Warning message “3.11
Scheduled Maintenance Required” is displayed, and thereafter every time the printer is
switched on. This warning message continues to be displayed until the scheduled
maintenance has been carried out and the Service interval has been reset by the service
engineer.
If the warning is ignored, the time continues to decrement and is displayed as a negative
value, indicating how long ago the scheduled maintenance should have been carried out.
If the Service time is altered in error, and before the [enter] key is pressed, the [esc] key can
be used to exit the System Times menu without the original time setting being affected.
Refer to Maintenance Instructions > Scheduled Maintenance in this chapter.
See also: Chapter 6: System Events > System Warnings > 3.11 Scheduled Maintenance
Required.
MP65557–1
5.3.11 System Configuration
The SYSTEM CONFIGURATION menu provides a full list of the printer’s hardware and
software configuration. These details may be required by Linx or a Linx distributor if
additional logo or software features are required.
Most of the information shown is for display purposes only and cannot be altered:
49325
SYSTEM CONFIGURATION
> Head Type : Ultima
Message Type
Messages Stored : 26
SW Links : A
SW Version : v1.0.15 (257)

PCB Issue : 1
Configuration : SS
Language Group : Euro1
Enabled Options
Figure 5-6. System Configuration Menu
Head Type
The type of printhead fitted to the printer is shown against this option. The 4900 printer
currently supports two printhead types—Ultima and Ultima plus, and these can be selected
in the PRINTHEAD SETUP menu (Setup menu). The default printhead type is Ultima.
Message Type
Selecting this option displays the MESSAGE TYPE menu, which lists the message types
available for the particular printhead and configuration combination. The following menu
shows a sample of the message types available for the Ultima printhead with a 2-line,
Standard Speed (SS) configuration:
49013
MESSAGE TYPE
> 7 Quality
7 Flexible
16 Quality
16 Flexible
Figure 5-7. Message Type Menu
Messages Stored
This simply displays the number of messages currently stored in the printer.
SW Links
This option lists all the software links that are currently fitted. These links are not normally
fitted in customers’ printers.
SW Version
This displays the version number of the system software installed in the printer. Using the
example shown in the SYSTEM CONFIGURATION menu above, at the Service Level this
is in the form of: major version number (1.), minor version number (0.), issue number (15),
and build number in brackets (257). At lower security access levels the build number is not
displayed.
MP65557–1
PCB Issue
The issue number of the IPM PCB fitted to the printer is displayed against this option.
Configuration
This option displays the printer configuration. For example, 2-line Standard Speed (SS) or
2-line High Speed (HS).
Language Group
The languages available are determined by the Language Group installed in the 4900
printer: Euro 1, Euro 2, Euro 3, Russian, or Greek, as shown in the following table:
49326
Language Group
Euro 1 Euro 2 Euro 3 Russian Greek
Keyboard Euro Euro Euro Russian Greek
Driver
Keypad Euro Euro Euro Russian Greek
Languages English English English English English
French Norwegian Hungarian Russian Greek
German Swedish Polish
Italian Finnish German
Spanish Danish Croatian
Portuguese Czech
Dutch Turkish
Indonesian Slovakian
Figure 5-8. 4900 Language Groups

Refer to the Linx 4900 Operating Manual for more details.
See also: Chapter 4: Setup Menu > Change Language option.
Enabled Options
The ENABLED OPTIONS screen lists the additional software options that are enabled to
the customer. If there are no enabled options, the screen is blank. The following screen is
an example of what might be seen on a configured printer:
49327
ENABLED OPTIONS
> DDE Driver
LogoJet Driver
Figure 5-9. Enabled Options Screen Example

See also: Chapter 4: Setup Menu > Change Configuration option > Code option.
MP65557–1
5.3.12 Phase
This option shows the current phase position, in the range 0 to 15, that the printer is using
to charge the drops for printing or jet control. The actual figure displayed is not important,
but it should be stable and should not change by more than ±1 digit in normal operation.
The Phase position reflects the drop break-off point from the jet stream and is used to
synchronize the charge to the drop, and the Phase Offset option (see below) can be used to
artificially change this relationship. The degree of change can be a complete phase cycle of
0 to 15, but currently all 4900 printers should have the Phase Offset set to 8.
The printer checks the phase position at regular intervals during jet starting, jet running or
printing; the period between checks varies, depending on the jet state.
See also: Phase Offset option; Auto Phase option.
5.3.13 Phase Offset

This option adds an offset to the actual phase position, up to a complete phase cycle, which
changes the charging of the drops in relation to the drop break-off. The value displayed is
the current setting of the phase offset in the range 0 to 15.
Ultima and Ultima plus printheads fitted to 4900 printers have a default phase offset value
of 8; currently this is the only value that should be used. It should only be altered as an aid
to fault diagnosis, or as directed in Product Bulletins that give information on future ink
releases, which may require the phase offset to be altered.
See also: Phase option; Auto Phase option.
5.3.14 Ref Pressures

This option displays the key pressure values used by the printer to maintain the correct ink
viscosity, and the maximum allowable system pressure. The example menu shown below
is for an Ultima printhead:
49230
PRESSURE REFS
> Printhead Ref : 184
Solvent Add : 188
Maximum Run : 255
Figure 5-10. Pressure Refs Menu

The values shown are for display purposes only and cannot be altered.
Printhead Ref
This is the printhead Reference Pressure value, which is unique to each individual
printhead, and is specified as part of the printhead code (and always expressed in bits)
found on the printhead conduit label. It also forms part of the code that is entered in the
Printhead Code option (Setup menu > Printhead Setup menu > Printhead Code option).
NOTE: The printhead Reference Pressure value is automatically adjusted whenever the
Head Height option is changed.
See also: Chapter 4: Setup Menu > Printhead Setup and Head Height options.
MP65557–1
Solvent Add
The Solvent Add Pressure is a reference pressure that the printer uses as a trigger to add
solvent. This Solvent Add Pressure value is different for each individual printhead, and is
calculated using the printhead Reference Pressure (normal running default pressure) with
an offset added. The Solvent Add Pressure offsets for each printhead type are:
Ultima 4 bits
Ultima plus 4 bits
The addition of solvent to maintain correct ink viscosity is dependent upon a number of
conditions, which must all be met before solvent can be added. The amount of solvent
added depends on the setting of the Ink Type Selection option in the SETUP menu.
Solvent Add Conditions

• TOF is within ±0.5% of Reference TOF
• Warm-up period has expired
• Solvent level is OK (i.e. the printer solvent level is above the minimum required and
See also: Chapter 3: Technical Description > Printhead Principles of Operation > Viscosity
Control.
Addition.
Sequences > Printhead Dependent Parameters Table.
Sequences > Ink Type Dependent Parameters Tables.
Chapter 4: Setup Menu > Ink Type Selection option.
Maximum Run
This is the maximum pressure that the printer uses to establish the jet and maintain the
TOF. The maximum pressures for the different printhead types are as follows:
Ultima 255 bits
Ultima plus 255 bits
See also: Chapter 3: Technical Description > Ink System > Startup and Shutdown
Sequences > Printhead Dependent Parameters Table.
5.3.15 Pressure Tracking

During normal operation (jet running), the Set Pressure value is automatically adjusted by
the system to maintain the correct TOF, i.e. with Pressure Tracking enabled.
For diagnostic purposes it may be required to alter the Set Pressure value while the jet is
running. If the Set Pressure were manually altered, the system would automatically
readjust the pressure back to maintain the correct TOF. In order to override this function,
the Pressure Tracking option can be disabled (set to Off) to allow the Set Pressure value to
be varied independently as required.
By default, Pressure Tracking is enabled during startup and disabled during shutdown.
MP65557–1
5.3.16 Set Pressure
When the printer is in a jet state, i.e. Jet Running or Ready to Print, this pressure value is set
and adjusted by the microprocessor to maintain the Time Of Flight (TOF) within the
control parameters. Alternatively, the value reflects the different pressures required by the
software for other sequences, e.g. startup and shutdown. This item allows the pressure to
be altered manually.
Set Pressure must be looked at in two ways. Firstly, when the jet is running, this option
displays the pressure required by the printer to obtain the correct TOF. During a particular
jet sequence, e.g. startup or shutdown, the display reflects the different pressure values
being used during the sequence. Thus, the Set Pressure item can be used to monitor the
progression of pressure changes of a particular sequence.
Secondly, when the jet is stopped, the Set Pressure option becomes a very powerful
diagnostic tool. It can be used to start and stop the pump. Also, it can aid ink system fault
diagnosis, providing that the pump is operating and ink is flowing through the venturi.
Under these conditions it provides a vacuum in the gutter line, which can be used to help
clear blockages or to flush out the printhead.
The Set Pressure option allows values in the range 0 to 255 bits to be set.
NOTE: 1 bit = 0.255 p.s.i.
255 bits = 65 p.s.i.
Typical diagnostic uses for setting a specific pressure are as follows:
• Diagnosing faults caused by pressure loss
• Cleaning the printhead
• Purging the main ink filter
• Varying the pressure when using the diagnostic Quick Start Jet option to try to obtain
TOF measurements, in order to ascertain whether the ink is of high or low viscosity.
See also: Pressure Tracking option; Set Pressure and Read Pressure (Monitor Jet screen);
Quick Start Jet option.
5.3.17 Modulation Tracking

The current Reference Modulation values (see Monitor Jet earlier in this section) are set as
defaults in terms of modulation/viscosity slopes. During normal operation (jet running)
the Modulation Tracking function is enabled (set to On). As the Set Pressure deviates from
the Reference Pressure, the modulation voltage is varied to track the Set Pressure by an
offset value (in V/bit) that is ink type and printhead dependent.
When Modulation Tracking is disabled (set to Off), the modulation is set to the Reference
Modulation, allowing the Set Pressure to be varied independently. By default, Modulation
Tracking is enabled during startup and disabled during shutdown.
See also: Set Modulation option.
Chapter 4: Setup Menu > Mod. Tracking Slope option.
5.3.18 Set Modulation

During normal operation (jet running) the Modulation Tracking function is enabled (set to
On) and operates as described above in ‘Modulation Tracking’.
For diagnostic purposes it may be required to alter the modulation voltage while the jet is
running. The Modulation Tracking option can be disabled (set to Off) to allow the Set
Modulation value to be varied independently as required.
See also: Modulation Tracking option; Modln (Monitor Jet screen).
MP65557–1
5.3.19 Filter Purge
When a new main ink filter is fitted, this option is used to pump ink through the filter to
purge it. The two settings are simply On and Off:
On
When set to On, the closed loop circuit runs the pump at a fixed pressure of 120 (30.59
p.s.i.) for 5 minutes to purge the new filter.
NOTE: Auto Power Down is disabled during Filter Purge.
Off
When Off is selected, the pressure is reset to zero to stop the purging process.
See also: Chapter 5: Maintenance > Maintenance Instructions > Main Ink Filter Purging.
5.3.20 Phase Fault

Under normal operating conditions the Phase Fault option is set to On (the default setting).
The printer monitors the operation of the jet for phase and TOF, and reports any errors that
are detected. These errors, in most instances, cause a print failure and the jet is
automatically shut down. In this situation fault diagnosis would be very difficult as it is
impossible to restart the jet to obtain the jet readings.
Phase Fault is used to switch the error detection function off so that the jet can be restarted
for diagnostic purposes, even though either the phase or TOF sensing functions may not be
operating correctly.
When the phase or TOF fault has been diagnosed and rectified using the diagnostics, it is
important that the Phase Fault function is set back to On, so that it can be confirmed that
phase or TOF faults are no longer being detected. However, the printer automatically
resets the Phase Fault option to On when the jet state is changed to Ready To Print using
the [start] or [F1] keys.
NOTE: If the Quick Start Jet option is used, the Phase Fault function is automatically
switched off, however, it is switched on again after the warm-up period has
elapsed. The warm-up period is ink type dependent—for the relevant timings,
refer to the ‘Ink Type Dependent Parameters’ tables in the ‘Ink System’ section of
‘Chapter 3: Technical Description’. If the jet has been stopped and then restarted,
but the printer has not been switched off, the Phase Fault function must be
manually set to On again.
See also: Quick Start Jet option; Monitor Jet option.
5.3.21 Phase Period

Under normal idle running conditions the printer alternately carries out phase and TOF
checks every 3 seconds, which equates to a Phase Period option setting of 30. This phase
interval can be altered in increments of 100 milliseconds. For diagnostic purposes it can be
useful to use a Phase Period setting of 1 (100 ms), which allows both phase cycle
waveforms to be observed on an oscilloscope (i.e. Phase with Phase Offset and Phase
without Phase Offset). Also, with a Phase Period setting of 1 the MONITOR JET screen
parameters are updated more frequently.
If the Phase Period is altered, it should be reset to the default value of 30 before leaving
diagnostics. However, the printer automatically resets the Phase Period option to 30 when
the jet state is changed to Ready To Print using the [start] or [F1] keys.
MP65557–1
5.3.22 Auto Phase
Under normal operating conditions the Auto Phase option is set to On (the default setting).
The printer automatically performs TOF measurements and adjusts the phase position to
give optimum drop charging conditions. The Off setting is not normally used.
See also: Phase option; Phase Offset option.
5.3.23 TOF Correction

Under normal operating conditions the TOF Correction option is set to On (the default
setting). The printer attempts to maintain the TOF within ±0.5% of the Reference TOF by
adjusting the pressure and adding solvent when necessary.
If it is necessary to set the TOF Correction option to Off for fault diagnosis purposes, the
printer will not perform any pressure adjustments or solvent additions to maintain the
correct TOF. It is important to remember to set the TOF Correction option back to On
when the TOF fault diagnosis has been completed. However, the printer automatically
resets the TOF Correction option to On when the jet state is changed to Ready To Print
using the [start] or [F1] keys.
5.3.24 TOF Warm Up

Under normal operating conditions the TOF Warm Up option is set to On (the default
setting). The printer uses only pressure adjustments to control the TOF during the initial,
predetermined period of operation when the printer may be cold and the ink thick.
Solvent addition occurs only after this warm-up period has elapsed. The warm-up period
is ink type dependent—for the relevant timings, refer to the ‘Ink Type Dependent
Parameters’ tables in the ‘Ink System’ section of ‘Chapter 3: Technical Description’.
If, for fault diagnosis purposes during the warm-up period, it is necessary to check that the
solvent addition function is operating correctly, this option can be set to Off to allow the
printer to add solvent.
The TOF Warm Up option is automatically enabled when the jet is started, therefore, it can
only be set to Off once the jet is running. It is important to remember to set the TOF Warm
Up option back to On when the TOF fault diagnosis has been completed.
Great care must be taken when running the printer with the TOF Warm Up option
switched off, as it is possible for too much solvent to be added to the ink, simply because
the ink is cold and therefore has a high viscosity.
See also: Ref Pressures option.
Chapter 3: Technical Description > Printhead Principles of Operation > Viscosity
Control.
Addition.
MP65557–1
5.3.25 Calibration
WARNING: LETHAL VOLTAGE. WHEN THE DAC CAL MODE IS SET TO ‘ON’,
UP TO 300 V DC IS APPLIED TO THE PRINTHEAD CHARGE ELECTRODE.
ENSURE THAT THE PRINTHEAD COVER TUBE IS CORRECTLY FITTED AND
THE SECURING SCREW IS FIRMLY TIGHTENED BEFORE CARRYING OUT THE
CHARGE CALIBRATION PROCEDURE. THERE IS A DANGER OF DEATH OR
INJURY FROM ELECTRIC SHOCK IF THE PRINTHEAD COVER TUBE IS NOT
SECURELY FITTED DURING THE CALIBRATION PROCEDURE.
NOTE: The Calibration option is available only when the jet is off (Idle).
The CALIBRATION menu is used to calibrate the Charge hardware and to enter various
calibration figures:
49231
CALIBRATION
> DAC Cal Mode : Off
DAC Cal Value : 1001
EHT Cal Value : 8.19
Saved Cal Value : 1001
Figure 5-11. Calibration Menu

NOTE: Refer to Maintenance Instruction ‘IPM PCB Calibration’ for details on how to
correctly carry out the Charge Amplifier Calibration procedure referred to in the
following description.
DAC Cal Mode

This option sets the charge DAC control system to calibration mode so that the charge
amplifier output voltage can be calibrated.
When the DAC Cal Mode option is set to On, a constant DC voltage is generated by the
charge DAC, allowing the charge voltage to be adjusted (see DAC Cal Value below).
Setting the DAC Cal Mode to Off, or exiting the CALIBRATION menu, resets the charge
DAC to normal mode for printing.
DAC Cal Value

Various values are entered in the range 800 to 1200, which adjust the charge DAC gain
until a output voltage from the charge amplifier circuit of 255 volts is obtained (measured
with a DVM). When this predetermined voltage has been reached, the DAC Cal Value that
obtained it is saved (see Saved Cal Value below).
EHT Cal Value

Each individual EHTPSU is pre-calibrated using the EHT Program Input voltage to give an
output of 8 kV ±1.7%. The calibration voltage (for example 8.19) is printed on a label
attached to the EHTPSU, and this value must be entered in the EHT Cal Value option.
Saved Cal Value

When the predetermined charge amplifier output voltage has been obtained (as described
in DAC Cal Value above), the value displayed in the DAC Cal Value option is then entered
in the Saved Cal Value option. This option is used to store the calibration value in Non-
Volatile RAM (NVR).
MP65557–1 Amdt 01
5.3.26 Alarm Test
This option is used to switch On and Off the alarm for test purposes, and can be used to
test any device fitted to the external alarm output.
See also: Chapter 4: Setup Menu > Alarm option.
5.3.27 Generate Test Pattern

Selecting this option generates a standard test pattern for each of the message types
available for the particular printer configuration. These test patterns should be used when
taking print samples during scheduled maintenance, after fault rectification, or when
checking for print quality problems.
Once the test patterns have been generated, the following message is displayed in the
status line:
“Test Patterns Generated”
The printer creates as many test patterns as possible dependent on the available message
storage capacity, which is a maximum of 50 messages. For example, if there are already 47
messages stored in the printer, only three test patterns can be produced. On completion of
the maintenance task, it is recommended that the test patterns are deleted to preserve
message storage capacity.
See also: System Config menu > Messages Stored option.
Test pattern messages are generated and stored with automatically allocated names
beginning with ‘Test’, followed by the message type name, for example, ‘Test16 Quality’.
For message types used with the Mini printhead only, in order to comply with the 15-
character restriction on message names, the test messages are not prefixed with ‘Test’ but
instead have the suffix ‘T’. For example, ‘4T 1x16 Q 0.85T’.
Up to 14 characters can be added to the test pattern, which for reference purposes would
normally include the printer and printhead serial numbers (for example, ‘AB123CD456’).
These characters are entered in the end portion of the pattern, immediately in front of the
automatically generated time and date.
To select and edit a test pattern in this manner, press the [F1] Change Message key from
the CURRENT MESSAGE screen to access the SELECT MESSAGE menu:
49232
SELECT MESSAGE
> Test16 Flexible
Test16 Quality
Test7 Flexible
Test7 Quality
Figure 5-12. Select Message Menu

It is recommended that the maximum available message height (raster) is used for test
purposes, which, with the Ultima printhead for example, is 16 Flexible, 16 Quality, 16
Speed or 16 Wide. The default Print Delay and Print Width settings are used. Select the
required test pattern by scrolling the menu using the up and down arrow keys, then press
[enter], which displays the MESSAGE OPTIONS screen:
49233
MESSAGE OPTIONS : Test16 Flexible

F1 : Edit
F2 : Select
F3 : Delete
Figure 5-13. Message Options Screen
Amdt 01 MP65557–1
Press the [F1] Edit key to access the EDIT MESSAGE screen. Press the right arrow key
while pressing and holding the [shift] key to reveal the end of the test pattern:
49234
EDIT MESSAGE : Test16 Flexible

TEST 0000000 dd.mm.yy hh:mm
F1 : Size 7 FH (Caps) F2 : Bold On

F3 : Field Type F4 : Save & Exit
Figure 5-14. Editing the Test Pattern in the Edit Message Screen
Enter the printer and printhead serial numbers in place of the zeros, immediately in front
of the time and date, then press [F4] Save & Exit. The edited test pattern is now ready for
printing.
5.3.28 System Flush

The System Flush option can only be selected when the jet is off, and is used to completely
flush the ink system in the following circumstances:
• Before packing for shipment or storage
• To remove contaminated ink
• To convert an ‘in use’ printer to a new ink, in readiness for calibration
• To prepare a ‘new’, unused printer with new ink, in readiness for calibration
This option has been designed for use primarily by the Linx production department to
make cleaning of the ink system more efficient during manufacture. However, it may be
used by service personnel but with limitations (see note below).
Selecting the System Flush option displays the following menu:
49290
SYSTEM FLUSH
> Flush Cycle / Tank Empty
Valve Dry
Figure 5-15. System Flush Menu

Prior to the system being flushed with solvent, all ink must be removed from the ink tank.
The procedure for carrying out both of these operations is self-explanatory, and prompts
are displayed in the status line at each stage to guide the operator through the process.
However, to ensure that the ink system is correctly and thoroughly flushed, it is
recommended that the ‘System Flush Procedure’ maintenance instruction (contained in the
‘Maintenance Instructions’ section of this chapter) be used.
IMPORTANT: The Valve Dry option in the SYSTEM FLUSH menu is for use only by the
Linx production department during manufacture, and is NOT to be used
by service personnel.
See also: Chapter 5: Maintenance > Maintenance Instructions > System Flush Procedure.
MP65557–1
5.3.29 Valve Test
This option allows the printhead and ink system valves to be operated by manual selection
from the keyboard to aid fault diagnosis:
49235
VALVE TEST
> Feed : Off
Purge : Off
Gutter : Off
Solvent Top-Up : Off
Solvent Flush : Off

Printhead Feed : Off
Figure 5-16. Valve Test Menu

The valve options are only selectable when the jet is off. When the printer is in the Jet
Running or Ready to Print states, the VALVE TEST menu shows only the current state of
the valves; they cannot be selected.
The up and down arrow keys are used to scroll to the valve to be tested. For the Purge,
Gutter, and Solvent Flush valves, pressing the [enter] key switches the valve on for 1
second after which it automatically switches off. If the [enter] key is held down, the valve
remains on until the key is released.
In the case of the Feed, Solvent Top-Up (Solvent Add), and Printhead Feed valves, pressing
the [enter] key switches the valve on for a maximum of 3 minutes after which it
automatically switches off. Exiting from the VALVE TEST menu using the [esc] key while
any of these valves are switched on also automatically switches them off.
The Set Pressure option can be used in conjunction with the Valve Test option to assist in
fault diagnosis.
NOTE: Selection of the Solvent Top-Up (Solvent Add) valve also activates the Feed and
Printhead Feed valves, therefore, if the pump is running (i.e. a Set Pressure has
been set), the jet will be started.
Sequences.
MP65557–1
5.4 Maintenance Instructions
5.4.1 Introduction
The following Maintenance Instructions are provided for use by Linx-trained and
-authorized service engineers when carrying out certain maintenance tasks on the Linx
4900 Ink Jet Printer. The primary instruction is the ‘Scheduled Maintenance’ procedure,
which is used for carrying out maintenance at the recommended intervals for the ink type
used. The purpose of scheduled maintenance is to eliminate possible future causes of
failure.
The remaining instructions detail various individual aspects of maintaining the printer. For
example, draining and flushing the ink system; replacing parts in the ink system; valve
tests; aligning the jet; calibrating the IPM PCB. Although these instructions can be used for
individual maintenance tasks, some of them are also referred to in the ‘Scheduled
Maintenance’ instruction and are carried out as part of that maintenance task.
5.4.2 Maintenance Terminology

Certain maintenance actions detailed in this section have specific meanings, which are
defined as follows:
Check Make a comparison of a measurement of time, pressure, temperature,
resistance, dimension or other quantity with a known figure for that
measurement.
Test Ascertain, by using the appropriate test equipment, that a component or
system functions correctly.
Examine Carry out a survey of the condition of an item. For example, the condition
of an item can be impaired by one or more of the following:
• Insecurity of attachment
• Cracks or fractures
• Corrosion, contamination or deterioration
• Distortion
• Loose or missing rivets
• Chafing, fraying, scoring or wear
• Faulty or broken locking devices
• Loose clips or packing; obstruction of, or leaks from pipelines
• Discoloration due to overheating or fluid leaks
Operate Make sure that an item or system functions correctly, as far as can be
ascertained without the use of test equipment or reference to
measurements.
Replenish Refill a tank, bottle or other container to a predetermined level or quantity,
and where necessary:
• Remove caps or covers from filler orifices and/or drains
• Clear orifices
• Make sure that drains are free from obstruction
• Make sure that gaskets and caps or covers are free from damage
• Refit caps or covers
• Fit locking devices as necessary
Fit Correctly attach one item to another.
Refit Fit an item that has previously been removed.
Replace Remove an item and fit a new or serviced item.
Disconnect Uncouple or detach electrical cables, pipelines or controls.
Reconnect Reverse of Disconnect.
MP65557–1 Amdt 01
5.4.3 Antistatic Precautions
As with all modern electronic circuits, the PCBs in Linx printers use some static-sensitive
components that can be severely damaged if subjected to static discharge. Static, which is
generated on the human body through friction and movement, is discharged through the
first contacted route to earth. Static damage is not always immediately apparent and can
cause component failure at any time after the static discharge has occurred. Therefore, it is
very important that Linx-trained and -authorized service engineers use the following
antistatic precautions when handling PCBs:
• An industry approved antistatic wrist strap must be worn, which incorporates a
resistive component (greater than 2 MΩ) in the lead, and must be connected to an
effective earth point. The continuity of the wrist strap and the earth point must be
checked regularly
• Always handle a PCB by its edge and do not touch the components or printed circuit
tracks. After removing a PCB from a printer or its packaging, it should be placed on a
static-dissipative mat
• Antistatic packaging should always be used for transporting PCBs and software
components. All Linx PCBs are shipped in special antistatic boxes and these should be
reused for any further transportation
5.4.4 Good Practice

After switching off the printer it is good practice to wait at least 30 seconds before
switching on again. This allows the capacitors to discharge adequately before being
powered-up again.
Amdt 01 MP65557–1
5.4.5 4900 CE Approval Checklist
CE approval for the Linx 4900 Ink Jet Printer depends on the criteria listed below. If the
printer is left in an unsatisfactory condition, the CE approval for the printer may be
invalidated. It is the responsibility of all service engineers, on every customer visit, to
ensure that the printer conforms to the following conditions in order that CE approval and
general safety are maintained.
Electronics
• Links LK4, LK6 and LK11 must NOT be left fitted on the IPM PCB
• The PCBs must have all of their securing screws fitted
• The fan must be connected to the LVPSU and must be functioning
Ink System
• The ink spillage detector must be fitted and connected
• The ink system drain plug must be fitted, have an O-ring seal and be firmly tightened
• Gland fittings from the printhead to the ink system enclosure, and from the ink system
enclosure to the electronics compartment, must be correctly fitted and secure
• The O-rings on the top of the ink and solvent filler tubes must be present and correctly
fitted
• The valve gaskets must be correctly fitted, and the valves and caps must be firmly
secured
• The pressure transducer connector and protective boot must be securely fitted
Printhead
• The earth lead between the printhead and the chassis must be securely connected
• The printhead cover tube must be correctly fitted and the securing thumb screw firmly
tightened
Cabinet
• EMC gaskets on the top cover must be intact and correctly fitted
• The keyboard and all its securing brackets and fixings must be correctly and securely
fitted
• Nothing must impede ventilation of the printer
• The external alarm connector (ALARM OUTPUT on the rear panel) earth stud and nut
must be connected
• The mains power cable protective earth (PE) connector must be securely connected to
the earth terminal in the cabinet. All other earth connections within the cabinet must
be securely connected
• The earth bonding lead between the top cover and the chassis must be connected.
• The top cover must be correctly engaged with the hinge bracket on the rear chassis,
and the cover latch must be firmly secured
• The ink and solvent caps must be securely fitted
MP65557–1
5.4.6 Scheduled Maintenance Checklist
The Scheduled Maintenance Checklist summarizes the ‘Scheduled Maintenance’
instruction and provides useful information about a printer’s history. An example of the
form is given at the end of the ‘Scheduled Maintenance’ instruction and it is intended for
use by Distributor Service Engineers. It should be completed by the Service Engineer each
time a Scheduled Maintenance is carried out on a printer and then filed with the printer’s
history documents.
NOTE: Linx Service Engineers should use the official Service Report form when carrying
out a printer Scheduled Maintenance.
If Distributors wish to use this form, Linx recommends that it is reproduced as a two-page
duplicate document. The top copy is the Customer Copy and the duplicate is the Service
Copy (printer history).
5.4.7 Maintenance Instruction Documents

Maintenance Instructions detailing the correct procedures for carrying out various
maintenance tasks on the 4900 printer are contained in the following pages. These
instructions are designed to be ‘stand-alone’ documents, which can be individually
removed and photocopied for independent use.
MP65557–1
4900 Maintenance Instruction
Scheduled Maintenance
Parts Required
FA65027 4200CE/4800/6800 Scheduled Maintenance Kit

comprising:
FA13004 Ink Dip Tube Assembly
FA72050 Feed Damper Assembly
FA73044 Main Ink Filter 10 µm
FA65026 4200CE/4800/6800 Basic Scheduled Maintenance Kit

comprising:
Additional Parts Required

FA73014 O-ring 7.66 x 1.78 EPDM—Pack as required
FA74135 M3 x 28 Csk Poz SS Screw—Pack as required
FA74136 Gasket Fluid Connector 3-way—Pack as required
FA74163 3-way Connector Replacement Filter
FA13178 Air Filter for IP55 (as necessary)
Equipment Required
FA65016 Scheduled Maintenance Tool Kit

comprising:
FA65007 Blanking Set 1/8 Union Fitting
FA65022 Fluid Connector 3-way—Service Accessories
FA65023 Pre-Pump Swage Tool
FA69012 Lubricant Small—Main Ink Filter
FA74005 Damper Drain Tube
FA65337 4800/6800 Dip Tube Removal Tool
FA79018 Tube PTFE 1/8 OD x 1/16 ID, Natural, 5 metres
FA79019 Tube PTFE 1/8 OD x 1/16 ID, Blue, 5 metres
FA79020 Tube PTFE 1/8 OD x 1/16 ID, Red, 5 metres
FA79021 Tube PTFE 6 mm OD x 4 mm ID, Natural, 5 metres
FA79022 Tube PTFE 3/16 OD x 1/8 ID, Natural, 5 metres
FA900003 Solvent Cleaning Bottle
FA900005 Beaker 0.25 Litre
FA940003 Eyeglass x9 Magnification
MP65557–1
Linx 4900 Maintenance Instruction 5 — 29 Nov 2003
FA940021 Syringe Polypropylene 50 ml

FA940029 Solvent-resistant Cleaning Brush
FA940067 Double-Ended Trim Tool
FA999045 Gloves Latex Medical (large)
FA999076 Safety Spectacles Blue
Additional Equipment Required

FA72150 Fluid Connector 3-way—Service Accessories—Pigmented
FA74046 Nozzle Cleaning Service Accessory
FA16005 4900 Cover Removal Tool
FA65339 Mandrel Extraction Tool
FA940052 Tube Cutter Plastic 4 mm–14 mm
FA100007 Tube PTFE 6 mm OD x 4 mm ID, Coil 25 mm ID, 5 metres (Spectrum
printer only)
FA999046 Gloves Latex Medical (medium) ) as required
FA999047 Gloves Latex Medical (small) ) as required
FA999066 Gloves Latex Powder-Free (small) ) where recommended
FA999067 Gloves Latex Powder-Free (medium) ) where recommended
FA999068 Gloves Latex Powder-Free (large) ) where recommended
Antistatic Wrist Strap and Lead
DVM (Digital Voltmeter)
Tweezers
Waste ink container (at least 5 litres capacity)
Beaker, stainless steel or glass
Absorbent, lint-free paper towel
Recording
Raise and complete a Scheduled Maintenance Checklist (not applicable to Linx Service
Engineers). An example of the document is provided at the end of this Scheduled
Maintenance instruction.
MP65557–1
Nov 2003 5 — 30 Linx 4900 Maintenance Instruction
Procedures

DERMATITIS.
1 Speak to the operators and enquire if there are any problems with the printer’s
performance.
2 Record the printer model and serial number, and the printhead type and serial
number.
3 Record the printhead calibration code and Reference Modulation taken from the
printhead conduit label. Record these same parameters from the PRINTHEAD
SETUP menu and MONITOR JET screen, respectively.
4 Shut down and switch off the printer. Ensure that it is switched off at the mains
supply.
5 Examine the printhead conduit for damage and ensure that it is secured correctly
at the terminating bushes.
6 Examine the mains supply cable for damage and ensure that the connector is in
good condition and correctly connected. Replace as necessary.
7 Remove the printhead cover tube. Examine the printhead and components for
damage or obvious misalignment.
8 Clean the printhead using the correct solvent for the type of ink being used. If
the printer uses a pigmented ink, carry out the procedure detailed in maintenance
instruction ‘Printhead Cleaning for Pigmented Inks’.
9 Switch the printer on and start the jet. Record all of the required data from the
MONITOR JET and SYSTEM TIMES screens (Setup menu > Diagnostics menu).
Observe and record any fault or warning messages.
10 Shutdown the jet and switch off the printer.
11 Drain the ink from the ink system. Refer to maintenance instruction ‘Draining
the Ink System’.
12 Pigmented ink printers only:
(a) Remove the ink tank.
(b) Half fill the tank with clean solvent (of the correct type) and leave to stand in
a suitable container for 10 minutes to allow the pigment and conductive salts
to soften.
(c) Rinse out the tank with solvent until all deposits have been removed.
(d) Wash the outside of the tank using solvent and the Solvent Cleaning Bottle.
(e) Invert the tank in the container and leave to drain and dry before refitting.
MP65557–1
13 Remove the mandrel and filter assemblies from the ink and solvent filler tubes
using the Mandrel Extraction Tool. Examine the filters and filler tubes for any
debris (for example, foil seals from ink or solvent bottles) and remove if found.
Refit the mandrel and filter assemblies.
14 Replace the ink dip (pick-up) tube, which includes the in-line filter. Refer to
maintenance instruction ‘Ink Dip Tube Replacement’. This replacement should
be carried out at every Scheduled Maintenance.
15 Ensure that the ink system vent pipe is not blocked or obstructed with debris or
dried ink. Unblock and clean as necessary.
16 The damper should be replaced annually. Determine when the damper was last
replaced, and replace it if it is between 12 and 18 months old. A ‘damper
replacement date’ label is supplied with the replacement damper kit, which
should be filled in and stuck to the front of the ink system enclosure.
17 Examine the ink system tubing for trapping and kinks. Replace any damaged
tubing.
18 Replace the filter in the 3-way fluid connector (pigmented ink printers only).
Refer to maintenance instruction ‘3-way Fluid Connector Filter Replacement’.
19 Refill the ink system using two 0.5-litre bottles of new ink. Ensure the ink is the
correct type for the printer type.
20 Replace the main ink filter. Refer to maintenance instruction ‘Main Ink Filter
Replacement’.
21 Purge the main ink filter. Refer to maintenance instruction ‘Main Ink Filter
Purging’.
22 Examine the wiring and connectors within the electronics compartment and to the
Display PCB for trapping and signs of abrasion. Replace any damaged cables.
23 Remove the air filter as shown in Figure 1. The filter should be cleaned using
compressed air blown through in the reverse direction to the normal airflow, and
refitted. Examine the filter and replace it if it is severely blocked or damaged.
Ensure that the new filter is fitted with the metal side facing down.
49143
Figure 1. Removing the Air Filter
MP65557–1
24 Examine the printer for any loose hardware and secure as necessary.
CAUTION: The PCBs contain static-sensitive devices. Antistatic precautions must be

taken when handling the PCBs. An antistatic wrist strap must be worn and be
connected to an effective earth point. Always handle the PCBs by their edges and do
not touch the components, printed circuit tracks or connector pins.
25 Examine the PCBs for physical damage, signs of arcing between high and low
voltage tracks, and ink contamination. Rectify any faults. Clean off any dust or
debris from the PCBs using a soft brush.

MUST BE TAKEN WHEN MAKING ANY INTERNAL ADJUSTMENTS WHILE
POWER IS APPLIED TO THE PRINTER. THE CORRECT, STANDARD
ELECTRICAL SAFETY PRECAUTIONS MUST BE TAKEN. THERE IS A DANGER
OF DEATH OR INJURY FROM ELECTRIC SHOCK IF THE CORRECT
ELECTRICAL SAFETY PRECAUTIONS ARE NOT TAKEN.
26 Calibrate the IPM PCB. Refer to maintenance instruction ‘IPM PCB Calibration’.
27 Perform printhead valves tests. Refer to maintenance instruction: ‘Printhead
Valves Tests’.
28 Ensure that the jet is correctly aligned. Refer to maintenance instruction ‘Jet
Alignment and Nozzle Cleaning’.
29 Start the printer (as necessary) and record the parameters displayed in the
MONITOR JET screen (Setup menu > Diagnostics menu).
30 While observing the printhead, shut down and then restart the jet using the [stop]
and [start] keys. Repeat the shutdown/startup operation four times, monitoring
the time taken to start up, and recording all the parameters and times taken. Both
the shutdown and startup should be clean. If any startup takes longer than
nominally 2 minutes, check for any associated fault or warning messages and
investigate the cause of the problem.
31 Take print samples using the standard test message and record the calculated Ref
Modulation on the Scheduled Maintenance Checklist. Refer to maintenance
instruction ‘Modulation Range Checks’.
32 Remove the printhead cover tube and reconfirm correct jet alignment. Refer to
maintenance instruction ‘Jet Alignment and Nozzle Cleaning’.
33 Refit the printhead cover tube ensuring that the securing screw is fully tightened.
34 Ensure that the printer conforms to the required conditions for CE approval.
Refer to the ‘4900 CE Approval Checklist’ provided at the beginning of this
‘Maintenance Instructions’ section.
MP65557–1
35 In the SYSTEM TIMES menu (Setup menu > Diagnostics menu), reset the Service
(Hours) time to the recommended maintenance interval for the ink type used in
the printer.
36 Run the printer for 30 minutes, taking print samples every 10 minutes using the
standard test message. Record the calculated Reference Modulation on the
Scheduled Maintenance Checklist. Refer to maintenance instruction ‘Modulation
Range Checks’.
37 Run the printer ‘on line’ and advise the operator or production manager of any
specific points relating to the operation of the printer, its location, or the mounting
of the printhead. Record any advice given on the Service Report form.
38 Ensure that the printer top cover is securely refitted.
39 Clean the printer top cover and base unit.
40 On completion of the scheduled maintenance ensure that the customer signs the
Service Report form.
41 Ensure that all print samples are retained with the Service Report form.
42 The ‘Scheduled Maintenance’ maintenance instruction is now complete.
MP65557–1
SCHEDULED MAINTENANCE CHECKLIST
CUSTOMER DATE CALL NUMBER
PRINTER MODEL PRINTER SERIAL No.
PRINTHEAD TYPE PRINTHEAD SERIAL No.
PRINTHEAD CAL. CODE (CONDUIT) REF MOD PRINTHEAD CAL. CODE (PRINTER) REF MOD
POWER ON TIME (HRS) TOTAL JET RUNNING TIME (HRS) TOTAL
POWER ON TIME (HRS) PRESENT JET RUNNING TIME (HRS) PRESENT
ITEM ✔ ITEM ✔
• Speak with Operators to determine any problems • Examine for loose hardware
• Record printer and printhead details • Remove, examine, clean and refit PCBs
• Examine conduit/supply cable • Calibrate PCB(s)
• Examine and clean printhead • Perform valve tests
• Start printer and record data • Ensure correct jet alignment
Pressure TOF Phase Solvent Read Pressure TOF Phase Solvent Read
steady? Add Pressure steady? Add Pressure
• Drain ink system • Start printer and record jet parameters

• Clean ink tank (pigmented inks only) • Stop/start checks
• Examine ink/solvent filler tubes for debris • Perform Mod range checks with print samples
• Replace pre-pump filter (N/A* to 4900 & 6800)p • Record calculated Ref Mod value ➨
• Replace ink dip tube (N/A* to 6200 & Spectrum) • Reconfirm jet alignment
• Replace damper • Reset Service/Maintenance time interval
• Replace solvent pick-up filter (N/A* to 4900 & 6800) • Perform Mod range checks with print samples
• Examine ink system tubing • Record calculated Ref Mod value ➨
• Replace 3-way fluid connector filter (pig. inks only) • Run printer ‘on line’ and advise operator
• Refill ink system • Refit and secure top cover and all screws
• Replace main ink filter • Clean printer top cover and base unit
• Examine electronics wiring and connectors • Complete paperwork
• Clean/replace air filter
* N/A = Not Applicable
CUSTOMER’S SIGNATURE
NAME
SIGNATURE
Issue 7 Sep 03
MP65557–1
MP65557–1
Printhead Cleaning for Pigmented Inks
Equipment Required
FA81505/5L General Purpose MEK 1505
FA940029 Solvent-resistant Cleaning Brush
FA999066 Gloves Latex Powder-Free (small) )
FA999067 Gloves Latex Powder-Free (medium) ) as required
FA999068 Gloves Latex Powder-Free (large) )
Introduction
This maintenance instruction details the procedure for cleaning printheads fitted to
printers that use the following pigmented inks:
• Black Pigmented Ink 1009
• Yellow Pigmented Ink 1039
• White Pigmented Ink 1059
• Brilliant White Ink 1305
Linx recommends that the printhead should be checked daily for ink build-up and
cleaned if necessary. It should also be cleaned at intervals of 1 working week using a non-
abrasive, solvent-resistant brush (FA940029).

DERMATITIS.
CAUTION: Contamination of the Printhead Nozzle Assembly. It is recommended that
powder-free latex gloves be worn to avoid introducing any contamination into the
printhead nozzle assembly. If the standard non-powder-free gloves are worn during
this procedure, contamination could be introduced into the printhead nozzle assembly,
which could result in print failures.
MP65557–1
Procedure
supply.
2 Remove the printhead cover tube.
CAUTION: Ensure solvent is the correct type for the printer. Do not wash the nozzle
with solvent unless it is blocked or obstructed with ink. NEVER BRUSH THE
NOZZLE.
3 Hold the printhead over a beaker, as shown in Figure 1, and wash the area
(shown circled) from the charge electrode downwards with solvent.
68123
MIDI -PLUS
WASH THIS
AREA ONLY
Figure 1. Correct Area of the Printhead to Wash with Solvent
MP65557–1
4 Use the brush to gently remove any ink deposits that will not wash off from the
circled area shown in Figure 1, paying particular attention to the deflector plates
(Figure 2). Do not use the brush to clean the nozzle.
68124
MIDI -PLUS
CLEAN ONLY THIS

AREA WITH THE BRUSH.
DO NOT USE THE BRUSH
ON THE NOZZLE
Figure 2. Correct Area of the Printhead to Clean with the Brush

CAUTION: Black pigmented ink 1009 contains carbon particles. It is particularly
important to ensure that ALL traces of carbon are removed from the printhead surface
around the charge electrode and between the deflector plates. If these areas are not
thoroughly cleaned, the residual carbon can cause short circuits, which may damage the
printhead.
5 Alternately, wash and then gently brush the circled area of the printhead (Figure
2), finishing with a wash when all the ink deposits have been removed. Only use
new solvent. Do not recycle the solvent.
6 Allow the printhead to dry.
MP65557–1
7 Wash the inside of the printhead cover tube with solvent, as shown in Figure 3,
until all ink has been removed. Use the brush, where possible, to remove ink
deposits that do not immediately wash off. Finish the cleaning with a wash and
allow the cover tube to dry.
Figure 3. Washing the Printhead Cover Tube with Solvent

8 Refit the printhead cover tube and firmly tighten the knurled securing screw.
9 The ‘Printhead Cleaning for Pigmented Inks’ maintenance instruction is now
complete.
MP65557–1
Draining the Ink System
Equipment Required
FA999045 Gloves Latex Medical (large) )
FA999047 Gloves Latex Medical (small) )
Waste ink container (at least 5 litres capacity)
Procedure

DERMATITIS.
supply.
2 Remove the ink and solvent filler caps.
3 Unlock the security latch on the front of the top cover and remove the cover.
Position the cover so that the keyboard and display can be accessed.
4 Temporarily refit the solvent filler cap to reduce evaporation of the solvent.
5 Switch on the printer and access the SYSTEM FLUSH menu (Setup menu >
Diagnostics menu):
49290
SYSTEM FLUSH
Valve Dry
Figure 1. System Flush Menu: Process Options

NOTE: The Valve Dry option is for use only by Linx during the manufacturing
process and is NOT to be used by service personnel.
MP65557–1
6 Select the Flush Cycle / Tank Empty option. The following menu is displayed
with the instruction “Check Solvent OK” in the status line:
49329
SYSTEM FLUSH
> OK
Quit
Check Solvent OK
Figure 2. System Flush Menu: “Check Solvent OK” Instruction

7 To continue with the System Flush procedure (and therefore the Empty Tank
sequence) it is necessary to perform a number of actions on the printer before the
flushing cycles can begin. These required actions are displayed in the status line,
and should be performed in accordance with the following expanded
explanations for each instruction. Once each action has been completed, select the
OK option by pressing the [enter] key, which displays the next instruction.
NOTE: To return to the initial SYSTEM FLUSH menu, select the Quit option and press the
[enter] key. To return to the DIAGNOSTICS menu (System Flush option), press
the [esc] key.
8 Check Solvent OK. This action is not applicable when only draining the ink
system. Press the [enter] key to proceed to the next instruction.
9 Prop Up Printer. Before commencing the ink draining procedure, the printer
must be raised by approximately 50 mm at the front left-hand side to aid drainage
of the ink, as the ink dip tube is situated at the rear right-hand side of the tank.

MUST BE TAKEN WHEN WORKING ON THE PRINTER WHILE POWER IS APPLIED
TO IT AND THE TOP COVER IS REMOVED. THE CORRECT, STANDARD
ELECTRICAL SAFETY PRECAUTIONS MUST BE TAKEN. THERE IS A DANGER OF
DEATH OR INJURY FROM ELECTRIC SHOCK IF THE CORRECT ELECTRICAL
10 Orientate Filter and Damper. Ignore the instruction regarding the filter.
Carefully lift the feed damper clear of the ink system enclosure. Hold the feed
damper in the vertical position with the drain cap uppermost.
MP65557–1
11 Connect Bleed Line To Damper. Remove the damper drain cap and connect the
Damper Drain Tube Luer fitting (included in the Damper Drain Tube kit) to the
damper drain. Insert the other end of the drain tube into a waste container of at
least 5 litres capacity. Orientate the damper so that the drain is at the bottom, i.e.
at its lowest position, as shown in the following illustration:
68050
Drain Tube
Figure 3. Feed Damper Orientation with Drain Tube Connected

12 Turn On Tap On Bleed Line. The bleed line tap is used in the Linx
manufacturing process only. There is no bleed line in the service engineer’s
Damper Drain Tube kit, therefore, any action referring to the bleed line tap should
be ignored. Simply press the [enter] key to continue the procedure.
13 When all the required actions have been completed, the following menu is
displayed:
49330
SYSTEM FLUSH
> Empty Tank
Access Flushing Cycle
Solvent Drain
Flush Count : 0
Quit
Figure 4. System Flush Menu: Sequence Options
MP65557–1
CAUTION: Pump damage. Do not allow the ink system pump to run dry. Initiate the
Empty Tank sequence only the number of times required to empty the system of ink.
The pump must not be run for longer than 30 seconds after it becomes noisy through
cavitation (ink starvation). Damage to the pump will result if it is allowed to run
continuously in a dry condition.
14 Select the Empty Tank option, which starts the pump and displays the following
screen with the “Empty Tank In Progress…” message displayed in the status line.
The pump will run at maximum pressure for approximately 1 minute and 40
seconds, and then automatically stop on completion of the Empty Tank sequence.
Select the Stop option if the audible pitch of the pump changes indicating that the
ink tank is empty:
49331
SYSTEM FLUSH
> Stop
Empty Tank In Progress...
Figure 5. System Flush Menu: “Empty Tank In Progress…”

15 At some point towards the end of the Empty Tank sequence the ‘ink low’
condition should be reached. Ensure that the System Warning message “3.03 Ink
Low” is displayed in the status line.
16 On completion of the Empty Tank sequence, the display reverts to the sequence
options menu (Figure 4).
17 If the tank is not empty after a single Empty Tank sequence, select the Empty
Tank option again to repeat the sequence. Select the Stop option when the audible
pitch of the pump changes indicating that the ink tank is empty.
18 Disconnect the drain tube from the damper and refit the drain cap.
19 Reposition the damper back in its original location in the ink system enclosure.
20 The ‘Draining the Ink System’ maintenance instruction is now complete.
MP65557–1
Ink Dip Tube Replacement
Parts Required
FA79021 Tube PTFE 6 mm OD x 4 mm ID, Natural, 5 metres
Equipment Required
FA69012 Lubricant Small—Main Ink Filter
FA65337 4800/6800 Dip Tube Removal Tool
Abrasive paper
Introduction
The ink dip (pick-up) tube has an integral 40 µm, stainless steel, in-line filter fitted inside
the tube. The dip tube and filter, together with relevant O-rings, come ready assembled in
the spare part pack. A compression fitting is also included.
48216
Figure 1. Ink Dip (Pick-up) Tube and Filter Assembly

This maintenance instruction details the procedure for the replacement of the ink dip tube
and filter assembly, which should be carried out at every Scheduled Maintenance.
MP65557–1
Procedure

DERMATITIS.
supply.
Position the cover so that the keyboard can be accessed.
4 Temporarily refit the ink and solvent filler caps to reduce evaporation of the ink
and solvent.
5 Place absorbent, lint-free paper towel around the area of the ink dip tube to
contain any ink that might be spilt.
6 Remove the dip tube from the ink tank using the Dip Tube Removal Tool. Note
that the dip tube is not threaded but is a push fit.
7 Unscrew the ink dip tube compression fitting and disconnect the ink pick-up pipe.
Discard the compression fitting and the dip tube.
8 Prepare the end of the ink pick-up pipe by cutting off the portion previously
compressed by the compression fitting and containing the steel insert
(approximately 20 mm). Use the Tube Cutter to ensure the pipe is cut clean and
straight.
9 Remove the stainless steel insert from the cut portion of pipe and push it back into
the pick-up pipe until it is flush with the end. (It may help to grip the pipe if it is
held in a piece of abrasive paper.)
10 Slide the new compression fitting onto the ink pick-up pipe. Insert the pipe into
the new dip tube outlet and slide the compression fitting down to the dip tube
connection.
11 Apply two drops of thread assembly lubricant to the dip tube threads and screw
the compression fitting firmly onto the connection.
MP65557–1
12 Lightly lubricate the two O-rings fitted to the neck of the new dip tube assembly
with thread assembly lubricant. Fit the dip tube to the ink tank by pushing it
firmly into place.

MUST BE TAKEN WHEN WORKING ON THE PRINTER WHILE POWER IS
APPLIED TO IT AND THE TOP COVER IS REMOVED. THE CORRECT,
STANDARD ELECTRICAL SAFETY PRECAUTIONS MUST BE TAKEN. THERE IS
A DANGER OF DEATH OR INJURY FROM ELECTRIC SHOCK IF THE CORRECT
NOTE: If the ink tank dip tube replacement is being done as part of the Scheduled
Maintenance, there will be no ink in the tank at this point. Therefore, the
following leak check must be carried out at a later stage in the Scheduled
Maintenance once the tank has been refilled with ink.
13 Reconnect the printer to the mains supply and switch on the printer.
14 Start the jet and examine the dip tube compression fitting for leaks.
15 Shut down and switch off the printer.
16 Remove any absorbent material from the ink system.
18 Refit the top cover and secure the locking latch.
19 Refit the ink and solvent filler caps.
20 The ‘Ink Dip Tube Replacement’ maintenance instruction is now complete.
MP65557–1
MP65557–1
3-way Fluid Connector Filter Replacement
Parts Required
FA74163 3-way Connector Replacement Filter (Ultima printhead)
FA74189 3-way Connector Replacement Filter (Ultima plus printhead)
Equipment Required
Tweezers
Procedure

SOLVENT-RESISTANT PROTECTIVE GLOVES MUST BE WORN THROUGHOUT
THE FOLLOWING PROCEDURE. FAILURE TO COMPLY WITH THIS SAFETY
WARNING COULD RESULT IN IRRITATION AND REVERSIBLE LOCAL DAMAGE
TO THE EYES, AND NON-ALLERGIC CONTACT DERMATITIS.
supply.
and solvent.
5 Carefully lift the 3-way fluid connector clear of the ink system enclosure.
6 Place absorbent, lint-free paper towel under the 3-way fluid connector to contain
any ink that might be spilt.
MP65557–1
7 Unscrew and remove the 3-way fluid connector assembly screw and separate the
two parts of the connector (see Figure 1):
68053
Assembly Filter
screw
O-ring gasket
Locating
lug
Locating
recess
Figure 1. 3-way Fluid Connector Disassembled

8 Remove and discard the old O-ring gasket from the fluid connector.
9 Remove and discard the old filter from inside the larger of the two parts of the
fluid connector, using the thicker, grooved end of the plastic insert/extract tool
supplied with the new filter.
CAUTION: Contamination of the 3-way Fluid Connector Filter and O-ring. Extreme
care must be taken when handling the new filter and O-ring gasket to avoid
introducing any contamination. They must not come into contact with any fibres, and
skin contact should be avoided. It is recommended that powder-free latex gloves be
worn. Handling of the new parts must be performed carefully using a pair of tweezers.
The procedure must also be carried out in a clean, dust free environment. If a Clean
Room is available, then it should be used.
10 Remove the new filter from its protective bag and examine it for any damage and
contamination.
11 Insert the new filter fully into the fluid connector using the thinner, smooth end of
the insert/extract tool supplied with the new filter.
12 Remove the new O-ring gasket from its protective bag and examine it for any
damage and flash.
13 Using the tweezers, carefully position the new O-ring gasket in the shaped recess
in the larger part of the fluid connector.
14 Fit and hold the two parts of the fluid connector together, making sure that the
locating lug and recess are correctly aligned.
MP65557–1
15 Refit and fully tighten the fluid connector assembly screw.

NOTE: If the 3-way fluid connector filter replacement is being done as part of the
Scheduled Maintenance, there will be no ink in the tank at this point. Therefore,
the following jet alignment, nozzle cleaning, and leak check must be carried out at
a later stage in the Scheduled Maintenance once the tank has been refilled with ink.
16 Carry out the ‘Jet Alignment and Nozzle Cleaning’ maintenance instruction,
checking the 3-way fluid connector for leaks at the same time.
17 Remove any absorbent material from the ink system enclosure and reposition the
3-way fluid connector back in its original location.
21 The ‘3-way Fluid Connector Filter Replacement’ maintenance instruction is now
complete.
MP65557–1
MP65557–1
Main Ink Filter Replacement
Parts Required
Equipment Required
FA69012 Lubricant Small—Main Ink Filter (for use on pre-LOT #087 filters only)
Abrasive paper
Introduction
This maintenance instruction details the procedure for replacing the main ink filter with
the new style filter, on the 4900 printer.
New style filters marked with a LOT number earlier than LOT #L087 are to have the
assembly lubricant FA69012 applied to the fluid connections, as described in the following
procedure. Filters with a post-LOT #L087 number are pre-lubricated and therefore do not
require the application of assembly lubricant.
MP65557–1 Amdt 01
Linx 4900 Maintenance Instruction 5 — 53 Jan 2006
Procedure

THIS SAFETY WARNING COULD RESULT IN SEVERE IRRITATION AND
TEMPORARY (REVERSIBLE) EYE DAMAGE, AND NON-ALLERGIC CONTACT
DERMATITIS.
supply.
and solvent.
5 Carefully lift the main ink filter clear of the ink system enclosure.
6 Place absorbent, lint-free paper towel under the main ink filter and venturi
manifold to contain any ink that might be spilt.
7 Remove the new filter, two lengths of pipe and two stainless steel inserts from
their packaging.
8 Cut the two lengths of pipe to the following lengths (if necessary), using the Tube
Cutter to ensure they are cut cleanly and straight:
120 mm (for the older ‘380’ model motor fitted to the pump/motor assembly)
OR
230 mm (for the new ‘I-Drive’ model motor fitted to the pump/motor assembly)
AND
185 mm
9 Push a stainless steel insert into one end of each of the two lengths of pipe
ensuring that the inserts are pushed in flush with the end of the pipes.
Amdt 01 MP65557–1
Jan 2006 5 — 54 Linx 4900 Maintenance Instruction
10 Remove the nuts, grippers and sleeves from both sides of the new filter and fit
them over the steel insert ends of the pipes, in the correct order (see Figure 1):
Insert Sleeve Gripper Nut

6203
Figure 1. Correct Assembly of the Main Ink Filter Fluid Connections

11 Insert the 120 mm or 230 mm pipe (refer to step 8) into the inlet port of the new
filter until it meets the pipe stop inside the elbow. Do not push the pipe past the
pipe stop.
12 Pre-LOT #L087 filters only. Apply two drops of assembly lubricant to the threads
of the filter inlet elbow (see Figure 2):
6223
Figure 2. Applying Thread Lubricant to Pre-LOT #L087 Main Ink Filter Fluid Connections
MP65557–1 Amdt 01
13 Push the sleeve, gripper and nut up to the elbow and screw the nut on until finger
tight.
14 Mark the nut on one face and, using a spanner, tighten it two full turns only. Note
that if the nut reaches the end of the threaded portion of the elbow, the nut has
been over tightened and there is a risk of the elbow shearing.
15 Repeat steps 11 to 14 for the outlet port of the new filter using the 185 mm pipe
(refer to step 8).
16 Unscrew and disconnect the fluid connection from the inlet port (pump side) of
the old filter.
17 Hold the disconnected end of the filter, and pull off the glove from the hand
holding the filter so that the glove turns inside out over the filter (see Figure 3). Fit
a new glove on bare hand.
68051
Figure 3. Enclosing One End of the Main Ink Filter with a Rubber Glove
18 Unscrew and disconnect the fluid connection from the pump outlet. Discard the
pipe but retain the blue Festo nut and pipe elbow support.
Amdt 01 MP65557–1
19 Unscrew and disconnect the fluid connection from the outlet port (manifold side)
of the old filter.
20 Hold the disconnected end of the filter, and pull off the glove from the hand
holding the filter so that the glove turns inside out over the filter. Both ends of the
filter are now enclosed in gloves (see Figure 4). Dispose of the old filter and fit a
new glove on bare hand.
68052
Figure 4. Both Ends of the Main Ink Filter Enclosed in Rubber Gloves
21 Unscrew and disconnect the fluid connection from the venturi manifold inlet.
Discard the pipe but retain the blue Festo nut and pipe elbow support.
22 Fit the blue Festo nut that was removed from the venturi manifold over the end of
the new filter outlet pipe. Push the pipe onto the manifold connection (it may help
to grip the pipe with a piece of abrasive paper). Screw the Festo nut firmly onto
the manifold connection.
23 Fit the blue Festo nut that was removed from the pump over the end of the new
filter inlet pipe. Push the pipe onto the pump connection (it may help to grip the
pipe with a piece of abrasive paper). Screw the Festo nut firmly onto the pump
connection. Refit the pipe elbow support.
24 Remove any absorbent material from the ink system enclosure and position the
new main ink filter in its original location.
28 The ‘Main Ink Filter Replacement’ maintenance instruction is now complete.
MP65557–1 Amdt 01
Amdt 01 MP65557–1
MP65557–1 Amdt 01
Amdt 01 MP65557–1
IPM PCB Calibration
Equipment Required
FA940067 Double-Ended Trim Tool
Antistatic Wrist Strap and Lead
DVM (Digital Voltmeter)
Introduction
If either the IPM PCB or the Pressure Transducer is replaced, the electronics system must
be recalibrated. If the software alone is changed, the non-volatile RAM is reinitialized,
which causes the calibration values to be reset to the default values. Therefore, before the
software is changed, the Saved Cal Value should be noted from the CALIBRATION menu
(Setup menu > Diagnostics menu) and then re-entered after the software has been
changed. This also applies to the EHT Cal Value, which is displayed in the same menu.
The following procedures detail how to calibrate the Pressure Transducer and Charge
Amplifier, both of which must be carried out in the above circumstances.
NOTE: This maintenance instruction details a static calibration procedure. During
manufacture a dynamic calibration procedure is used, therefore, there may be a
difference in calibration settings when new printers are received. New printers
should not be recalibrated on receipt.
Procedures

MUST BE TAKEN WHEN MAKING ANY INTERNAL ADJUSTMENTS WHILE
POWER IS APPLIED TO THE PRINTER. THE CORRECT, STANDARD
ELECTRICAL SAFETY PRECAUTIONS MUST BE TAKEN. THERE IS A DANGER
OF DEATH OR INJURY FROM ELECTRIC SHOCK IF THE CORRECT
CAUTION: The PCBs contain static-sensitive devices. Antistatic precautions must be

taken when handling the PCBs. An antistatic wrist strap must be worn and be
connected to an effective earth point. Always handle the PCBs by their edges and do
not touch the components, printed circuit tracks, or connector pins.
MP65557–1 Amdt 01
IPM PCB Calibration
Pressure Transducer Calibration

1 Ensure that the printer is switched off at the mains supply.
Position the cover so that the IPM PCB and the keyboard can both be accessed.
and solvent.
5 Switch on the printer.
6 Set the Digital Volt Meter (DVM) to DC Volts. Connect the DVM negative lead to
a convenient 0 V test point on the IPM PCB (for example, TP13 or TP15) and the
positive lead to TP5 (RD PRESS).
7 Turn VR2 on the IPM PCB anticlockwise (using the Double-Ended Trim Tool)
until the DVM reading is greater than 1 volt.
8 Turn VR2 slowly clockwise until a reading of +20 millivolts is achieved, with a
tolerance of ±2 millivolts.
9 Switch off the printer.
10 Disconnect the DVM.
11 The pressure transducer calibration is now complete.
Charge Amplifier Calibration

12 Switch the printer on.
IMPORTANT: Leave the printer switched on for at least 30 minutes before proceeding
with the following calibration.
Charge at Zero
13 Connect the DVM negative lead to a convenient 0 V test point (for example, TP13
or TP15) and the positive lead to test point TP9 (CHG).
14 Adjust VR1 on the IPM PCB to give a reading as close to 0 volts as possible with a
tolerance of ±0.5 volts. Leave the DVM connected to these test points.
Charge at Full Scale
WARNING: LETHAL VOLTAGE. WHEN THE DAC CAL MODE IS SET TO ‘ON’,
UP TO 300 V D.C. IS APPLIED TO THE PRINTHEAD CHARGE ELECTRODE.
MAKE SURE THAT THE PRINTHEAD COVER TUBE IS CORRECTLY FITTED
AND THE SECURING SCREW IS FIRMLY TIGHTENED BEFORE CARRYING
OUT THE CHARGE CALIBRATION PROCEDURE. THERE IS A DANGER OF
DEATH OR INJURY FROM ELECTRIC SHOCK IF THE PRINTHEAD COVER
TUBE IS NOT SECURELY FITTED DURING THE CALIBRATION PROCEDURE.
Amdt 01 MP65557–1
IPM PCB Calibration
15 Access the CALIBRATION menu (Setup menu > Diagnostics menu):

49231
CALIBRATION
> DAC Cal Mode : Off
DAC Cal Value : 1001
EHT Cal Value : 8.19
Saved Cal Value : 1001
Figure 1. Calibration Menu

16 Press the [enter] key to select the DAC Cal Mode option setting. Set it to On using
the left or right arrow key, then press the [enter] key again.
17 Check that the DVM reading is 255 volts ±0.5 volt. If the reading is within this
specification, the charge amplifier is correctly calibrated. Set the DAC Cal Mode to
Off, switch off the printer, disconnect the DVM and refit the top cover. If the
reading is outside the specification, leave the DVM connected and continue with
the remainder of the calibration procedure.
18 Scroll to the DAC Cal Value option and press the [enter] key to select the setting.
Enter a value higher or lower than the displayed value to increase or decrease the
DVM reading. For example, if the DVM reading is 263 volts, try entering a DAC
Cal Value of 0960 to reduce the DVM reading to 255 volts.
19 Repeat the process of entering different values until the DVM reads within the
specification of 255 volts ±0.5 volt.
20 Make a note of the DAC Cal Value that gives the required DVM reading, then
press the [enter] key to deselect the option.
21 Scroll back to the DAC Cal Mode option and press the [enter] key to select the
option setting. Set it to Off using the left or right arrow key, then press the [enter]
key again and check that the DVM reading returns to 0 volts ±0.5 volt.
22 Scroll down to the Saved Cal Value option and press the [enter] key to select the
setting.
23 Enter the noted DAC Cal Value, then press the [enter] key.
24 Check that the EHTPSU calibration voltage, which is printed on a label attached
to the PSU, is the same as the value entered in the EHT Cal Value option. Re-enter
the value if it is different.
26 Disconnect the DVM leads from the IPM PCB.
30 The ‘IPM PCB Calibration’ maintenance instruction is now complete.
MP65557–1 Amdt 01
IPM PCB Calibration
Amdt 01 MP65557–1
Printhead Valves Tests
Equipment Required
Procedures

DERMATITIS.
Testing for a Leaking Printhead Feed Valve

1 Ensure the printer is switched on.
2 Access the DIAGNOSTICS menu and scroll to the Set Pressure option.
3 Press the [enter] key, enter the maximum Set Pressure of 255 (65.00 p.s.i.), then
press the [enter] key again.
4 Access the VALVE TEST menu (Setup menu > Diagnostics menu).
5 Press the [enter] key to switch the ink system Feed valve On:
49334
VALVE TEST
> Feed : On
Purge : Off
Gutter : Off
Figure 1. Feed Valve Switched On in the Valve Test Menu

6 Remove the printhead cover tube and observe the printhead nozzle for 2 to 3
minutes for signs of leakage (the Feed valve automatically switches off after 3
minutes). If leakage is not observed, proceed to Item 7.
If there are signs of leakage, proceed with the following sub-items:
(a) Switch off the Feed valve (if necessary) by pressing the [enter] key.
(b) Set the Set Pressure to 0 in the DIAGNOSTICS menu.
(c) Switch off the printer.
(d) Replace the Printhead Feed valve.
(e) Repeat the test from Item 1.
MP65557–1
Printhead Valves Tests
7 Switch off the Feed valve (if necessary) by pressing the [enter] key.
8 Set the Set Pressure to 0 in the DIAGNOSTICS menu.
10 Refit and secure the printhead cover tube.
11 The ‘Testing for a Leaking Printhead Feed Valve’ procedure is now complete.
Testing for a Leaking Printhead Purge Valve

3 Start the jet using the Quick Start Jet option in the DIAGNOSTICS menu.
4 While the jet is running, switch off the printer using the mains power switch on
the rear panel. The jet should stop abruptly. If it decays slowly, the Printhead
Purge valve is leaking. Therefore, the printhead should be replaced, and the test
repeated from Item 1.
5 Observe the printhead nozzle for 1 minute for signs of leakage. If leakage is not
observed, proceed to Item 6.
If there are signs of leakage, replace the printhead, then repeat the test from Item
1.
7 The ‘Testing for a Leaking Printhead Purge Valve’ procedure is now complete.
MP65557–1
Ink System Feed Valve Test
Equipment Required
Procedure

SOLVENT-RESISTANT PROTECTIVE GLOVES MUST BE WORN THROUGHOUT
THE FOLLOWING PROCEDURE. FAILURE TO COMPLY WITH THIS SAFETY
WARNING COULD RESULT IN IRRITATION AND REVERSIBLE LOCAL DAMAGE
TO THE EYES, AND NON-ALLERGIC CONTACT DERMATITIS.
Testing for a Leaking Ink System Feed Valve (closed)

4 Access the VALVE TEST menu (Setup menu > Diagnostics menu) and scroll to the
Printhead Feed valve option.
5 Press the [enter] key to switch the valve On:
49335
VALVE TEST
Gutter : Off
Solvent Flush : Off
> Printhead Feed : On
Figure 1. Printhead Feed Valve Switched On in the Valve Test Menu
MP65557–1
Ink System Feed Valve Test
6 Remove the printhead cover tube and observe the printhead nozzle for 2 to 3
minutes for signs of leakage (the Printhead Feed valve automatically switches off
after 3 minutes). If leakage is not observed, proceed to Item 7.
If there are signs of leakage, proceed with the following sub-items:
(a) Switch off the Printhead Feed valve (if necessary) by pressing the [enter] key.
(b) Set the Set Pressure to 0 in the DIAGNOSTICS menu.
(c) Switch off the printer.
(d) Replace the ink system Feed valve.
(e) Repeat the test from Item 1.
7 Switch off the Printhead Feed valve (if necessary) by pressing the [enter] key.
11 The ‘Ink System Feed Valve Test’ maintenance instruction is now complete.
MP65557–1
Purge and Gutter Valves Tests
Parts Required
or
FA74135 M3 x 28 CSK POZ SS Screw—Pack as required
Equipment Required
Procedures

DERMATITIS.
Testing for a Leaking Purge or Gutter Valve (closed)

1 Switch on the printer and start the jet using the Quick Start Jet option in the
DIAGNOSTICS menu.
2 Access the MONITOR JET menu (Setup menu > Diagnostics menu).
Set Pressure Reference TOF

Actual TOF
49332
MONITOR JET
Press : 185 (186) Add Press : 188
TOF : 7862 Ref TOF : 7843
Figure 1. Monitor Jet Screen
MP65557–1
3 Observe the jet parameters. Wait until the Actual TOF reading is within ±0.5% of
the Reference TOF reading, and the Set Pressure reading has stabilized. Note the
Set Pressure reading.
supply.
and solvent.
two parts of the connector.
11 Connect the Purge/Gutter Test fluid connector between the printhead and the ink
system parts of the 3-way fluid connector, using the extra screw supplied with the
assembly (Figure 2). Ensure that the O-ring gaskets are fitted to both connections
before assembly to avoid the possibility of leaks. Ensure that the assembly screws
are tight.
NOTE: The purpose of the Purge/Gutter Test fluid connector is to blank off the
purge line.
O-ring gasket
68094
Assembly
screw
O-ring gasket
d
thea
Assembly
he Prin
screw To t
Purge line tube

Locating
lug
Locating
m recess
kS yste
e In
m th
Fro
Figure 2. Purge/Gutter Test Fluid Connector Fitted in the 3-way Fluid Connector
DIAGNOSTICS menu.
13 Access the MONITOR JET menu and observe the jet parameters. Wait until the
Actual TOF reading is within ±0.5% of the Reference TOF reading, and the Set
Pressure reading has stabilized. Note the Set Pressure reading.
MP65557–1
14 If the Set Pressure reading is less than the reading noted at Item 3, minus 3 (0.77
p.s.i.), the Purge or Gutter valve is leaking. To determine which valve is leaking,
continue from Item 16.
15 Otherwise, proceed with the following sub-items:
(a) Shut down the printer.
(b) Disconnect and remove the Purge/Gutter Test fluid connector.
(c) Reconnect the 3-way fluid connector using a new O-ring gasket (supplied in
FA74136 Gasket Fluid Connector 3-way—Pack). Ensure that the assembly
screw is tight.
(d) Proceed to Item 19.
CAUTION: In the following test, use the correct solvent type that corresponds to the
ink type being used in the printer.
16 Place the free end of the purge line tube in a container of clean solvent (Figure 3).
If solvent is seen to be drawn up the tube, the Gutter valve is leaking and must be
replaced. If solvent is not drawn up the tube, and the Set Pressure values from
Item 14 are different, then the Purge valve is leaking and must be replaced.
68095
Purge/Gutter Test
fluid connector
Purge line of the

Purge/Gutter Test fluid connector
placed in a beaker of solvent
Figure 3. Testing for a Leaking Purge or Gutter Valve (closed)
MP65557–1
17 Repeat this instruction from the beginning after replacing either valve as both
valves may have been leaking.
18 On completion of the test, proceed with the following sub-items:
(a) Shut down the printer.
(b) Disconnect and remove the Purge/Gutter Test fluid connector.
(c) Reconnect the 3-way fluid connector using a new O-ring gasket (supplied in
FA74136 Gasket Fluid Connector 3-way—Pack). Ensure that the assembly
screw is tight.
Testing for a Leaking or Inoperative Gutter Valve (open)

CAUTION: In the following test, use the correct solvent type that corresponds to the
ink type being used in the printer.
20 Access the DIAGNOSTICS menu and scroll to the Clear Nozzle option.
21 Press the [enter] key to select the option setting, then press the [enter] key again to
initiate one Clear Nozzle sequence.
22 While the Clear Nozzle sequence is in operation (20 seconds), apply small
amounts of solvent to the gutter. The solvent should not be drawn into the gutter
except for the first 5 seconds of the sequence. If solvent is drawn in during the
remaining 15 seconds of the sequence, the Gutter valve is leaking. If solvent is not
drawn in at all, the Gutter valve is not operating. To rectify either fault replace
the Gutter valve and repeat the test.
28 The ‘Purge and Gutter Valves Tests’ maintenance instruction is now complete.
MP65557–1
Solvent Flush Valve Tests
Equipment Required
Procedures

DERMATITIS.
Testing for an Inoperative Solvent Flush Valve

IMPORTANT: Only carry out this test after having successfully completed the ‘Purge and
Gutter Valves Tests’ maintenance instruction, Items 19 to 28.
supply.
and solvent.
DIAGNOSTICS menu.
6 When the jet has successfully started, press the [stop] key on the keyboard to
cause a full normal shutdown to occur. During the shutdown sequence, observe
the feed line (red striped-pipe) and ensure that it is drained of ink and then
refilled with solvent. (Note that the solvent in the tank may not be clear but
coloured slightly with ink.) If the feed line is not drained, the Solvent Flush valve
may not be operating. This symptom could be caused by a faulty Solvent Flush
valve, but is more likely to be no solenoid energizing voltage from the IPM PCB.
MP65557–1
7 Test for an audible click when the Solvent Flush valve is switched on and off.
This can be determined by setting the Solvent Flush valve option in the VALVE
TEST menu (Setup menu > Diagnostics menu) to On and allowing it to
automatically switch off 1 second later:
49333
VALVE TEST
Purge : Off
Gutter : Off
> Solvent Flush : On
Figure 1. Solvent Flush Valve Switched On in the Valve Test Menu

8 If the Solvent Flush valve is heard to operate (audible click), then the fault is more
likely to be elsewhere in the solvent pick-up circuit, e.g. no solvent in the tank; a
blocked solvent dip (pick-up) tube filter; inefficient venturi; blocked in-line feed
filter. All possibilities should be investigated before deciding to replace the
Solvent Flush valve. Repeat the test after investigating and rectifying either fault.
Testing for a Leaking Solvent Flush Valve

Printhead Feed valve option.
10 Press the [enter] key to switch the valve On (the Printhead Feed valve
automatically switches off after 3 minutes):
49335
VALVE TEST
Gutter : Off
Solvent Flush : Off
> Printhead Feed : On
Figure 2. Printhead Feed Valve Switched On in the Valve Test Menu

MP65557–1
13 While the Nozzle Clear sequence is in operation (20 seconds), use a finger to
gently flick the pipe connecting the solvent tank to the Solvent Top-up (Solvent
Add) and Solvent Flush valves to cause bubbles to appear (Figure 3). Observe the
bubbles, and if movement is seen in the direction of the Solvent Flush valve, then
the valve is leaking and must be replaced.
68104
Solvent Flush
valve
From solvent tank

pick-up tube
Figure 3. Creating Bubbles to Test the Solvent Flush Valve for Leakage
14 Access the VALVE TEST menu and switch off the ink system Feed valve (if
necessary) by scrolling to the valve option and pressing the [enter] key.
19 The ‘Solvent Flush Valve Tests’ maintenance instruction is now complete.
MP65557–1
MP65557–1
Solvent Top-up (Solvent Add) Valve Tests
Equipment Required
Procedures

DERMATITIS.
Testing for a Leaking Solvent Top-up (Solvent Add) Valve

supply.
and solvent.
5 Switch the printer on.
6 Using a finger, gently flick the pipe connecting the solvent tank to the Solvent
Top-up (Solvent Add) and Solvent Flush valves to cause bubbles to appear
(Figure 1):
68104
Solvent Flush
valve
From solvent tank

pick-up tube
Figure 1. Creating Bubbles to Test the Solvent Top-up (Solvent Add) Valve for Leakage
MP65557–1
9 Observe the bubbles in the pipe between the Y-piece connector and the Solvent
Flush valve. If the bubbles are seen to move in the direction of the Solvent Flush
valve, the Solvent Top-up (Solvent Add) valve is leaking and must be replaced.
Testing for an Inoperative Solvent Top-up (Solvent Add) Valve

NOTE: Only carry out the following test if the ‘Solvent Flush Valve Tests’ maintenance
instruction has been successfully completed proving that the valve is serviceable.
10 Using a finger, gently flick the pipe connecting the solvent tank to the Solvent
Top-up (Solvent Add) and Solvent Flush valves to cause bubbles to appear
(Figure 1).
12 Press the [enter] key, enter a Set Pressure of 50 (12.75 p.s.i.), then press the [enter]
key again.
Solvent Top-Up (Solvent Add) valve option.
14 Press the [enter] key to switch the valve On. Note that the Feed and Printhead
Feed valves are also automatically switched on (all three valves automatically
switch off after 3 minutes):
49336
VALVE TEST
Feed : On
Purge : Off
Gutter : Off
> Solvent Top-Up : On
Figure 2. Solvent Top-up (Solvent Add) Valve Switched On in the Valve Test Menu
15 Observe the bubbles in the pipe between the Y-piece connector and the Solvent
Flush valve. The bubbles should be seen moving along the pipe in the direction of
the Solvent Flush valve. If the bubbles do not move and the Solvent Top-up
(Solvent Add) valve is not heard to operate when selected (no audible click), then
the Solvent Top-up (Solvent Add) valve is not operating. This symptom could be
caused by a faulty Solvent Top-up (Solvent Add) valve, but is more likely to be no
solenoid energizing voltage from the IPM PCB.
If the bubbles do not move but the Solvent Top-up (Solvent Add) valve is heard to
operate (audible click), the fault is more likely to be elsewhere in the solvent pick-
up circuit, e.g. no solvent in the tank; a blocked solvent dip (pick-up) tube filter;
inefficient venturi. All possibilities should be investigated before deciding to
replace the Solvent Top-up (Solvent Add) valve. Repeat the test after
investigating and rectifying either fault.
MP65557–1

17 Access the VALVE TEST menu and switch off the Solvent Top-up (Solvent Add)
valve (if necessary) by scrolling to the valve option and pressing the [enter] key.
22 The ‘Solvent Top-up (Solvent Add) Valve Tests’ maintenance instruction is now
complete.
MP65557–1
MP65557–1
Jet Alignment and Nozzle Cleaning
Parts Required
FA73051 Screw M2 x 6 Pan Poz SS—Pack
FA73052 Washer Shakeproof M2 SS—Pack
Equipment Required
FA74046 Nozzle Cleaning Service Accessory
Ultrasonic bath
Empty 0.5 litre ink bottle
Beaker, stainless steel or glass
Correct solvent for the printer as required
Clean hot water (preferably deionized)
between 55 °C and 100 °C as required
Procedures

DERMATITIS.
CAUTION: Under no circumstances should the printhead be immersed in solvent for
any period of time.
MP65557–1
Correct Jet Alignment

DIAGNOSTICS menu.
3 Examine the alignment of the jet with an eyeglass. The jet should pass exactly
through the centre of the charge electrode and enter the centre of the gutter when
viewed from the front (Figure 1):
50% 50%
50%
50%
Mk7 Midi/Midi plus

and
Mk7 Ultima/Ultima plus
Gutter Alignment
The jet must enter

the centre of the gutter
68055
The jet must pass exactly

through the centre of
the charge electrode
Figure 1. Correct Alignment of the Jet into the Gutter
MP65557–1
4 Examine the jet to establish if it is perpendicular to the nozzle face (Figure 2):
Misaligned jet
For correct jet alignment,

this angle must be
90˚
6219
Figure 2. Correct Alignment of the Jet from the Nozzle

5 If the jet is misaligned or non-existent due to dried ink or debris in the nozzle,
carry out the following ‘Nozzle Clear Sequence’ procedure:
Nozzle Clear Sequence

1 Shut down the jet.
2 Invert the printhead and wrap absorbent, lint-free paper towel around the area
below the nozzle (Figure 3).
MP65557–1
CAUTION: In the following cleaning process, use the correct solvent type that
corresponds to the ink type being used in the printer.
5 While the Clear Nozzle sequence is in operation (20 seconds), apply small
amounts of solvent to the inverted nozzle face. Observe that the solvent is drawn
in through the nozzle (Figure 3):
68056
Take care to build up

a good coating of MIDI
solvent on the nozzle

face, as shown here
Figure 3. Nozzle Clear Sequence—Applying Solvent to the Nozzle Face

6 When the Clear Nozzle sequence has finished, attempt to start the jet using the
Quick Start Jet option in the DIAGNOSTICS menu, and observe the alignment of
the jet. If the jet is still out of alignment or the nozzle is still blocked, press the
[stop] key on the keyboard to stop the jet.
7 Repeat Items 4 to 6 until the jet is perpendicular to the nozzle face, but no more
than a further 7 times (i.e. a Clear Nozzle sequence with an attempt to start the jet
carried out after each sequence). The Clear Nozzle sequence must not be
performed more than a total of 8 times.
8 If the jet is now correctly aligned, this maintenance instruction can be terminated.
Shut down and switch off the printer, and refit the printhead cover tube.
9 If after 8 Clear Nozzle sequences the jet is still misaligned due to a partial nozzle
blockage (or non-existent), continue with the ‘Nozzle Soaking’ procedure. If the
jet is now perpendicular to the nozzle face (Figure 2) but is misaligned with the
gutter, proceed to the ‘Nozzle Realignment’ part of this maintenance instruction.
MP65557–1
Nozzle Soaking
CAUTION: Contamination of the Printhead Nozzle Assembly. Extreme care must be
taken when handling the nozzle assembly (or replacement nozzle assembly) to avoid
introducing any contamination. The pipe on the rear of the nozzle assembly must not
come into contact with any fibres, and skin contact must be avoided. It is
recommended that powder-free latex gloves be worn. Removing and handling the
nozzle assembly must be carried out in a clean, dust free environment. If a Clean
2 Remove the printhead nozzle protection cover screw and remove the cover.
3 Clean the printhead thoroughly with the correct solvent type paying particular
attention to the nozzle and surrounding area.
4 Remove the two securing screws and shakeproof washers from the nozzle
assembly plate and remove the nozzle assembly. Remove the nozzle O-ring from
the nozzle assembly and retain in a safe place.
5 Using a paper clip or similar device as a hanger, suspend the nozzle in a beaker
(stainless steel or glass, not plastic) of solvent with the nozzle face uppermost
(Figure 4):
6220
Figure 4. Suspending the Nozzle in a Beaker of Solvent

6 Place the beaker in an ultrasonic bath partly filled with water for 20 minutes.
7 Refit the nozzle O-ring to the nozzle assembly, and then refit the nozzle assembly
to the printhead using new securing screws and shakeproof washers. While doing
this, avoid touching the nozzle assembly pipe with fingers.
DIAGNOSTICS menu.
9 Check that the jet is now correctly aligned into the gutter, as described in ‘Correct
Jet Alignment’ at the beginning of this maintenance instruction. If this is correct,
this maintenance instruction can be terminated. Carefully refit the nozzle
protection cover ensuring that the jet alignment is not disturbed. Shut down and
switch off the printer, and refit the printhead cover tube.
10 If the jet is still not perpendicular to the nozzle face (Figure 2), this may be due to
a build-up of conductive salts in the nozzle. If this is suspected, the following
‘Nozzle Washing’ procedures can be tried.
11 If the jet is perpendicular to the nozzle face but is not correctly aligned into the
gutter, use the method described in ‘Nozzle Realignment’.
MP65557–1
Nozzle Washing
This procedure is intended for use on nozzles that are experiencing jet misalignments due
to severe blockages, which cannot be cleared using the normal Clear Nozzle function or
by nozzle soaking. It is especially useful when the insides of nozzle assemblies have
become obstructed by deposits of the water-soluble conductive salts present in the ink.
The Nozzle Cleaning Service Accessory is required for this procedure.
Solvent Wash
2 Remove the securing screw from the printhead nozzle protection cover and
remove the cover (if not previously removed).
assembly plate and remove the nozzle assembly. Remove the nozzle O-ring from
the nozzle assembly and retain in a safe place.
4 Wash the nozzle assembly with solvent of the same type as that used in the
printer.
5 Soften the free end of the PTFE tube supplied with the Nozzle Cleaning Service
Accessory by dipping it into hot water for a few seconds. Fit the end of the tube
to the pipe on the back of the nozzle assembly.
6 Connect the syringe to the Luer fitting on the other end of the PTFE tube.
7 Fill a clean, dry beaker or similar container (stainless steel or glass, not plastic)
with solvent.
8 Position the nozzle assembly in the solvent and withdraw the syringe plunger to
draw solvent back through the nozzle assembly and into the syringe. Depress the
plunger and withdraw again, with the nozzle assembly remaining in the solvent
in the beaker. Take care at this point because the syringe may dribble slightly
around the plunger. Repeat this operation three times.
9 Finally, lift the nozzle assembly out of the solvent, and empty the syringe and
nozzle assembly by depressing the plunger to the bottom of the syringe.
10 Dry the nozzle assembly by withdrawing the plunger to suck only air into the
syringe through the nozzle. Depress the plunger again to force air through the
nozzle assembly. Repeat this drying process three times.
MP65557–1
Hot Water Wash

11 Fill a clean beaker or similar container (stainless steel or glass, not plastic) with
hot water (preferably deionized and between 55 °C and 100 °C).
12 Position the nozzle assembly in the water and withdraw the syringe plunger to
draw water back through the nozzle assembly and into the syringe. Depress the
plunger and withdraw again, with the nozzle assembly remaining in the water in
the beaker. Repeat this operation three times.
13 Finally, lift the nozzle assembly out of the water and empty the syringe and
nozzle assembly by depressing the plunger to the bottom of the syringe. While
doing this, check that the jet of water from the nozzle is perpendicular to the
nozzle face. If the jet emerges at an angle other than 90 degrees, this indicates that
a blockage is still present in the nozzle, and the washing process should be
repeated until the blockage is cleared.
14 Dry the nozzle assembly by withdrawing the plunger to suck only air into the
syringe through the nozzle. Depress the plunger again to force air through the
nozzle assembly. Repeat this drying process three times.
15 Repeat the solvent washing and nozzle drying procedures described in Items 7 to
10 inclusive.
16 Before refitting the nozzle assembly, the gun assembly needs to be flushed with
ink. Place the printhead in an empty 0.5 litre ink bottle, ensuring that the gun
body is well below the neck of the bottle. Seal the neck of the bottle around the
printhead using a plastic bag or absorbent, lint-free paper towel.
19 Press the [enter] key, enter a Set Pressure of 120 (30.59 p.s.i.), then press the [enter]
key again.
ink system Feed valve option.
21 Press the [enter] key to switch the valve On:
22 Scroll to thePrinthead Feed valve option.
23 Press the [enter] key to switch the valve On (both valves automatically switch off
after 3 minutes).
24 Leave the valves switched on for 5 seconds during which time ink will be ejected
from the gun.
25 Switch off both Feed valves by scrolling to each and pressing the [enter] key.
28 Remove the printhead from the ink bottle and, using the appropriate solvent for
the ink type used in the printer, thoroughly wash the printhead paying
particular attention to the nozzle assembly location on the printhead.
29 Disconnect the syringe from the PTFE tube and remove the tube from the pipe at
the rear of the nozzle assembly.
MP65557–1
30 Refit the nozzle O-ring to the nozzle assembly, and then refit the nozzle assembly
to the printhead using new securing screws and shakeproof washers. While doing
this, avoid touching the nozzle assembly pipe with fingers.
DIAGNOSTICS menu.
32 Check that the jet is now correctly aligned into the gutter as described in ‘Correct
Jet Alignment’ at the beginning of this maintenance instruction. The jet should
now be perpendicular to the nozzle face. If this is correct but the jet is not
correctly aligned into the gutter, proceed to the following ‘Nozzle Realignment’
procedure.
33 If jet alignment is correct, carefully refit the nozzle protection cover ensuring that
the jet alignment is not disturbed.
35 Refit the printhead cover tube.
Nozzle Realignment
remove the cover (if not previously removed).
2 Realignment of the nozzle is best achieved using a finger and thumb only with
very little force applied until the alignment is correct (do not use pliers or any
other tool). The nozzle will move a little, and will probably spring back to its
original position. Apply a little more force, such that the nozzle will be deflected
but when released will not return fully to its original position. Continue using
this method until the jet is correctly aligned into the gutter as described in
‘Correct Jet Alignment’ at the beginning of this maintenance instruction.
3 Shut down the printer and then restart the jet using the [start] key on the control
panel. Repeat this four times to ensure that the jet alignment is maintained, the jet
is stable during the start and stop operations, and that no warning or fault
messages are reported.
4 Carefully refit the nozzle protection cover ensuring that the jet alignment is not
disturbed.
7 The ‘Jet Alignment and Nozzle Cleaning’ maintenance instruction is now
complete.
MP65557–1
Modulation Range Checks
Introduction
This maintenance instruction checks the quality of the printed message and ensures that
the Reference Modulation value is set such that optimum print quality is maintained with
varying ink viscosity. It can also be used to assess the relative viscosity of the ink.
Procedure
2 Access the GENERATE TEST PATTERN menu (Setup menu > Diagnostics menu).
3 When the test patterns have been generated, select the biggest message type
(raster) available.
5 Access the MONITOR JET menu (Setup menu > Diagnostics menu):
Set Pressure Reference TOF

Actual TOF
49332
MONITOR JET
Press : 185 (186) Add Press : 188
TOF : 7862 Ref TOF : 7843
Figure 1. Monitor Jet Screen

6 Note the Reference Modulation and Actual Modulation values.
7 Return to the DIAGNOSTICS menu and scroll to the Modulation Tracking option.
8 Press the [enter] key to select the option setting. Set the Modulation Tracking to
Off using the left or right arrow key, then press the [enter] key again.
9 Carry out a modulation range analysis using the following method. Produce a
series of print samples, starting at the original Reference Modulation value and
then decreasing the Actual Modulation value in steps of 10 volts (using the Set
Modulation option in the DIAGNOSTICS menu) until the print quality just starts
to deteriorate (see Figure 2), and record the setting (Vm1). Then increase the
Actual Modulation from the original value in steps of 10 volts until the print
quality just starts to deteriorate (see Figure 3), or until the maximum of 255 is
reached, and record the setting (Vm2).
NOTE: It may be that the maximum setting for Vm2 is reached without there being
evidence of over modulation. In this case record Vm2 as the maximum
value. The same applies to under modulation.
MP65557–1
Modulation Range Checks
48168
Figure 2. Under Modulation—Expected Deterioration when Reference Mod is < Vm1
48169
Figure 3. Over Modulation—Expected Deterioration when Reference Mod is > Vm2

10 Check that the original Reference Modulation value is approximately equal to the
calculated modulation, as follows:
68092
Vmc = Vm1 + (Vm2 – Vm1)

3
11 Record the calculated value (Vmc) on the Scheduled Maintenance Checklist.
12 Reset the Actual Modulation (Set Modulation option in the DIAGNOSTICS menu)
to the original value noted in Item 6.
13 Scroll to the Modulation Tracking option.
14 Press the [enter] key to select the option setting. Set the Modulation Tracking to
On using the left or right arrow key, then press the [enter] key again.
Evaluating the Relative Viscosity

15 Compare the Reference Modulation with the calculated modulation (Vmc):
(Vmc) = Ref Modulation viscosity correct.
(Vmc) < Ref Modulation viscosity low but no action required.
(Vmc) << Ref Modulation viscosity too low. If printer is failing, change
the ink.
(Vmc) > Ref Modulation viscosity high but no action required.
(Vmc) >> Ref Modulation viscosity too high. If printer is failing, change
the ink.
16 If the printer has been failing because the ink viscosity is too low or too high,
appropriate action should be taken to determine the root cause of the viscosity
problem.
17 The ‘Modulation Range Checks’ maintenance instruction is now complete.
MP65557–1
Blocked Gutter Clearance Procedure
Parts Required
or
FA74135 M3 x 28 Csk Poz SS Screw—Pack as required
Equipment Required
Empty 0.5 litre ink bottle
Introduction
If the gutter has become totally blocked with dried ink, it can be cleared by connecting the
feed line directly to the gutter line and starting the jet. This forces ink out of the gutter
(i.e. in the reverse direction), which should clear the blockage.
This procedure is best carried out with the printhead positioned in an empty 0.5 litre ink
bottle with absorbent, lint-free paper towel wrapped around the top to contain the ink jet.
Alternatively, the printhead can be enclosed in a suitable size plastic bag, again sealed to
contain the ink jet.
Procedure

DERMATITIS.
WARNING: HIGH PRESSURE INK JET. DURING THE FOLLOWING
PROCEDURE INK IS FORCED FROM THE GUTTER AT MAXIMUM PRESSURE.
THE PRINTHEAD MUST BE ENCLOSED IN A SUITABLE CONTAINER TO
CONTAIN THE INK JET, AND THE CORRECT FULL EYE AND HAND
PROTECTION MUST BE WORN. FAILURE TO COMPLY WITH THESE SAFETY
PRECAUTIONS MAY RESULT IN EYE DAMAGE OR SKIN CONTAMINATION.
MP65557–1
supply.
and solvent.
two parts of the connector.
8 Connect the Gutter Clear fluid connector between the printhead and the ink
system parts of the 3-way fluid connector, using the extra screw supplied with the
assembly (Figure 1). Ensure that the O-ring gaskets are fitted to both connections
before assembly to avoid the possibility of leaks. Ensure that the assembly screws
are tight.
O-ring gasket
68096
Assembly
screw
O-ring gasket
d
thea
Assembly
he Prin
screw To t
Ink system feed line

Locating connected to the
lug printhead gutter line
Locating
m recess
Syste
Ink
the
From
Figure 1. Gutter Clear Fluid Connector Fitted in the 3-way Fluid Connector
10 Place the printhead in an empty 0.5 litre ink bottle and seal the neck of the bottle
around the printhead using a plastic bag or absorbent, lint-free paper towel.
MP65557–1
ink system Feed valve option.
15 Press the [enter] key to switch the valve On. The full force of the maximum
running pressure will now be applied to the gutter.
16 Leave the Feed valve switched on for 1 minute or until ink is ejected from the
gutter. As soon as ink pours from the gutter, switch off the Feed valve by
pressing the [enter] key.
18 If the gutter is still blocked after 1 minute, wait a further 1 minute and repeat
Items 12 to 17. If after this the gutter is still blocked, the printhead must be
replaced.
20 Remove the printhead and sealing material from the ink bottle.
21 Thoroughly wash the printhead with solvent, paying particular attention to the
gutter assembly area on the printhead.
22 Disconnect and remove the Gutter Clear fluid connector, and reconnect the 3-way
fluid connector using a new O-ring gasket (supplied in FA74136 Gasket Fluid
Connector 3-way—Pack). Ensure that the assembly screw is tight.
25 Refit the printhead cover tube ensuring that the securing screw is fully tightened.
29 The ‘Blocked Gutter Clearance Procedure’ maintenance instruction is now
complete.
MP65557–1
MP65557–1
System Flush Procedure
Equipment Required
FA940021 Syringe Polypropylene 50 ml as required
Correct solvent for the ink used in the printer as required
Waste container—15 litres capacity
Empty solvent bottle—base removed
Introduction
This maintenance instruction provides the procedures to completely flush a 4900 printer
in the following circumstances:
1. Before packing for shipping or storage.
2. To remove contaminated ink.
3. To convert an ‘in use’ printer to a new ink, in readiness for calibration.
4. To prepare a ‘new’, unused printer with new ink, in readiness for calibration.
The detailed ‘System Flush’ process referred to within the individual procedures for the
above circumstances, is provided separately in Part B of this maintenance instruction.
The procedure for purging the main ink filter is referred out to the ‘Main Ink Filter
Purging’ maintenance instruction provided earlier in Chapter 5.
It is important to ensure that the procedures outlined in this maintenance instruction are
followed carefully to achieve reliable printer operation.
Printer Conditions during the Flush Cycle

• The Flush Cycle will not run if the pressure test at the beginning of the cycle fails
• The level of solvent in the ink tank is checked at each stage of the cycle, and the cycle
terminates if the level is low. If this error is detected, the advisory message “Flush
Cycle Stopped” is displayed in the status line
• The cycle terminates with all valves off and zero system pressure
• The cycle can be terminated by the operator at any stage by selecting the Stop option.
This action takes immediate effect, so no advisory message, such as “Stopping Cycle :
Please Wait”, is displayed. It is used for speed in preference to the power switch in
situations, for example, where a pressurized leak has occurred. Use of the Stop option
may leave the ink system in an undefined state. If the cycle is terminated for any
reason, the Flush Count is not incremented.
MP65557–1
Procedures

DERMATITIS.
Part A—System Flush Procedures
1. Before Packing for Shipping or Storage

CAUTION: In the following procedure, use the correct solvent type that corresponds to
the ink type being used in the printer.
supply.
4 Carry out the System Flush process detailed in Part B of this maintenance
instruction (i.e. Empty Tank sequence, Flush Cycle and Solvent Drain sequence).
5 Repeat Item 4 TWO more times before proceeding to Item 6.
6 Carry out the Empty Tank part of the System Flush process once more. The
solvent tank should be empty, but if it is not, syphon off any remaining solvent.
10 The printer is now flushed ready for packing.
MP65557–1
2. To Remove Contaminated Ink

CAUTION: In the following procedure, use the correct solvent type that corresponds to
the ink type being used in the printer.
supply.
7 Replace the main ink filter and the ink tank dip (pick-up) tube. Maintenance
instructions for these tasks can be found earlier in Chapter 5.
8 The printer can now be recommissioned with fresh ink (one or two bottles, until
the ‘ink low’ status warning has cleared) and fresh solvent (one or two bottles,
until the ‘solvent low’ status warning has cleared).
9 Carry out the ‘Main Ink Filter Purging’ maintenance instruction.
NOTE: If the main ink filter or damper does not fill with ink, the pump needs to
be primed. This must be done with the printer switched OFF. Insert the
nozzle of the syringe (Linx part number FA940021—Syringe
Polypropylene 50 ml) into the Luer fitting on the damper. Withdraw the
syringe plunger to draw ink through the pump. Continue withdrawing
the plunger until ink is present in the pipe on the outlet side of the pump.
Note that the syringe is a disposable item, with a limited functional life of
approximately two applications when used with solvent-based inks.
10 Carry out at least six Clear Nozzle sequences.
14 Start the jet using the [start] key.
15 The printer is now clear of contaminated ink and ready for use.
MP65557–1
3. To Convert an ‘In Use’ Printer to a New Ink, in Readiness for Calibration

supply.
CAUTION: In the following operation, ensure that the solvent type added to the ink
tank corresponds to the ink type being cleared from the printer.
tank corresponds to the ink type that will be added to the printer during the
recommissioning process.
8 Carry out the System Flush process again (i.e. Empty Tank sequence, Flush Cycle
and Solvent Drain sequence).
11 The printer can now be recommissioned with the new ink (one or two bottles,
until the ‘ink low’ status warning has cleared) and the new solvent (one or two
bottles, until the ‘solvent low’ status warning has cleared).
14 Start the jet using the Quick Start Jet option in the DIAGNOSTICS menu and run
the jet for 10 minutes.
15 Stop the jet.
16 Carry out the Empty Tank part of the System Flush process once more.
IMPORTANT: It is important to ensure that the ink tank, damper, and main ink filter are
drained completely of ink.
MP65557–1
17 The printer can now be recommissioned with fresh, new ink (one or two bottles,
until the ‘ink low’ status warning has cleared), which must be of the same batch
and viscosity, as marked on the ink bottle label.
IMPORTANT: Items 11 to 17 must be carried out, despite the apparent duplication of ink
commissioning. These steps help to remove traces of solvent remaining
from the flushing process, which could decrease the viscosity of the ink
and cause incorrect calibration.
18 Repeat the ‘Main Ink Filter Purging’ maintenance instruction.
19 Place an earthed container under the printhead as solvent will be present in the
pipes.
23 The printer is now ready for calibration. Refer to the ‘Ink Conversion
Calibration (Offset Calibration)’ maintenance instruction, which follows this
instruction.
MP65557–1
4. To Prepare a ‘New’, Unused Printer with New Ink, in Readiness for Calibration
supply.
5 Carry out the Flush Cycle and Solvent Drain parts of the System Flush process
detailed in Part B of this maintenance instruction.
6 Carry out the Empty Tank part of the System Flush process.
7 Repeat Items 5 and 6 TWO more times.
8 At this stage the solvent tank should be empty, but if it is not, syphon off any
remaining solvent.
9 The printer can now be recommissioned with the new ink (one or two bottles,
until the ‘ink low’ status warning has cleared) and the new solvent (one or two
bottles, until the ‘solvent low’ status warning has cleared).
12 Start the jet using the Quick Start Jet option in the DIAGNOSTICS menu and run
the jet for 10 minutes.
13 Stop the jet.
14 Carry out the Empty Tank part of the System Flush process once more.
IMPORTANT: It is important to ensure that the ink tank, damper, and main ink filter are
drained completely of ink.
MP65557–1
15 The printer can now be commissioned with fresh, new ink (one or two bottles,
until the ‘ink low’ status warning has cleared), which must be of the same batch
and viscosity, as marked on the ink bottle label.
IMPORTANT: Items 9 to 15 must be carried out, despite the apparent duplication of ink
commissioning. These steps help to remove traces of solvent remaining
from the flushing process, which could decrease the viscosity of the ink
causing incorrect calibration.
16 Repeat the ‘Main Ink Filter Purging’ maintenance instruction.
17 Place an earthed container under the printhead as solvent will be present in the
pipes.
21 The printer is now ready for calibration. Refer to the ‘Ink Conversion
Calibration (Offset Calibration)’ maintenance instruction, which follows this
instruction.
MP65557–1
Part B—System Flush Process
Precautions
During the system flush process, the solvent tank needs to contain only enough solvent
(approximately 600 ml) to successfully complete the task. However, too much solvent in
the solvent tank may result in the ink tank overflowing during the cycle, due to solvent
being dumped into the ink tank as solvent is used to fill the system. Therefore, fill the
solvent tank just until the System Warning message “3.04 Solvent Low” is cleared. This
may necessitate drawing off some solvent first to see the warning message appear in the
status line, and then refilling with solvent until the warning message clears.
As a precautionary measure, fit an empty solvent bottle (with its base removed) to the ink
tank filler tube during flushing cycles in case the tank overflows. Also, it is advisable to
place the printhead in a beaker to contain any spillage from the nozzle.
NOTE: The Flush Cycle part of the System Flush process thoroughly flushes all the valves
and pipework with solvent.
Empty Tank
1 Switch on the printer and access the SYSTEM FLUSH menu (Setup menu >
Diagnostics menu):
49290
SYSTEM FLUSH
Valve Dry
Figure 1. System Flush Menu: Process Options

NOTE: The Valve Dry option is for use only by Linx during the manufacturing
process and is NOT to be used by service personnel.
2 Select the Flush Cycle / Tank Empty option. The following menu is displayed
with the instruction “Check Solvent OK” in the status line:
49329
SYSTEM FLUSH
> OK
Quit
Check Solvent OK
Figure 2. System Flush Menu: “Check Solvent OK” Instruction
MP65557–1
3 To continue with the System Flush procedure it is necessary to perform a number

of actions on the printer before the flushing cycles can begin. These required
actions are displayed in the status line, and should be performed in accordance
with the following expanded explanations for each instruction. Once each action
has been completed, select the OK option by pressing the [enter] key, which
displays the next instruction.
the [esc] key.
4 Check Solvent OK. Carry out the actions detailed in ‘Precautions’ above.
5 Prop Up Printer. Before commencing the ink draining procedure, the printer
must be raised by approximately 50 mm at the front left-hand side to aid drainage
of the ink, as the ink dip tube is situated at the rear right-hand side of the tank.
WARNING: LETHAL VOLTAGE. DANGEROUS VOLTAGES ARE

PRESENT IN THIS EQUIPMENT WHEN ELECTRICAL POWER IS
APPLIED. EXTREME CARE MUST BE TAKEN WHEN WORKING ON THE
PRINTER WHILE POWER IS APPLIED TO IT AND THE TOP COVER IS
REMOVED. THE CORRECT, STANDARD ELECTRICAL SAFETY
PRECAUTIONS MUST BE TAKEN. THERE IS A DANGER OF DEATH OR
INJURY FROM ELECTRIC SHOCK IF THE CORRECT ELECTRICAL
6 Orientate Filter and Damper. Ignore the instruction regarding the filter.
Carefully lift the feed damper clear of the ink system enclosure. Hold the feed
damper in the vertical position with the drain cap uppermost.
7 Connect Bleed Line To Damper. Remove the damper drain cap and connect the
Damper Drain Tube Luer fitting (included in the Damper Drain Tube kit) to the
damper drain. Insert the other end of the drain tube into a waste container of at
least 5 litres capacity. Orientate the damper so that the drain is at the bottom, i.e.
at its lowest position, as shown in the following illustration:
68050
Drain Tube
Figure 3. Feed Damper Orientation with Drain Tube Connected
MP65557–1
8 Turn On Tap On Bleed Line. The bleed line tap is used in the Linx
manufacturing process only. There is no bleed line in the service engineer’s
Damper Drain Tube kit, therefore, any action referring to the bleed line tap should
be ignored. Simply press the [enter] key to continue the procedure.
9 When all the required actions have been completed, the following menu is
displayed:
49330
SYSTEM FLUSH
> Empty Tank
Solvent Drain
Flush Count : 0
Quit
CAUTION: Pump damage. Do not allow the ink system pump to run dry. Initiate the
Empty Tank sequence only the number of times required to empty the system of ink.
The pump must not be run for longer than 30 seconds after it becomes noisy through
cavitation (ink starvation). Damage to the pump will result if it is allowed to run
continuously in a dry condition.
10 Select the Empty Tank option, which starts the pump and displays the following
screen with the “Empty Tank In Progress…” message displayed in the status line.
The pump will run at maximum pressure for approximately 1 minute and 40
seconds, and then automatically stop on completion of the Empty Tank sequence.
Select the Stop option if the audible pitch of the pump changes indicating that the
ink tank is empty:
49331
SYSTEM FLUSH
> Stop
Empty Tank In Progress...
Figure 5. System Flush Menu: “Empty Tank In Progress…”

11 At some point towards the end of the Empty Tank sequence the ‘ink low’
condition should be reached. Ensure that the System Warning message “3.03 Ink
Low” is displayed in the status line.
12 On completion of the Empty Tank sequence, the display reverts to the sequence
options menu (Figure 4).
13 If the tank is not empty after a single Empty Tank sequence, select the Empty
Tank option again to repeat the sequence. Select the Stop option when the audible
pitch of the pump changes indicating that the ink tank is empty.
14 Disconnect the drain tube from the damper and refit the drain cap.
MP65557–1
Flush Cycle
15 Select the Access Flushing Cycle option. The following menu is displayed with
the instruction “Turn Off Tap On Bleed Line” in the status line:
49337
SYSTEM FLUSH
> OK
Quit
Turn Off Tap On Bleed Line
Figure 6. System Flush Menu: “Turn Off Tap On Bleed Line” Instruction
the [esc] key.
16 The bleed line tap is used in the Linx manufacturing process only. There is no
bleed line in the service engineer’s Damper Drain Tube kit, therefore, any action
referring to the bleed line tap should be ignored. Simply select the OK option by
pressing the [enter] key, which displays the next instruction:
49338
SYSTEM FLUSH
> OK
Quit
Fill Ink Tank with 0.5ltr of Solvent
Figure 7. System Flush Menu: “Fill Ink Tank with 0.5ltr of Solvent” Instruction
17 It is necessary to add solvent to the ink tank before the Flush Cycle can begin.
Add 1.0 litre of solvent to the ink tank. If this is the first time the Flush Cycle has
been run (Flush Count is 0) and a “3.04 Solvent Low” warning message is
displayed, the Flush Cycle cannot proceed. If necessary, fill the solvent tank just
until the “3.04 Solvent Low” warning message is cleared.
18 Once solvent has been added to the ink tank, select the OK option by pressing the
[enter] key, which starts the Flush Cycle and displays the following screen and
status line message. The Flush Cycle runs for approximately 1 minute and 40
seconds, and automatically stops on completion. The sequence can be stopped
before completion by selecting the Stop option, in which case the Flush Count
option in the sequence options menu (Figure 4) is not incremented:
49339
SYSTEM FLUSH
> Stop
Flush Cycle In Progress...
Figure 8. System Flush Menu: “Flush Cycle In Progress…”
MP65557–1
NOTE: The “3.04 Solvent Low” warning message may be reported during the
Flush Cycle as solvent is used to fill the system. This warning can be
ignored, except when the software will not allow the sequence to continue
and action is required as detailed in Item 17.
19 On completion of the Flush Cycle, the display reverts to the ‘OK/Quit’ options
menu with the instruction “Turn On Tap On Bleed Line” in the status line. Ignore
this instruction and select the OK option by pressing the [enter] key, which
displays the sequence options menu where the Flush Count has now incremented
to ‘1’:
49340
SYSTEM FLUSH
> Empty Tank
Solvent Drain
Flush Count : 1
Cycle Complete, Now Empty Tank

20 Ignore the status line instruction “Cycle Complete, Now Empty Tank”.
Solvent Drain
21 Select the Solvent Drain option. The following menu is displayed with the
instruction “Turn Off Tap On Bleed Line” in the status line:
49337
SYSTEM FLUSH
> OK
Quit
Turn Off Tap On Bleed Line
Figure 10. System Flush Menu: “Turn Off Tap On Bleed Line” Instruction
the [esc] key.
MP65557–1
22 The bleed line tap is used in the Linx manufacturing process only. There is no
bleed line in the service engineer’s Damper Drain Tube kit, therefore, any action
referring to the bleed line tap should be ignored. Simply select the OK option by
pressing the [enter] key, which starts the Solvent Drain sequence and displays the
following screen and status line message. The Solvent Drain sequence runs for
approximately 10 minutes, and automatically stops on completion. The sequence
can be stopped before completion by selecting the Stop option:
49341
SYSTEM FLUSH
> Stop
Solvent Drain In Progress...
Figure 11. System Flush Menu: “Solvent Drain In Progress…”

23 On completion of the Solvent Drain sequence, the display reverts to the ‘OK/Quit’
options menu with the instruction “Turn On Tap On Bleed Line” in the status line.
Ignore this instruction and select the OK option by pressing the [enter] key, which
returns the display to the sequence options menu.
24 Now that the System Flush procedure is completed (i.e. Empty Tank sequence,
Flush Cycle and Solvent Drain sequence), it is necessary to flush the gutter line
(from the gutter through the gutter valve). To do this, first exit from the SYSTEM
FLUSH menu to the DIAGNOSTICS menu by pressing the [esc] key.
25 Scroll up to the Set Pressure option.
27 Apply solvent to the gutter using the solvent cleaning bottle until the solvent in
the gutter line flows clear. Note that a minimum of 250 ml of solvent must be
used.
29 Return to Part A of this maintenance instruction.
MP65557–1
MP65557–1
Ink Conversion Calibration (Offset Calibration)
Parts Required
FA20012 Printhead Calibration Label–Pack
Introduction
This maintenance instruction details the procedure for calibrating a 4900 printer, fitted
with a Mk7 Ultima 62 µm, Ultima plus 75 µm or Mini 50 µm printhead, following a
conversion from one ink type to another. See Figures 5, 6 and 7 for allowed ink
conversions.
New printheads and nozzles are supplied with a calibration sheet, and Reference Pressure
and Reference Modulation Offset Tables, which give offset values for conversion to (printhead
specific) approved inks.
IMPORTANT: It is most important that the Reference Pressure and Reference Modulation
Offset Tables sheet supplied with each individual printhead or nozzle is
retained and filed. If it is required to convert a printer to a different ink in
the future, the offset values from the original sheet for the printhead or
nozzle must be used. However, if the original offset values are not
available or were not supplied, they should be obtained from the Linx
International Technical Support department before carrying out a
recalibration.
Preparation
Before this calibration is attempted, the printer must be flushed and recommissioned with
the new ink in accordance with the ‘System Flush Procedure’ maintenance instruction,
which precedes this instruction.
It is important that the procedures outlined in the following maintenance instruction are
understood fully and followed carefully to ensure reliable printer operation.
Procedure
1 Carry out the ‘Preparation’ instructions detailed above.
2 Access the SETUP menu and scroll to the Ink Type Selection option.
3 Select the option and set it to the correct ink type group for the ink that the printer
is to be converted to. The ‘4900 Ink Type’ letter for the new ink is given in the
offset table supplied with the printhead or nozzle. An example of the offset table
is shown in Figure 1:
68723
PRESSURE AND MODULATION OFFSET TABLE.
FROM 3103 TO DYE BASED OR PIGMENTED INK TYPES
Ink Type
Mk7 ULTIMA 3103 1010 1014 1016 1018 1035 1055 1070 1121 1240 1270 1290 1405 2030 2035 3123 3124 3240
Reference Pressure
— 0 1 13 4 3 9 –1 –1 1 2 6 3 1 1 0 0 1
Offset (bits)
— 10 –10 –15 0 –30 –25 –10 –10 10 20 –30 5 –10 –10 0 0 10
Offset (VM + offset) (V)
Modulation Slope 2.5 2.0 2.0 1.0 2.0 1.0 1.0 1.5 2.0 2.0 1.0 1.0 1.3 2.0 2.0 2.5 2.5 2.0
4900 Ink Type B B B B B B B B B B B B A C C B B C
Table issue no: 2.4
Figure 1. Example of Reference Pressure and Reference Modulation Offset Table
MP65557–1 Amdt 01
4 Access the PRINTHEAD SETUP menu (Setup menu), and amend the existing
Reference Pressure part of the Printhead Code option (see Figure 2) in accordance
with the ‘Reference Pressure Offset (bits)’ value given for the new ink in the offset
table supplied with the printhead or nozzle (Figure 1):
49342
PRINTHEAD SETUP
Type : Ultima
Conduit Length : 2m
> Printhead Code : 184-090-255
Figure 2. Reference Pressure Value in the Printhead Code Option

NOTE: The Reference Pressure offset is relative to 3103 ink.
The following are two examples of the method:
1. When calibrating a printer fitted with a Mk7 Ultima printhead, after
converting from 3103 to 1270 ink, add 2 bits to the existing 3103 Reference
Pressure value.
converting from 1290 to 1240 ink, subtract 6 bits from the existing 1290
Reference Pressure to obtain the 3103 value, then add 1 bit to obtain the new
1240 Reference Pressure value.
5 Amend the existing Reference Modulation part of the Printhead Code option (see
Figure 3) in accordance with the ‘Reference Modulation Offset (VM + offset) (V)’
value given for the new ink in the offset table supplied with the printhead or
nozzle (Figure 1):
49343
PRINTHEAD SETUP
Type : Ultima
Conduit Length : 2m
Figure 3. Reference Modulation Value in the Printhead Code Option

NOTE: The Reference Modulation offset is relative to 3103 ink.
The following are two examples of the method:
converting from 3103 to 1270 ink, add 20 volts to the existing 3103 Reference
Modulation value.
converting from 1290 to 1240 ink, add 30 volts to the existing 1290 Reference
Modulation to obtain the 3103 value, then add 10 volts to obtain the new 1240
Reference Modulation value.
6 Exit from the PRINTHEAD SETUP menu to the SETUP menu by pressing the [esc]
key.
Amdt 01 MP65557–1
7 Scroll to the Mod. Tracking Slope option.

8 Press the [enter] key to select the option setting. Enter the ‘Modulation Slope’
value for the new ink from the offset table supplied with the printhead or nozzle
(Figure 1), then press the [enter] key again.
9 Check the new Reference Modulation value by carrying out a modulation range
analysis in accordance with the ‘Modulation Range Checks’ maintenance
instruction.
10 Enter the following information onto a new Printhead Calibration Label, using an
indelible pen:
• The new Reference Pressure (in the CODE box)
• The new Reference Modulation (in the MODULATION box)
• The new ink type (in the INK TYPE box)
• The date (in the FITTED ON box)
11 Remove any dust or dirt from the existing printhead conduit label protective
sheath using a damp cloth, and then wipe dry. Do not use any solvents to clean
this conduit label.
12 Remove the backing paper from the completed Printhead Calibration Label and
attach it to the printhead conduit, on the existing conduit label. The label should
be wrapped around the conduit in such a way that it extends out from the conduit
at 90 degrees, and all written information is covered by the transparent tail (see
Figure 4):
6318
1 Write the date of fitting here. 2 Remove the backing paper from
the flag label.
3 Fold the label in half around the
conduit and stick the sides together
so that the label is tight on the
conduit.
Figure 4. Correct Fitting of the Printhead Calibration Label on the Conduit

13 The ‘Ink Conversion Calibration (Offset Calibration)’ maintenance instruction is
now complete and the printer is now calibrated for use with the new ink.
MP65557–1 Amdt 01
The following inks are approved for use in 4900 printers with Mk7 Ultima printheads:
3103 1010 1014 1016 1018 1035 1055 1056 1065 1070 1121 1240 1243 1270 1280 1290 1405 2030 2035 2250 3123 3124 3160 3240
Amdt 01
Jan 2006
The following ink conversions are allowed on 4900 printers with Mk7 Ultima printheads:
Conversions are allowed "To"

3103 1010 1014 1016 1018 1035 1055 1056 1065 1070 1121 1240 1243 1270 1280 1290 1405 2030 2035 2250 3123 3124 3160 3240
3103 ✓ ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1010 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓ ✓
1014 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓ ✓
1016 ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✗ ✗ ✗ ✗ ✗ ✗ ✓
1018 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓ ✓
1035 ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓ ✓
1055 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓ ✓
1056 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓ ✓
1065 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓ ✓
1070 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓ ✓
1121 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓ ✓
1240 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓ ✓
5 — 112
1243 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓ ✓
1270 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓ ✓
1280 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓ ✓
Ink conversion "From"

1290 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓ ✓
1405 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓ ✓
2030 ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
2035 ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
2250 ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
3123 ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
3124 ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
3160 ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
3240 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓
Figure 5. Approved Ink Types for Use in 4900 Printers with Mk7 Ultima Printheads, and Allowed Ink Conversions
Linx 4900 Maintenance Instruction

MP65557–1
The following inks are approved for use in 4900 printers with Mk7 Ultima plus printheads:
3103 1009 1010 1014 1016 1018 1035 1039 1055 1056 1065 1070 1121 1240 1243 1270 1280 1290 1405 2030 2035 2250 3123 3124 3160 3240
MP65557–1
The following ink conversions are allowed on 4900 printers with Mk7 Ultima plus printheads:

3103 1009 1010 1014 1016 1018 1035 1039 1055 1056 1065 1070 1121 1240 1243 1270 1280 1290 1405 2030 2035 2250 3123 3124 3160 3240
3103 ✗ ✓ ✓ ✗ ✓ ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1009 ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗
1010 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓ ✓
1014 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓ ✓
1016 ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✗ ✗ ✗ ✗ ✗ ✗ ✓
1018 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓ ✓

1035 ✓ ✗ ✓ ✓ ✗ ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓ ✓
1039 ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗
1055 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓ ✓
1056 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓ ✓
1065 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓ ✓
1070 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓ ✓
5 — 113
1121 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓ ✓
1240 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓ ✓
1243 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓ ✓
1270 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓ ✓

1280 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓ ✓
1290 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓ ✓
1405 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓ ✓
2030 ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
2035 ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
2250 ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
3123 ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
3124 ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
3160 ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
3240 ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✗ ✓ ✓ ✓ ✗ ✗ ✗ ✓ ✓ ✓
Figure 6. Approved Ink Types for Use in 4900 Printers with Mk7 Ultima plus Printheads, and Allowed Ink Conversions
Amdt 01
Jan 2006
Amdt 01
Jan 2006
The following inks are approved for use in 4900 printers with Mk7 Mini printheads:
1056 1240 1405
The following ink conversions are allowed on 4900 printers with Mk7 Mini printheads:

1056 1240 1405
1056 ✓ ✓
1240 ✓ ✓
5 — 114
1405 ✓ ✓

Figure 7. Approved Ink Types for Use in 4900 Printers with Mk7 Mini Printheads, and Allowed Ink Conversions

MP65557–1
Calibrated Nozzle Replacement (Offset Calibration)
Parts Required
FA74070/3103 Calibrated Nozzle Assembly 62 µm (for use with non-food grade inks)
or
FA74194/3103 Calibrated Nozzle Assembly 75 µm (for use with non-food grade inks)
FA20012 Printhead Calibration Label–Pack
Equipment Required
Tweezers
Introduction
The procedure in this maintenance instruction is primarily for use when replacing the
nozzles on Mk7 Ultima 62 µm and Ultima plus 75 µm printheads, in circumstances where
it has not been possible to clear a blocked nozzle after carrying out the full ‘Jet Alignment
and Nozzle Cleaning’ maintenance instruction.
This instruction also contains details for recalibrating a 4900 printer to operate with a new
printhead/nozzle combination following a printhead or nozzle replacement.
New printheads and nozzles are supplied with a calibration sheet, and Reference Pressure
and Reference Modulation Offset Tables, which give offset values to be used when the
printhead or nozzle is replaced.
IMPORTANT: It is most important that the Reference Pressure and Reference Modulation
Offset Tables sheet supplied with each individual printhead or nozzle is
retained and filed. If it is required to convert a printer to a different ink in
the future, the offset values from the original sheet for the printhead or
nozzle must be used. However, if the original offset values are not
available or were not supplied, they should be obtained from the Linx
International Technical Support department before carrying out a
recalibration.
MP65557–1
Procedure

DERMATITIS.
Nozzle Replacement
supply.
remove the cover.
assembly plate and remove the nozzle assembly.
5 Remove the old O-ring from the recess of the gun body, or from the nozzle
assembly plate if it has become adhered. Discard the O-ring.
CAUTION: Nozzle O-ring cleanliness. It is important that no rubber particles from
the new O-ring enter the nozzle plate or the gun assembly, as these particles could
cause a blockage.
6 Carefully remove the new calibrated nozzle assembly and O-ring from the
packaging, and examine for cleanliness and damage.
7 Thoroughly clean the nozzle assembly plate location and the gun body recess with
solvent.
8 Carefully place the new O-ring into the recess of the gun body using the tweezers.
9 Position the nozzle assembly on the printhead and loosely refit the two securing
screws and shakeproof washers.
CAUTION: Nozzle damage. Do not use pliers or any other tool to adjust the nozzle
position as this may cause damage to the nozzle.
MP65557–1
10 Adjust the nozzle alignment until the jewel is visible through the slot in the charge
electrode when viewed from the gutter.
11 Fully tighten the two nozzle assembly securing screws.
13 Consult the offset table and calibration sheet supplied with the new nozzle, and
add the ‘Reference Pressure Offset (bits)’ for the ink type used in the printer to the
new Reference Pressure given on the calibration sheet. An example of the offset
table is shown below:
68723
PRESSURE AND MODULATION OFFSET TABLE.
FROM 3103 TO DYE BASED OR PIGMENTED INK TYPES
Ink Type
Mk7 ULTIMA 3103 1010 1014 1016 1018 1035 1055 1070 1121 1240 1270 1290 1405 2030 2035 3123 3124 3240
Reference Pressure
— 0 1 13 4 3 9 –1 –1 1 2 6 3 1 1 0 0 1
Offset (bits)
— 10 –10 –15 0 –30 –25 –10 –10 10 20 –30 5 –10 –10 0 0 10
Offset (VM + offset) (V)
Modulation Slope 2.5 2.0 2.0 1.0 2.0 1.0 1.0 1.5 2.0 2.0 1.0 1.0 1.3 2.0 2.0 2.5 2.5 2.0
4900 Ink Type B B B B B B B B B B B B A C C B B C
Table issue no: 2.4
Figure 1. Example of Reference Pressure and Reference Modulation Offset Table

14 Access the PRINTHEAD SETUP menu (Setup menu), and amend the existing
Reference Pressure part of the Printhead Code option (see Figure 2) with this new,
adjusted Reference Pressure:
49342
PRINTHEAD SETUP
Type : Ultima
Conduit Length : 2m
Figure 2. Reference Pressure Value in the Printhead Code Option

15 Consult the offset table and calibration sheet supplied with the new nozzle, and
add the ‘Reference Modulation Offset (VM + offset) (V)’ for the ink type used in
the printer to the new Reference Modulation given on the calibration sheet.
16 Amend the existing Reference Modulation part of the Printhead Code option (see
Figure 3) with this new, adjusted Reference Modulation:
49343
PRINTHEAD SETUP
Type : Ultima
Conduit Length : 2m
Figure 3. Reference Modulation Value in the Printhead Code Option
MP65557–1
Jet Realignment
18 Examine the alignment of the jet with an eyeglass. The jet should pass exactly
through the centre of the charge electrode and enter the centre of the gutter when
viewed from the front (see Figure 4):
50% 50%
50%
50%
Mk7 Midi/Midi plus

and
Mk7 Ultima/Ultima plus
Gutter Alignment
The jet must enter

the centre of the gutter
68055
The jet must pass exactly

through the centre of
the charge electrode
Figure 4. Correct Alignment of the Jet into the Gutter

19 If the jet is not correctly aligned, the nozzle may require adjustment to realign the
jet. Realignment of the nozzle is best achieved using a finger and thumb only
with very little force applied until the alignment is correct (do not use pliers or
any other tool). The nozzle will move a little, and will probably spring back to its
original position. Apply a little more force, such that the nozzle will be deflected
but when released will not return fully to its original position. Continue using
this method until the jet is correctly aligned into the gutter as shown in Figure 4.
20 Shut down the printer and then restart the jet using the [start] key on the control
panel to ensure that the jet alignment is maintained, the jet is stable during the
start and stop operation, and that no warning or fault messages are reported.
MP65557–1
21 Carefully refit the nozzle protection cover using the securing screw, ensuring that
the jet alignment is not disturbed.
23 Check the new Reference Modulation value by carrying out a modulation range
analysis in accordance with the ‘Modulation Range Checks’ maintenance
instruction.
Flag Label Fitting

25 Enter the following information onto a new Printhead Calibration Label, using an
indelible pen:
• The new Reference Pressure (in the CODE box)
• The new Reference Modulation (in the MODULATION box)
• The new ink type (in the INK TYPE box)
• The date (in the FITTED ON box)
26 Remove any dust or dirt from the existing printhead conduit label protective
sheath using a damp cloth, and then wipe dry. Do not use any solvents to clean
this conduit label.
27 Remove the backing paper from the completed Printhead Calibration Label and
attach it to the printhead conduit, on the existing conduit label. The label should
be wrapped around the conduit in such a way that it extends out from the conduit
at 90 degrees, and all written information is covered by the transparent tail (see
Figure 5):
6318
1 Write the date of fitting here. 2 Remove the backing paper from
the flag label.
3 Fold the label in half around the
conduit and stick the sides together
so that the label is tight on the
conduit.
Figure 5. Correct Fitting of the Printhead Calibration Label on the Conduit

28 The ‘Calibrated Nozzle Replacement (Offset Calibration)’ maintenance
instruction is now complete.
MP65557–1
MP65557–1
Printer Installation Procedure
Equipment Required
FA65557 4900 Maintenance Manual
MP65317 Commissioning Checklist (supplied with printer)
FA65492 4900 Operating Manual
Service/Install Report
Procedure

DERMATITIS.
1 Configuration
Configure the printer by entering the supplied Configuration Code in the
CONFIGURATION menu (Setup menu > Change Configuration option > Code
option).
Refer to the 4900 Maintenance Manual, ‘Chapter 4: Setup Menu’.
2 Installation Parameters
Enter the required installation parameters in the SETUP menu:
• Time (Set Time option)
• Date (Set Date option)
• Date format (Julian Date Format option)
• Ink type (Ink Type Selection option)
• Printhead operating height (HEAD HEIGHT option)
• Printhead type (PRINTHEAD SETUP menu > Type option)
• Printhead conduit length (PRINTHEAD SETUP menu > Type option)
• Language (CHANGE LANGUAGE menu)
3 Commissioning
Commission the printer in accordance with the Commissioning Checklist.
MP65557–1
Printer Installation Procedure
4 Installation on Line
Position the printer on the production line and install the relevant accessories (e.g.
cabinet, gantry, product sensor, and line speed detector).
5 Line Parameters
Set the required production line parameters in the SETUP menu:
• Trigger signal (Primary Trigger option)
• Product speed detection (Shaft Encoder option)
• External alarm configuration (ALARM menu)
• Power down conditions (AUTO POWER DOWN menu)
6 Message Creation
Set message defaults. Create a template and adjust the print parameters as
necessary.
Refer to the 4900 Operating Manual, chapter 4, ‘Creating and Editing Messages’.
7 Operator/Supervisor Training
Carry out operator training.
Refer to the 4900 Maintenance Manual, ‘Chapter 8: Training Documentation’.
8 Password
Set the required password level in the CHANGE PASSWORD menu (Setup
menu).
9 Documentation
Complete the Service/Install Report ensuring that the customer signs the report.
10 The ‘Printer Installation Procedure’ maintenance instruction is now complete.
MP65557–1
24-volt Alarm Beacon Fitting (Printer Mounted)
Parts Required
FA61094 Alarm Beacon 6800
Procedure
supply.
2 Loosely fit the Alarm Beacon Mounting Bracket to the Alarm Beacon Stalk
Assembly, in the correct orientation as shown in Figure 1, using two of the four
screws provided in the kit:
48173
Clamp screw (x2)
Stalk assembly Mounting bracket
Figure 1. Alarm Beacon Mounting Bracket Fitted to the Stalk Assembly
MP65557–1
3 Fit the mounting bracket and stalk assembly to the two holes in the ink system
vent on the printer rear panel, using the two remaining screws provided in the kit
(Figure 2):
49344
Alarm Beacon
Stalk Assembly
Mounting Bracket Ink System Vent

clamp screws (x2)
Fit Mounting Bracket Alarm Beacon

securing screws Cableform—connect to
here (x2) ALARM OUTPUT
connector
Figure 2. Fitting the Alarm Beacon to the Rear of the Printer

4 Adjust the vertical position of the stalk assembly in the mounting bracket so that
the cableform exit from the stalk is clear of the printer mounting surface. Tighten
the mounting bracket clamp screws.
CAUTION: The printer ALARM OUTPUT connector must not be connected to the
mains or any other power source. Doing so could severely damage the printer.
5 Connect the stalk assembly cableform connector to the ALARM OUTPUT
connector on the printer rear panel.
6 Switch on the printer and access the ALARM menu (Setup menu).
MP65557–1
7 Press the [enter] key to select the Mode option setting. Set it to Continuous using
the left or right arrow key, then press the [enter] key again. Make sure that the
other options are set as shown in Figure 3:
49345
ALARM
> Mode : Continuous
Failure : Yes
Warning : Yes
Print Disabled : No
Figure 3. Alarm Option Settings for Testing the Alarm Beacon

8 Remove the printhead cover tube and make sure that the alarm beacon lights and
remains lit while the printhead cover tube is removed.
9 Make sure that the System Warning message “3.12 Printhead Cover Off” is
displayed in the status line.
10 Refit the printhead cover tube and make sure that, after a few seconds, the alarm
beacon switches off when the warning message clears from the status line.
11 Reset the ALARM menu options to their original settings.
13 The ‘24-volt Alarm Beacon Fitting (Printer Mounted)’ maintenance instruction is
now complete.
MP65557–1 Amdt 01
Amdt 01 MP65557–1
Mains (VFC) External Alarm Conversion
Parts Required
FA71060 VFC Alarm Upgrade
Equipment Required
Procedure

THIS EQUIPMENT WHEN ELECTRICAL POWER IS APPLIED. THE CORRECT,
OFF THE PRINTER AND DISCONNECT IT FROM THE MAINS SUPPLY BEFORE
REMOVING OR REFITTING ANY COMPONENTS OR LINKS. THERE IS A
DANGER OF DEATH OR INJURY FROM ELECTRIC SHOCK IF THE CORRECT
1 Shut down and switch off the printer. Make sure that it is switched off at the
mains supply.
and solvent.
5 Disconnect the 24 V Alarm Cableform from the Alarm PCB and the IPM PCB
(PL9). (This cableform is not required for the Mains External Alarm Conversion
but can be retained for future reinstallation of the 24 V Alarm, if desired.)
6 Remove and discard the two Nyloc nuts securing the Alarm PCB to the back of
the ALARM OUTPUT connector.
7 Remove and retain the Alarm PCB.
8 Remove the ALARM OUTPUT connector dust cap and unclip the retaining strip
from the connector, and retain.
9 Remove the locking ring from the back of the 2-pin ALARM OUTPUT connector
and remove the connector from the printer rear panel. (This alarm output
connector is not required for the Mains External Alarm Conversion but can be
retained for future reinstallation of the 24 V Alarm, if desired.)
10 Attach the new yellow and black “PL10” label, supplied in the kit, to the printer
inside rear panel adjacent to the ALARM OUTPUT connector. Do not use the
“PL11” label in the kit as this is intended for the 6800 printer.
11 Remove and discard the three screw terminals from the back of the new 3-pin
ALARM OUTPUT connector supplied in the kit.
12 Fit the three brass pillars, supplied in the kit, to the three terminals on the new 3-
pin connector.
MP65557–1 Amdt 01
13 Fit the new connector through the printer rear panel; fit and secure the connector
locking ring.
14 Refit the dust cap and retaining strip to the new connector.
15 Refit the Alarm PCB to the three pillars on the connector and secure using the
three new Nyloc nuts.
16 Connect the new VFC (volt-free contacts) Alarm Cableform to the Alarm PCB and
the IPM PCB (PL10).
17 Remove the warning label adjacent to the ALARM OUTPUT connector on the
printer outside rear panel (“Do Not Connect A Power Source To The Alarm Output”).
18 Connect the mains alarm beacon to the ALARM OUTPUT connector on the
printer rear panel.
WARNING. LETHAL VOLTAGE. IF A MAINS POWERED EXTERNAL ALARM IS

CONNECTED TO THE PRINTER, THERE MAY BE MAINS VOLTAGE ON THE
PCB ATTACHED TO THE ALARM CONNECTOR AND ON THE IPM PCB IN THE
AREA OF THE EXTERNAL ALARM RELAY, EVEN IF THE PRINTER IS ISOLATED
FROM ITS OWN MAINS POWER SUPPLY. WHEN THE PRINTER TOP COVER IS
REMOVED, DO NOT TOUCH THE ALARM CONNECTOR PCB, OR THE IPM PCB
IN THE AREA OF THE EXTERNAL ALARM RELAY. FAILURE TO COMPLY
WITH THIS SAFETY WARNING COULD RESULT IN ELECTRIC SHOCK, WHICH
MAY CAUSE INJURY OR DEATH.
19 Switch on the external alarm beacon mains supply.
20 Switch on the printer and access the ALARM menu (Setup menu).
21 Press the [enter] key to select the Mode option setting. Set it to Continuous using
the left or right arrow key, then press the [enter] key again. Make sure that the
other options are set as shown in Figure 1:
49345
ALARM
> Mode : Continuous
Failure : Yes
Warning : Yes
Print Disabled : No
Figure 1. Alarm Option Settings for Testing the Mains External Alarm
22 Remove the printhead cover tube and make sure that the alarm beacon lights and
remains lit while the printhead cover tube is removed.
23 Make sure that the System Warning message “3.12 Printhead Cover Off” is
displayed in the status line.
24 Refit the printhead cover tube and make sure that, after a few seconds, the alarm
beacon switches off when the warning message clears from the status line.
Amdt 01 MP65557–1
25 Reset the ALARM menu options to their original settings.

27 Switch off the external alarm mains supply.
31 The ‘Mains (VFC) External Alarm Conversion’ maintenance instruction is now
complete.
MP65557–1
MP65557–1
Positive Air Pump Fitting Instructions
Parts Required
FA67050 Positive Air Upgrade Internal
Equipment Required
Procedure

THIS EQUIPMENT WHEN ELECTRICAL POWER IS APPLIED. THE CORRECT,
OFF THE PRINTER AND DISCONNECT IT FROM THE MAINS SUPPLY BEFORE
REMOVING OR FITTING ANY COMPONENTS OR LINKS. THERE IS A
supply.
and solvent.
5 Locate the coiled, yellow-striped positive air pipe. It is routed from the printhead
conduit entry point in the printer rear panel, through the ink system enclosure
and out through a grommet in the ink system enclosure wall to the electronics
area (see Figure 1):
MP65557–1
49346
Yellow-striped
positive air pipe
Connect to
PL8 on the
IPM PCB
Positive Air Pump
Figure 1. Locations of the Positive Air Pump and Air Supply Pipe
6 Remove and discard the tie wrap securing the coiled pipe and neatly cut off the
protective end cap using the Tube Cutter.
MP65557–1
7 Connect the pipe to the A1–C1 barb fitted to the short pipe on the pump assembly
(Figure 2):
49347
Yellow-striped
positive air pipe
A1–C1 barb
Figure 2. Connecting the Positive Air Pipe to the Pump A1–C1 Barb
8 Position the pump assembly on the air filter housing, between the cooling fan and
the EHTPSU, in the orientation shown in Figure 1. Secure the pump assembly to
the air filter housing using the ear clamp and the two M4x5 pan head screws, two
plain washers, and two spring washers supplied in the kit.
9 Connect the pump assembly’s electrical supply cable to PL8 on the IPM PCB (see
Figure 1).
10 Tidy and secure the electrical cable and air supply pipe using the tie wraps
supplied in the kit. Ensure that the electrical cable is routed clear of the pump
assembly’s body.
MP65557–1
12 Remove the printhead cover tube and check for airflow from the positive air pipe
outlet on the printhead (see Figure 3):
49348
Positive air
pipe outlet
Figure 3. Printhead Positive Air Pipe Outlet

18 The ‘Positive Air Pump Fitting Instructions’ maintenance instruction is now
complete.
MP65557–1
Printhead Feed Valve Replacement
Parts Required
FA74160 Printhead Valve Assembly Mk7
comprising:
1 x 6800 Micro Valve Body
1 x O-ring
FA74219 Mk7 Printhead Valve Filter Assembly 15 µm (Ultima and Mini)
comprising:
1 x Feed Filter 15 µm
1 x O-ring
OR
FA74221 Mk7 Printhead Valve Filter Assembly 35 µm (Ultima plus)
comprising:
1 x O-ring
Equipment Required
Procedure
CAUTION: Contamination of the Printhead Feed Valve Components. Extreme care

must be taken when handling the feed valve assembly, mounting block, filter and O-
ring to avoid introducing contamination. These components must not come into contact
with any fibres, and skin contact must be avoided. Powder-free latex gloves must be
worn and the procedure should also be carried out in a clean, dust-free environment. If
a Clean Room is available, then it should be used.
supply.
MP65557–1 Amdt 01
2 Remove the one or two small cross head securing screw(s) from the printhead
upper cover (see Figure 1 below), and slide the cover back along the conduit to
expose the feed valve assembly.
Printhead
Upper Cover
68800
MIDI
Cross Head
Securing Screw(s) (x1 or x2)
Figure 1. Printhead Upper Cover and Securing Screws

3 Refer to Figure 2 and Figure 3 below for identification of the valve assembly parts
referred to in this procedure:
68801
Pipe Valve Assembly

Elbow Supports Knurled
Connecting Nut
Feed Valve
Solenoid
Valve Assembly
Hexagonal-drive
Securing Screws
Feed Valve
Body
Figure 2. Printhead Feed Valve Assembly
Amdt 01 MP65557–1
Valve Assembly
Knurled Connecting Nut Barb Connection
68803
Valve Solenoid
Valve Body
Valve Assembly
Hexagonal-drive
Securing Screws
O-ring Filter
Filter Housing Valve Mounting Block
Figure 3. Printhead Feed Valve Component Parts

4 Remove the two hexagonal-drive securing screws from the front face of the feed
valve assembly and carefully ease the assembly away from the valve mounting
block.
5 Carefully remove and discard the O-ring from the valve mounting block.
6 Remove the elbow supports from the ink feed pipe, and carefully cut the pipe off
the barb connection as close as possible to the barb.
7 Unscrew the valve assembly knurled connecting nut from the top of the valve
solenoid, being careful to retain the metal washer, and separate the valve body
from the solenoid.
8 Fit the new valve body from the spare parts pack (FA74160) to the solenoid. Secure
with the knurled nut, ensuring that the retained metal washer is in place and the
two parts of the valve assembly are squarely in line with each other.
9 Prepare the end of the ink feed pipe using the Tube Cutter to ensure the pipe is cut
cleanly and straight.
10 Connect the ink feed pipe to the valve barb connection.
NOTE: At this stage it is recommended that the feed filter in the valve mounting block is
replaced.
CAUTION: Contamination from Ink Build-up. In the following steps extreme care must
be taken to prevent any ink build-up from entering the filter housing.
11 Carefully remove the filter from its housing and discard it.
12 Carefully insert the new filter into its housing ensuring that the notches on the
filter are facing the inside of the valve mounting block. Take care not to damage
the filter when inserting it fully.
MP65557–1 Amdt 01
13 Refit the elbow supports to the ink feed pipe.

14 Fit the new O-ring (supplied in the spare parts pack FA74160) to the valve
mounting block.
15 Position the valve assembly onto the valve mounting block, ensuring that the filter
and O-ring are correctly seated, and secure using the two hexagonal-drive screws.
Tighten the screws until firm resistance is felt, then tighten a further ¼ turn.
16 Slide the printhead upper cover back down the conduit into position, ensuring
that the cover does not trap any wires or pipes. Secure the cover using the one or
two small cross head screw(s).
17 The ‘Printhead Feed Valve Replacement’ maintenance instruction is now
complete.
Amdt 01 MP65557–1
Printhead Feed Valve Filter Replacement
Parts Required
FA74219 Mk7 Printhead Valve Filter Assembly 15 µm (Ultima and Mini)
comprising:
1 x O-ring
OR
FA74221 Mk7 Printhead Valve Filter Assembly 35 µm (Ultima plus)
comprising:
1 x O-ring
Equipment Required
Procedure
CAUTION: Contamination of the Printhead Feed Valve Components. Extreme care

must be taken when handling the feed valve assembly, mounting block, filter and O-
ring to avoid introducing contamination. These components must not come into contact
with any fibres, and skin contact must be avoided. Powder-free latex gloves must be
worn and the procedure should also be carried out in a clean, dust-free environment. If
a Clean Room is available, then it should be used.
supply.
2 Remove the one or two small cross head securing screw(s) from the printhead
upper cover (see Figure 1 below), and slide the cover back along the conduit to
expose the feed valve assembly.
Printhead
Upper Cover
68800
MIDI
Cross Head
Securing Screw(s) (x1 or x2)
Figure 1. Printhead Upper Cover and Securing Screws
MP65557–1 Amdt 01
3 Refer to Figure 2 and Figure 3 below for identification of the valve assembly parts
referred to in this procedure:
68801
Pipe Valve Assembly

Elbow Supports Knurled
Connecting Nut
Feed Valve
Solenoid
Valve Assembly
Hexagonal-drive
Securing Screws
Feed Valve
Body
Figure 2. Printhead Feed Valve Assembly
Valve Assembly
Knurled Connecting Nut Barb Connection
68803
Valve Solenoid
Valve Body
Valve Assembly
Hexagonal-drive
Securing Screws
O-ring Filter
Filter Housing Valve Mounting Block
Figure 3. Printhead Feed Valve Component Parts
Amdt 01 MP65557–1
4 Remove the two hexagonal-drive securing screws from the front face of the feed
valve assembly and carefully ease the assembly away from the valve mounting
block.
5 Carefully remove and discard the O-ring from the valve mounting block.
CAUTION: Contamination from Ink Build-up. In the following steps extreme care must
be taken to prevent any ink build-up from entering the filter housing.
6 Carefully remove the filter from its housing and discard it.
7 Carefully insert the new filter into its housing ensuring that the notches on the
filter are facing the inside of the valve mounting block. Take care not to damage
the filter when inserting it fully.
8 Fit the new O-ring (supplied in the spare parts pack FA74219) to the valve
mounting block.
9 Position the valve assembly onto the valve mounting block, ensuring that the filter
and O-ring are correctly seated, and secure using the two hexagonal-drive screws.
Tighten the screws until firm resistance is felt, then tighten a further ¼ turn.
10 Slide the printhead upper cover back down the conduit into position, ensuring
that the cover does not trap any wires or pipes. Secure the cover using the one or
two small cross head screw(s).
11 The ‘Printhead Feed Valve Filter Replacement’ maintenance instruction is now
complete.
MP65557–1 Amdt 01
Amdt 01 MP65557–1
Correct Installation of Mk7 Printheads
Introduction
Correct installation and routing is critical to the life and reliability of the conduit. By
adhering to the following basic installation guidelines, the life of the conduit is significantly
increased.
The most important factor limiting the life of a conduit is the minimum bend radius it is
subjected to in an application. The recommendations are therefore to install the printhead
in a manner that maximizes this radius, and ensures that the minimum is never exceeded.
This document is divided into three main topics, namely:
1. Printhead Choice (for a particular application)
2. Conduit Routing (for particular applications)
3. Printer Position
Topics 1 and 2 are further sub-divided into two categories, dealing with the dynamics of
the application, namely:
• Static applications. The printhead is fixed in position relative to the printer or product
line, and the product moved relative to it. 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.
1 Printhead Choice
Linx Mk7 printheads are available in both straight and right-angled designs—it is
important to specify the correct one for the installation. The following diagrams illustrate
some of the factors to consider.
1.1 Printhead Choice for Static Applications

The printhead must be chosen so that the conduit can be routed with the minimum strain
on the conduit due to bending. The conduit must never be bent to a radius less than 75 mm
(measured to the inside of the conduit). Always select the printhead to give the most gentle
curves on the conduit, particularly in the area at the back of the printhead.
AS167
The conduit is strained if a There is very little strain if a

straight printhead is used right-angled printhead is used
MP65557–1 Amdt 01
AS168

straight printhead is used. right-angled printhead is used
The conduit is also exposed
and vulnerable to damage
AS169

right-angled printhead is used straight printhead is used
AS170

straight printhead is used right-angled printhead is used
Amdt 01 MP65557–1
AS171

1.2 Printhead Choice for Dynamic Installations

The printhead must be chosen so that the conduit can be routed with the minimum strain
on the conduit due to bending, or pulling the conduit away from the printhead. The
conduit must not be repeatedly bent to a radius less than 150 mm (measured to the inside
of the conduit). Always select the printhead to give the most gentle curves on the conduit,
particularly in the area at the back of the printhead.
AS172
The conduit is repeatedly tugged if a The conduit is gently flexed if a

2 Conduit Routing
• Do not force the conduit to take on a sharp bend
• Leave a loop to take up movements on dynamic applications; use a 4-m conduit to help
achieve this
• Support the conduit to stop it flopping around or making contact with other
machinery, but remember to allow access to the printhead for cleaning. Ensure that
there are cut-outs in guarding to prevent the conduit being crushed when the guards
are closed.
MP65557–1 Amdt 01
2.1 Conduit Routing for Static Applications

The conduit must never be bent to a radius less than 75 mm (measured to the inside of the
conduit). Always select the route to give the most gentle curves on the conduit, supporting
it where necessary.
AS173
The conduit is left to hang down The conduit is supported out of the
towards the production line way of the production line
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
AS175
The conduit is forced into a tight bend A conduit support prevents the conduit
over a sharp edge being bent over a sharp edge
Amdt 01 MP65557–1
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
2.2 Conduit Routing for Dynamic Applications

AS177
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
AS178
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
MP65557–1 Amdt 01
AS179
The conduit is twisted as the printhead The conduit is only bent as the printhead
moves. This reduces reliability moves. This improves reliability
3 Printer Installation
The printer must be installed so that the conduit is not bent sharply at the rear of the
printer. Always allow 150 mm clearance for the conduit to bend.
AS180
<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 behind the
150 mm behind the printer printer for it to bend
Amdt 01 MP65557–1
Changing the Orientation of Mk7 Right-Angled Printheads
Equipment Required
2.5 mm hexagon key
Introduction
The 2-metre and 4-metre Mk7 right-angled printheads have the facility to orientate the
right angle in any one of eight positions through 360° (i.e. at 45° intervals). This allows the
printhead to be correctly installed in any given application, with the minimum strain on
the conduit due to bending. (See also maintenance instruction, ‘Correct Installation of
Mk7 Printheads’).
This maintenance instruction details the procedure for changing the orientation of the right
angle on Mk7 right-angled printheads.
Procedure
1 Support the printhead in the vertical position, preferably in a Linx Printhead
Mounting Assembly.
Referring to Figure 1
2 Remove the two Conduit Collar securing screws.
3 Unscrew and remove the four securing screws from the Right-Angle Adaptor Top
Section, and remove the Top Section.
Right-Angle Adaptor
—Top Section
Securing Screws
Right-Angle Adaptor
Top Section
Gasket
O-Ring
Conduit Collar
Conduit Collar
Securing Screws
Right-Angle
Orientation
Screw
AS181
Figure 1. Removing the Right-Angle Adaptor Top Section
MP65557–1 Amdt 01
4 Lift the conduit clear of the Right-Angle Adaptor Bottom Section and hold it in the
vertical position.
5 Unscrew and remove the Orientation Location Screw.
Orientation Location Screw
Orientation Location Screw Hole
O-Ring Right-Angle Adaptor

Bottom Section
8 x orientation location
holes at 45° intervals
AS182
Figure 2. Changing the Orientation of the Right-Angle Adaptor Bottom Section

6 Whilst holding the conduit firmly to ensure that it does not twist, rotate the
Right-Angle Adaptor Bottom Section to the desired position.
7 Align the Orientation Location Screw Hole with the nearest of the eight
orientation holes in the printhead body and refit the Orientation Location Screw,
ensuring that the O-ring is correctly seated.
Amdt 01 MP65557–1
8 Lay the conduit straight back down in the Right-Angle Adaptor Bottom Section
ensuring that it does not twist.
9 Refit the Right-Angle Adaptor Top Section and loosely refit the four securing
screws, ensuring that the gasket is correctly seated.
10 Refit and tighten the two Conduit Collar securing screws, ensuring that the O-ring
is correctly seated.
11 Fully tighten the four securing screws on the Right-Angle Adaptor Top Section.
12 The ‘Changing the Orientation of Mk7 Right-Angled Printheads’ maintenance
MP65557–1 Amdt 01
Amdt 01 MP65557–1
Auto Mains Power Off Bypass Kit Fitting Procedure
Parts Required
FA67058 4900 Auto Mains Power Off Bypass Kit
Introduction
The purpose of the Auto Mains Power Off Bypass Kit is to remove the auto power off
facility from the printer to allow it to be integrated into OEM applications. This means
that the power control for the printer is provided solely by the mains power supply switch
on the printer’s rear panel.
Procedure
1 Shut down and switch off the printer. Disconnect the printer from the mains
supply.
4 Disconnect the Display PCB ribbon cableform connector from PL12 on the IPM
PCB, and disconnect the top cover’s earth lead from the push-on blade connector
on the floor of the cabinet. Place the top cover safely to one side.
and solvent.
Removing the Existing Auto Power On/Off Cableform

6 Disconnect the Auto Power On/Off Cableform connector PL4 on the IPM PCB,
which is located at the top-left corner of the PCB as viewed from the component
side (see Figure 1, and item ‘A’ in Figures 2 and 3).
Auto Power On/Off

Connector PL4
49353
Figure 1. Location of the Auto Power On/Off Connector PL4 on the IPM PCB
MP65557–1 Amdt 01
7 Disconnect the four connections on the Power On Switch SW2 at the front of the
printer (labelled ‘B’ in Figures 2 and 3).
49354 B
C
A
KEY
A Auto Power On/Off Cableform connector PL4
B Power On Switch SW2
C Low Voltage Power Supply Unit connector SK2
D Mains Power Supply Switch SW1
Figure 2. Rear View of the Printer Showing the Auto Power On/Off Cableform
KEY A
A Auto Power On/Off Cableform connector PL4
B Power On Switch SW2
C Low Voltage Power Supply Unit connector SK2
D Mains Power Supply Switch SW1 49355
B
Figure 3. Front View of the Printer Showing the Auto Power On/Off Cableform
Amdt 01 MP65557–1
8 Disconnect the cableform’s two earth connections from the push-on blade
connectors adjacent to switch SW2.
9 Disconnect the cableform connector SK2 on the Low Voltage Power Supply Unit
(labelled ‘C’ in Figures 2 and 3).
10 Disconnect the cableform’s four connections (2 x brown and 2 x blue) on the
Mains Power Supply Switch SW1 at the rear of the printer, noting the colour
coding of these connections (labelled ‘D’ in Figures 2 and 3).
11 Disconnect the cableform’s three connections (brown, blue, and yellow and green)
from the Mains Filter MF1 located below the Mains Power Supply Switch SW1,
noting the colour coding of these connections.
12 Remove the Auto Power On/Off cableform from the printer.
13 Remove the Power On Switch SW2 at the front of the printer by unscrewing its
retaining nut.
14 Insert the blanking plug supplied in the spares kit into the vacant hole and secure
with its retaining nut.
Connecting the New Auto Mains Power Off Bypass Cableform (see Figure 4)
G
49356
KEY
C To Low Voltage Power Supply Unit connector SK2
D To Mains Power Supply Switch SW1
E To Mains Filter MF1
F To push-on blade earth connectors adjacent to switch SW2
G Power On Switch SW1 blanking plug and retaining nut
Figure 4. 4900 Auto Mains Power Off Bypass Kit

15 Connect the Auto Mains Power Off Bypass Cableform’s three connections (brown,
blue, and yellow and green) to the Mains Filter MF1 (labelled ‘E’ in Figure 4),
ensuring that the colour coded wires are connected in the same sequence as those
removed.
MP65557–1 Amdt 01
16 Connect the cableform’s four connections (2 x brown and 2 x blue) to the Mains
Power Supply Switch SW1 at the rear of the printer (labelled ‘D’ in Figure 4),
ensuring that the colour coded wires are connected in the same sequence as those
removed.
17 Connect the cableform connector SK2 to the Low Voltage Power Supply Unit
(labelled ‘C’ in Figure 4).
18 Connect the cableform’s two earth connections to the push-on blade connectors
adjacent to the redundant switch SW2 location (labelled ‘F’ in Figure 4).
19 Fit link LK13 ‘POW_O/R’ (Power Off Override) on the IPM PCB.
20 Reconnect the Display PCB ribbon cableform connector to PL12 on the IPM PCB,
and reconnect the top cover’s earth lead to the push-on blade connector on the
floor of the cabinet.
NOTE: Ensure that the customer is made aware that this mains power modification has
been embodied on this printer, which means that the Auto Power Off facility has
been removed.
24 The ‘Auto Mains Power Off Bypass Kit Fitting Procedure’ maintenance
Amdt 01 MP65557–1
CHAPTER 6: SYSTEM EVENTS
6.1 Introduction
This chapter describes the failure and warning system events in Version 1.5 System
Software for the 4900 printer. System events are divided into four categories:
1. System Failures
2. Print Failures
3. System Warnings
4. Advisory Messages
System Failures, Print Failures and System Warnings are defined as those that can occur at
any time and are NOT a direct response to user commands.
Advisory messages are those displayed as a direct response to user commands, for
example, “Invalid Data” or “Startup in Progress”. They are not failures or warnings. As
these messages are numerous and self explanatory, they are not described in this chapter.
6.2 System Event Types

6.2.1 Event Reporting
Each failure and warning message is given a unique code number, which identifies the
type and source of the failure or warning, and is followed by a short description when
displayed in a screen or menu status line. For example:
49157

F3 : New Message F4 : Change Setup
Error 3.03 Ink Low
Figure 6-1. Event Message Displayed in the Current Message Screen Status Line
The message continues to be displayed until the cause of the event has been rectified.
6.2.2 System Failures

These faults prevent normal printer operation. The messages are prefixed with “Sys Fail
1”. For example:
“Sys Fail 1.00 Internal Failure”
6.2.3 Print Failures

These faults occur when the software detects a problem that affects printing. The
messages are prefixed with “Printer Fail 2”. For example:
“Printer Fail 2.00 Printhead Over Temperature”
6.2.4 System Warnings

These are events that are not serious enough to shut down the printer, but give advanced
warning of potential problems. The messages are prefixed with “Error 3”. For example:
“Error 3.00 Shutdown Incomplete”
MP65557–1 Amdt 01
6.3 Warning & Fault Reporting Configuration
This facility allows all current System Warning event messages to be viewed, and the
reporting of all System Warning and Print Failure events to be configured. Access to these
options is achieved by pressing the [F2] key (Check Status) from the CURRENT MESSAGE
screen, which then displays the PRINT STATUS screen:
49157

F3 : New Message F4 : Change Setup 49158
Error 3.03 Ink Low
PRINT STATUS
F1 : Event List Count : 9
F2 : Warning Info. Status : Jet Off
F3 : Fault Info. Solvent : OK
Ink : OK
Figure 6-2. Accessing the Print Status Screen
6.3.1 Print Status Screen

This screen contains information about the current status of the printer.
The options Warning Info. and Fault Info. are included as diagnostic tools for the service
engineer and, therefore, access to these options is only possible with the Service Level
password and with link LK10C fitted on the IPM PCB. If these two conditions are not met,
the PRINT STATUS screen displays only the ‘F1 : Event List’ option. Also, the Password
option must be set to Off using the Service Level password to enable the ‘F2 : Warning
Info.’ and ‘F3 : Fault Info.’ options to be displayed.
The four parameters shown on the right-hand side of the screen are briefly explained first.
Count
Shows the cumulative number of messages printed. This value can be altered in the Print
Count option of the SETUP menu.
Status
This displays one of three printer states:
Jet Off: the jet has not been started or has been stopped
Jet Running: the jet is running but printing is stopped
Ready to Print: the jet is running and the printer is ready to print
Solvent
Shows the status of the solvent level check, either OK or Low.
Ink
Shows the status of the ink level check, either OK or Low.
Refer to the Linx 4900 Ink Jet Printer Operating Manual for instructions on filling the printer
with ink and solvent.
IMPORTANT: Only one bottle of ink or solvent should be added when the level is
reported as Low.
Amdt 01 MP65557–1
F1 : Event List
All current System Warning events are logged and can be displayed by pressing the [F1]
key (Event List) from the PRINT STATUS screen:
49017
EVENT LIST
> 3.12 Printhead Cover Off
3.04 Solvent Low
Figure 6-3. Event List Menu

A shortcut to the Event List menu can be used from the CURRENT MESSAGE screen by
pressing the [L] accelerator key.
This menu displays all System Warning events that have occurred since the printer was
last switched on. An attempt can be made to clear a System Warning message by selecting
it from the Event List menu and pressing [enter]. Some messages can be cleared, in which
case the control panel ‘warning’ LED extinguishes. Other messages cannot be cleared and
the control panel ‘warning’ LED remains lit until the cause of the event has been rectified,
for example “3.03 Ink Low”—refill with ink to clear the message.
NOTE: A System Warning message reports a problem with the printer that does not
immediately affect its ability to continue printing. A System Failure or Print
Failure immediately initiates a fault shutdown (with the exception of the “2.07
Internal Spillage” fault) after which the printer can be reset.
F2 : Warning Info.
Pressing the [F2] key (Warning Info.) from the PRINT STATUS screen accesses the
WARNING INFORMATION menu, which lists all the possible System Warning event
messages:
49159
WARNING INFORMATION
3.00 Shutdown Incomplete
3.02 Memory Corrupt
> 3.03 Ink Low
3.04 Solvent Low
3.05 Over Speed (Print Trigger)

3.06 Over Speed (Sychronous Data)
3.07 Over Speed (Asychronous Data)
3.11 Scheduled Maintenance Reqd
3.12 Printhead Cover Off
3.13 Cover Override Active
3.14 Power Off Override Active
3.15 Safety Override Active
3.16 Gutter Override Active
3.17 Gate Array Test Mode Active
3.18 Low Pressure
3.20 No Time Of Flight
3.26 User Data Corrupt
3.29 No Message Stored
3.30 Message Name Exists
3.31 Message Memory Full
3.32 Remote Error
3.33 Synchronisation
Figure 6-4. Warning Information Menu
MP65557–1 Amdt 01
How a System Warning event is reported can then be configured by selecting it and
pressing [enter], which displays the following menu:
49160
3.03 Ink Low

> Trigger : Once
Count : 0
Figure 6-5. Warning Message Configuration Menu

The menu title corresponds to the currently selected message in the WARNING
INFORMATION menu, and the two options available are Trigger and Count:
Trigger
This option can be altered to one of three settings—Once (the default), Always, and Never:
Once
Selecting Once results in the System Warning being reported only once in the status line
while the warning is valid, and while it remains in the Event List (that is, until it is deleted
from the Event List).
Always
Selecting Always results in the System Warning being reported every time it occurs,
regardless of whether it has been deleted from the Event List.
Never
Selecting Never results in the System Warning never being reported, although the number
of times it occurs (see Count below) is still incremented.
NOTE: This function should be used with discretion when the printer is receiving a lot
of events in quick succession, for example Over Speed errors. In this situation the
user interface could become swamped with constantly displayed reports.
Count
The Count option records the number of times the warning occurs (not the number of times
it is reported). This value is stored in Non-Volatile RAM (NVR) and is remembered while
the power is off, and therefore is a continuous record of the number of times the warning
has ever occurred.
NOTE: It is not possible to alter the Count value.
When the Trigger option is set to Always, and whilst a warning is being reported in the
status line, any subsequent warning is not displayed until the first warning display sequence
is completed. However, the Count increments on the occurrence of every warning.
For example, consider a situation where a “3.05 Over Speed (Print Trigger)” warning is
being reported constantly. The first occurrence causes the warning message to be
displayed, the internal alarm tone (beeper) to sound and the Count for that warning to
increment. If, during the display sequence of the first warning, two more over speed events
occur, the Count increments a further two times. Once the warning display sequence has
completed, the next occurrence (the fourth) of an over speed event causes the warning
message to be displayed for the second time, although four over speed events have
occurred since the beginning of the first display sequence.
Each warning message is displayed in turn for approximately 2 seconds before the next is
displayed. This allows all warnings that have occurred to be easily seen. Confirmation of
any warning can then be checked by examining the Event List.
Amdt 01 MP65557–1
F3 : Fault Info.
Pressing the [F3] key (Fault Info.) from the PRINT STATUS screen accesses the FAULT
INFORMATION menu, which lists all the possible Print Failure event messages:
49161
FAULT INFORMATION
2.00 Printhead Over Temperature
2.01 EHT Trip
2.02 Phase Failure
> 2.03 Time Of Flight Failure
2.04 300V Power Supply

2.05 Ink Tank Empty
2.06 Solvent Tank Empty
2.07 Internal Spillage
2.09 Misaligned Ink Jet
2.11 Pressure Limit Reached
2.12 Viscosity
2.13 Hardware Safety Trip
Figure 6-6. Fault Information Menu
The particular Print Failure event that is required to be configured can then be selected,
which displays the following menu:
49162
2.03 Time Of Flight Failure

> Count : 0
Figure 6-7. Fault Message Configuration Menu

The menu title corresponds to the currently selected message in the FAULT
INFORMATION menu, and the single option available is Count:
Count
As with the Warning Info. option, the Count option records the number of times the fault
occurs (not the number of times it is reported). This value is stored in Non-Volatile RAM
(NVR) and is remembered while the power is off, and therefore is a continuous record of
the number of times the fault has ever occurred.
NOTE: It is not possible to alter the Count value.
MP65557–1 Amdt 01
6.4 System Event Designations
49163
1. System Failures 2. Print Failures 3. System Warnings
1.00 Internal Failure 2.00 Printhead Over Temperature 3.00 Shutdown Incomplete
1.01 Stack Overflow 2.01 EHT Trip 3.01 Not used
1.02 Corrupt Program Data 2.02 Phase Failure 3.02 Memory Corrupt
1.03 Unexpected Interrupt 2.03 Time Of Flight Failure 3.03 Ink Low
1.04 Unexpected RST 2.04 300V Power Supply 3.04 Solvent Low
1.05 Unexpected NMI 2.05 Ink Tank Empty 3.05 Over Speed (Print Trigger)
1.06 Not used 2.06 Solvent Tank Empty 3.06 Over Speed (Synchronous Data)
1.07 System RAM 2.07 Internal Spillage 3.07 Over Speed (Asynchronous Data)
1.08 Not used 2.08 Not used 3.08 Not used
1.09 Not used 2.09 Misaligned Ink Jet 3.09 Not used
1.10 Not used 2.10 Not used 3.10 Not used
1.11 Not used 2.11 Pressure Limit Reached 3.11 Scheduled Maintenance Req’d
1.12 Language Version 2.12 Viscosity 3.12 Printhead Cover Off
1.13 No Raster Data 2.13 Hardware Safety Trip 3.13 Cover Override Active
1.14 Raster Version 2.14 Not used 3.14 Power Off Override Active
1.15 Not used 3.15 Safety Override Active
1.16 No Fonts 3.16 Gutter Override Active
1.17 Font Version 3.17 Gate Array Test Mode Active
1.18 Not used 3.18 Low Pressure
1.19 Not used 3.19 Not used
1.20 Logo Version 3.20 No Time Of Flight
1.21 Pixel RAM 3.21 Not used
1.22 Date Format Version 3.22 Not used
1.26 Not used 3.26 User Data Corrupt
1.29 Not used 3.29 No Message Stored
1.30 Not used 3.30 Message Name Exists
1.31 Not used 3.31 Message Memory Full
1.32 Not used 3.32 Remote Error
1.33 Not used 3.33 Synchronisation
1.34 Invalid Configuration
1.35 No UNIC Chip
Figure 6-8. System Event Designations Table
Amdt 01 MP65557–1
6.5 System Failures
System Failures occur when the software detects a condition that prevents the software
from operating. System Failures are fatal; it is not possible to continue to operate the
printer after a System Failure has occurred. The only way to clear the failure is to switch
the printer off and then on again.
Most System Failures are reported while the software is performing the self-test and
initialization routines, which are carried out after the printer is switched on, that is, while
the LINX logo and software version screen is displayed. When the CURRENT MESSAGE
screen is displayed, all the initialization and self-tests will have been completed.
WARNING: LETHAL VOLTAGE. BECAUSE SYSTEM FAILURES 1.00 AND 1.01

INDICATE A FAILURE IN THE OPERATION OF THE MICROPROCESSOR, THE
SOFTWARE CANNOT BE RELIED UPON TO SET THE PRINTER TO A SAFE
STATE. IT IS POSSIBLE THAT THE EHT AND THE 300 VOLTS D.C. WILL STILL
BE PRESENT.
System Failures that occur during normal operation indicate a serious problem that
prevents further printer operation. The software attempts to set the printer to a safe state
when the failure occurs, as follows:
• Set the pressure to zero
• Switch off the EHT
• Close all valves
• Switch off the 300 V d.c.
System Failures cause the printer to stop printing by simply closing the ink system and
printhead Feed valves; a normal jet shutdown is NOT carried out. This leads to a
subsequent messy startup and can cause permanent damage to the printhead if it is left in a
messy state.
When a System Failure occurs, the print ready line is set low and a System Failure message
is displayed. The internal alarm tone is switched on continuously, but the external alarm is
not activated because the software cannot be certain of the alarm enable state following
some System Failures.
6.5.1 “1.00 Internal Failure”

Undefined software failure. This fault message indicates that the software has received a
corrupting signal and the software has been reset in an undefined manner. It would be
more commonly expected to occur when the printer is in operation, having successfully
completed the normal switch-on system checks.
Possible Causes:
• Printer top cover not correctly secured, or printhead cover tube screw not in place
• Dirty IPM PCB caused by a damaged or missing air inlet filter
• Faulty IPM PCB
• EMC interference or spike on mains power supply
• Static discharge to the printhead from the operating environment
• Poor electrical connections
MP65557–1 Amdt 01
6.5.2 “1.01 Stack Overflow”
Software failure. The software stack has exceeded the maximum expected size. The stack is
an area of memory used by the microprocessor in which information is temporarily stored.
Possible Causes:
• Faulty or corrupt microprocessor
• Faulty IPM peripheral issuing too many interrupts
6.5.3 “1.02 Corrupt Program Data”

Program and/or Data stored in memory is corrupt.
Possible Causes:
• Faulty or corrupt memory
• Faulty IPM PCB
6.5.4 “1.03 Unexpected Interrupt”

This fault message indicates that the software has received an unexpected interrupt signal
and the software has been reset in an undefined manner. It would be more commonly
expected to occur when the printer is in operation, having completed the normal switch-
on system checks.
Possible Causes:
• An unrecognized interrupt vector has occurred. One of the CPU peripherals has issued
an invalid interrupt
6.5.5 “1.04 Unexpected RST”

This fault message indicates that the software has received a corrupting signal and the
software has been reset in an undefined manner. It would be more commonly expected to
occur when the printer is in operation, having successfully completed the normal switch-on
system checks.
Possible Causes:
• Faulty connection caused by poor seating of a socketed IC
• Dry solder joints
• PCB contamination
Amdt 01 MP65557–1
6.5.6 “1.05 Unexpected NMI”
This fault message indicates that the software has received an unexpected interrupt signal,
typically a non-maskable interrupt (NMI), and the software has been reset in an undefined
manner. It would be more commonly expected to occur when the printer is in operation,
having completed the normal switch-on system checks.
Possible Causes:
6.5.7 “1.07 System RAM”

The non-destructive System RAM test has failed. During initialization a non-destructive
test of the System RAM is carried out, and if any associated faults are detected then this
fault message is reported.
Possible Causes:
• Faulty System RAM
• Faulty PROM addressing circuit
6.5.8 “1.12 Language Version”

The language version data is incorrect or incompatible with the program data in the
Program PROM.
Possible Causes:
• Corrupt Program PROM
6.5.9 “1.13 No Raster Data”

There is no raster information stored in the Data area of the Program PROM, or the raster
information does not contain the required raster for the currently fitted printhead type.
Possible Causes:
6.5.10 “1.14 Raster Version”

The raster version data is incorrect or incompatible with the program data in the Program
PROM.
Possible Causes:
6.5.11 “1.16 No Fonts”

There are no fonts stored in the Data area of the Program PROM, or the data has been
corrupted.
Possible Causes:
MP65557–1 Amdt 01
6.5.12 “1.17 Font Version”
The font version data is incorrect or incompatible with the program data in the Program
PROM.
Possible Causes:
6.5.13 “1.20 Logo Version”

The logo version data is incorrect or incompatible with the program data in the Program
PROM.
Possible Causes:
• Corrupt Logo PROM
6.5.14 “1.21 Pixel RAM”

The Pixel RAM startup test has failed.
Possible Causes:
• Either or both pixel RAMs are faulty
• Hardware fault
6.5.15 “1.22 Date Format Version”

The date format version data is incorrect or incompatible with the program data in the
Program PROM.
Possible Causes:
6.5.16 “1.34 Invalid Configuration”

The configuration data is incorrect or incompatible.
Possible Causes:
• Faulty, corrupt or incorrect UNIC
6.5.17 “1.35 No UNIC Chip”

The software is unable to identify the UNIC. When this fault occurs the printer fails
(stops), and a serviceable, valid UNIC must be fitted before powering up the printer and
continuing.
Possible Causes:
• Missing, faulty, corrupt or incorrect UNIC.
Amdt 01 MP65557–1
6.6 Print Failures
Print Failures occur when the software detects an electrical or mechanical failure that
prevents printing. When a Print Failure occurs, a Print Failure message is displayed in the
screen status line and a jet shutdown sequence is initiated. The control panel ‘fail’ LED and
the internal alarm tone are switched on continuously and, depending on the status of the
Alarm options in the SETUP menu, the external alarm may be activated continuously. The
keyboard is inactive while the shutdown is taking place.
In some cases, although certain message editing facilities may still be available, the printer
must be switched off at the mains power switch and then on again before printing can be
continued; this resets the hardware. With these Print Failures the conditions cannot be
altered until the cause of the failure has been rectified, that is, the jet cannot be restarted.
However, most Print Failures initiate a normal shutdown sequence, and the printer can be
restarted in the normal manner afterwards without the need to cycle the mains power.
When the shutdown sequence has been completed the Print Failure screen is displayed:
49206
PRINT FAILURE
Print Fail 2.00 Printhead Over Temperature
F1 : Reset Printer
Print Fail 2.00 Printhead Over Temperature
Figure 6-9. Print Failure Screen

‘F1 : Reset Printer’ is the single option available and should normally be selected to reset
the printer.
Following a Print Failure shutdown, the software will have completed the following:
• Set the pressure to zero
• Switched off the EHT
• Closed all valves
• Switched off the 300 V d.c.
MP65557–1 Amdt 01
6.6.1 “2.00 Printhead Over Temperature”
WARNING: HIGH TEMPERATURE. WHEN THIS FAULT IS REPORTED THE

PRINTHEAD AND COVER TUBE MAY BE VERY HOT. EXTREME CARE MUST
BE TAKEN TO AVOID SKIN BURNS AND INCREASING THE RISK OF A FIRE.
DO NOT TOUCH THE PRINTHEAD OR ATTEMPT TO REMOVE THE
PRINTHEAD COVER TUBE UNTIL IT HAS BEEN ALLOWED TO COOL DOWN
NATURALLY. REMOVING THE PRINTHEAD COVER TUBE BEFORE IT HAS
COOLED DOWN SUFFICIENTLY MAY RESULT IN SEVERE BURNS TO THE
HANDS AND THE POSSIBILITY OF FIRE DUE TO THE SUDDEN INCREASE IN
OXYGEN AROUND THE PRINTHEAD.
Excessive high temperature at the printhead indicating a high ambient temperature or a
possible fire condition. The trip temperature is approximately 60 °C.
Possible Causes:
• Printhead too close to source of high temperature
• Short circuit printhead thermistor
• Short circuit connection on printhead connector
• Faulty IPM PCB
NOTE: Hot substrates should be printed on from the side to avoid heat convection to the
printhead.
6.6.2 “2.01 EHT Trip”

The EHT trip sense software has detected that an EHT trip has occurred, that is, the EHT
output has been switched off.
Possible Causes:
• Excessive build-up of ink on the EHT deflector plate, or the ink is shorting the plate to
another item in the printhead, for example, the gutter
• Static discharge
• High humidity
• Vibration
• Jet instability caused by contaminated ink or debris in the nozzle
• Printhead too close to the substrate
• High or low ink viscosity causing satellite drops, which have built up on the deflector
plates
• No modulation
Amdt 01 MP65557–1
6.6.3 “2.02 Phase Failure”
The printer failed to obtain a valid phase position after 48 attempts. This failure is normally
associated with invalid data from the hardware, and can be caused if the printhead
becomes very dirty with ink, particularly around the DPP.
When the jet is running, the phase position must be adjusted to ensure 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. A maximum of 48 attempts are made to find the phase
position, after which the printer will fail and carry out the jet shutdown sequence.
Possible Causes:
• No jet:
❐ Nozzle blocked
❐ No ink feed to the printhead
• Poor jet break-up:
❐ Ink viscosity too high or too low
❐ Reference modulation set very low
❐ Modulation too high or too low
❐ No modulation signal
• Jet misalignment:
❐ Partly blocked nozzle
❐ Debris in the nozzle
❐ Contaminated ink
❐ Mechanical misalignment
❐ An obstruction such as a fine hair impeding the jet, for example, through the
charge electrode
• No charge to electrode caused by bad connections, faulty Charge Amp or incorrect
charge DAC calibration
• No signal from phase/TOF connections
• Faulty phase amplifier on IPM PCB
• Faulty gate array circuitry on the IPM PCB
• Conductivity problems due to contaminated ink
• Very heavy ink build-up in printhead
• EHT tracking on printhead due to very damp/humid environments
NOTE: This failure detection is disabled whenever the Quick Start Jet option is used.
MP65557–1 Amdt 01
6.6.4 “2.03 Time Of Flight Failure”
This failure occurs if, after the jet has been started, there are no valid TOF readings for a
period of 40 minutes.
Possible Causes:
• The shaft encoder or production line stops mid-print
• Incorrect or no signal from the TOF sensor caused by a partially blocked nozzle or jet
misalignment
• Poor drop break-up caused by incorrect modulation/ink viscosity
• The ink viscosity is so far out of range that correctly measured TOF values are rejected
as being spurious readings
• Heavy build-up of dry ink on the deflector plates
• Noise (EMC) interference
6.6.5 “2.04 300V Power Supply”

The 300 volts sense signal has detected that the 300 V output from the EHTPSU is not
present.
Possible Causes:
• The EHTPSU 300 V output has failed
• Faulty 5 volts reference, which is compared with a proportion of the 300 volts line to
determine the presence of the 300 volts
• Printhead modulation/charge short circuit
• Faulty 300 volts control circuit on IPM PCB
• Faulty 300 volts sense comparator (IC35A)
6.6.6 “2.05 Ink Tank Empty”

This failure occurs when the ink level sensor has been indicating low (“3.03 Ink Low”
warning) for a predetermined time of 8 hours for Mini and Ultima printheads, and 6 hours
for the Ultima plus printhead.
The time limit prevents the ink from running out completely, and damaging the pump, if
the operator fails to refill the ink reservoir following a System Warning “3.03 Ink Low”
message. This failure only occurs when the jet is running, as the jet cannot normally be
started when the ink is low.
6.6.7 “2.06 Solvent Tank Empty”

This failure occurs when the solvent level sensor has been indicating low (“3.04 Solvent
Low” warning) for a predetermined time of 12 hours for all printheads.
The time limit prevents the solvent from running out completely if the operator fails to
refill the solvent reservoir following a System Warning “3.04 Solvent Low” message. This
failure only occurs when the jet is running, as the jet cannot normally be started when the
solvent is low.
Amdt 01 MP65557–1
6.6.8 “2.07 Internal Spillage”
The base of the ink system enclosure is sealed in order to contain any ink or solvent
spillage, preventing external leakage. In the event of a pressurized ink leak from the ink
system pipe work, manifold assembly or pump head, a spillage sensor stops the pump
within 5 seconds of detection (that is, there is no jet shutdown). The sensor is fitted through
(but insulated from) the lower front wall of the ink system enclosure. When a spillage
reaches a minimum of 50 ml, a short circuit occurs between the sensor and the ink system
enclosure through the conductive ink. This short circuit is detected by the microprocessor
on the IPM PCB and the System Failure “2.07 Internal Spillage” is reported.
Possible Causes:
• Ink or solvent reservoir overflow
• Incorrect ink replenishment procedure
• Leak within the ink system
• Faulty spillage detection circuit
6.6.9 “2.09 Misaligned Ink Jet”

Under normal operating conditions the gutter sense circuit detects the presence of ink flow
in the gutter. If ink flow is not detected in the gutter for any reason (for example, a
misaligned jet), the software will shut down the jet. Absence of ink in the gutter is detected
within approximately 10 seconds.
Possible Causes:
• Partly blocked nozzle
• Debris in the nozzle
• Blocked gutter
• Contaminated ink
• Mechanical misalignment
• An obstruction, such as a fine hair, impeding the jet through the charge electrode
6.6.10 “2.11 Pressure Limit Reached”

The software is unable to increase the pressure sufficiently to achieve a TOF within range.
This can occur during the jet start process.
Possible Causes:
• Blocked ink pick-up tube in-line filter or main ink filter
• Leaking purge or gutter valve
• Very high ink viscosity
• No modulation
• No charge
• Worn pump
• Faulty pressure transducer
• Incorrect calibration code entered
• Incorrect printhead type selected
• Excessive noise on the phase/TOF signal
MP65557–1 Amdt 01
6.6.11 “2.12 Viscosity”
The software is unable to establish Reference TOF at or below the Solvent Add Pressure.
The printer has added solvent a maximum number of times (see NOTE below) without
being able to bring the pressure below the Solvent Add Pressure.
NOTE: For the maximum number of consecutive solvent additions, see the ‘Ink Type
Dependent Parameters’ tables at the end of the ‘Ink System’ section in ‘Chapter
3: Technical Description’.
When the jet is running, the normal TOF adjustment routine may add solvent if the Solvent
Add conditions are met (see Chapter 3: Technical Description > Ink System > Ink and
Solvent Flows > Solvent Addition). A Solvent Add allows a fixed amount of solvent to be
added to the ink reservoir. Typically, it takes approximately 20 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 the TOF. However, if after 20
minutes the pressure is still greater than the Solvent Add Pressure, a further solvent
addition is allowed. This is repeated until the pressure is below the Solvent Add Pressure.
A maximum number of solvent additions (see NOTE above) is allowed in any one TOF
correction loop. If this limit is exceeded, this fault is reported and the jet is shut down.
Possible Causes:
• Blocked ink pick-up tube in-line filter or main ink filter
• Leaking purge or gutter valve
• Incorrect calibration code entered
• Solvent pick-up tube in-line filter blocked
• There is a loss of pressure in the ink system and the pressure has been set artificially
high in order to reach the TOF reference. Consequently, the maximum number of
solvent additions may have been exceeded, which results in this fault being reported
• Ink has been added to the solvent tank by mistake
6.6.12 “2.13 Hardware Safety Trip”

The hardware safety trip has activated, locking out certain hardware functions. This may
be initially reported as Print Failures “2.00 Printhead Over Temperature” or “2.01 EHT
Trip”.
Possible Causes:
• See Print Failures “2.00 Printhead Over Temperature” or “2.01 EHT Trip”.
Amdt 01 MP65557–1
6.7 System Warnings
System Warnings inform the user of problems that may affect the operation of the printer
but are not serious enough to require a shutdown. When a System Warning occurs, a
System Warning message is displayed in the screen status line for a minimum of
approximately 3 seconds. The control panel ‘warning’ LED is switched on and off twice
and then remains on. The internal alarm tone is switched on and off twice and, depending
on the status of the Alarm options in the SETUP menu, the external alarm may be activated
twice.
The warning message remains displayed in the screen status line after the 3-second interval
until the user presses any key, or another warning event occurs, or an Advisory Message is
displayed.
NOTE: An Advisory Message is a message without a number designator, which appears
in the screen status line, for example, “Invalid Key Pressed” or “Message Start”.
It is not a warning or fault.
All System Warning events are logged and can be displayed by selecting the ‘F1 : Error
List’ option from the PRINT STATUS screen (‘F2 : Check Status’ in CURRENT MESSAGE
screen). This screen displays all System Warning events that have occurred. The user can
attempt to clear a warning event by selecting the warning message from the Error List and
pressing [enter]. Some events can be cleared, in which case the control panel ‘warning’
LED extinguishes. Other events cannot be cleared and the control panel ‘warning’ LED
remains lit until the cause of the event has been rectified, for example, “3.03 Ink Low”. See
‘Warning & Fault Reporting Configuration’ earlier in this chapter.
6.7.1 “3.00 Shutdown Incomplete”

The printer was powered down before the shutdown sequence was completed.
This warning is reported at power on. It indicates that the printer was previously switched
off while the jet was still running, or before the printer had completed the shutdown
sequence. Printer start problems may be experienced if the shutdown sequence was
incomplete; these could be a blocked nozzle, a dirty start or a misaligned jet.
The warning is reported on every subsequent printer power up until a jet shutdown
sequence is fully completed.
6.7.2 “3.02 Memory Corrupt”

When the printer is switched on, each individual item stored in the back-up NVR is
checked. If one or more items are corrupt, the default values for those items are loaded and
this event is reported. The system will still function but some values may have been reset
to the defaults.
Possible Causes:
• The battery back-up has partially failed (flat battery)
• Link LK2 not fitted on IPM PCB
• Electrical spikes
• Faulty memory ICs
MP65557–1 Amdt 01
6.7.3 “3.03 Ink Low”
If the ink level sensor indicates that the volume of ink in the tank is low, this warning is
reported. The warning is cleared automatically when a sufficient quantity of ink is added
to the tank.
If this event is detected before the jet is started, the jet cannot be started until the event has
been cleared (that is, the ink tank is refilled). If the event is detected while the jet is
running, the jet continues to run for 8 hours (Mini and Ultima printheads) or 6 hours
(Ultima plus printhead) until the ink level is critically low, at which point the printer fails
(see Print Failure “2.05 Ink Tank Empty”).
IMPORTANT: The ink tank should be refilled only when this warning is reported (one
bottle of ink only).
6.7.4 “3.04 Solvent Low”

If the solvent level sensor indicates that the volume of solvent in the tank is low, this
warning is reported. The warning is cleared automatically when a sufficient quantity of
solvent is added to the tank.
If this event is detected before the jet is started, the jet cannot be started until the event has
been cleared (that is, the solvent tank is refilled). If the event is detected while the jet is
running, the jet will continue to run for 12 hours (all printheads) until the solvent level is
critically low, at which point the printer fails (see Print Failure “2.06 Solvent Tank Empty”).
IMPORTANT: The ink tank should be refilled only when this warning is reported (one
bottle of ink only).
6.7.5 “3.05 Over Speed (Print Trigger)”

Print triggers are occurring more quickly than the printer can print. This indicates that the
printer has received a second or false print trigger when it is currently printing a message.
When the Primary Trigger option (SETUP menu) is set to Leading Edge or Trailing Edge, a
print delay is started following the trigger. At the end of the delay a ‘print go’ is normally
issued to start printing. If the printer has not completed the previous print, this warning is
reported and the new message is not printed. In effect, this means that printing may not
occur on alternate objects.
This error may also occur when the Primary Trigger option is set to High Level, Low Level
or Off.
Possible Causes:
• The trigger device is providing false triggers due to electrical noise, or an inadequate
trigger device is being used for the application
• There is electrical ‘bounce’ on the trigger device input. Try fitting the SLOW debounce
link LK25 and/or the MED debounce link LK24
• The next object for printing has arrived at the printhead before the last message is
complete, because:
❐ The line speed is too fast
❐ The message is too long compared to the size of the objects to be printed upon
• The print delay is too small for the Primary Trigger options High Level, Low Level or
Off
Amdt 01 MP65557–1
6.7.6 “3.06 Over Speed (Synchronous Data)”
A ‘print go’ occurred before the message data could be generated, and printing may or
may not take place. When this warning is reported, one message may be missed but the
printer will continue to print.
This warning indicates that the printer may have missed printing at least one message
because it was unable to generate the message’s variable data (for example, sequential
numbers) before the next ‘print go’, that is, the printer was still generating the pixel data
for the next message.
NOTE: This warning indicates that the printer cannot generate pixels fast enough,
whereas System Warning “3.05 Over Speed (Print Trigger)” indicates that the
printer cannot print the rasters fast enough. This event is only likely to occur
with fast rasters, where pixel generation by the software is potentially slower
than the rate at which the hardware can print rasters.
Possible Causes:
• The amount of variable data in the message is too high for the current rate of print
triggers
• False trigger device triggers
6.7.7 “3.07 Over Speed (Asynchronous Data)”

A ‘print go’ occurred before the message data could be generated in response to an
asynchronous event. The unmodified message may be printed without the asynchronous
data.
Whilst printing is taking place an asynchronous command may be received, which
attempts to change the printed message, for example, the arrival of remote data. The
software may assume that the data has not arrived and ignore the command, depending on
the software setting, in which case the printer continues to print the unchanged previous
message.
Possible Causes:
• The printer has received a command to change the message during the delay time
• ‘Time change’ related data (sequential message with time trigger) has changed after
the delay time has started
6.7.8 “3.11 Scheduled Maintenance Req’d”

The time remaining to the next scheduled maintenance (in hours and in months) is
monitored. If it is zero or a negative value, this warning is reported and the jet can be
started as normal. The time remaining decrements only when the jet is running.
This warning message is displayed every time the printer is switched on. It continues to be
displayed until the scheduled maintenance has been carried out, and the intervals to the
next maintenance have been reset by the service engineer. The maintenance intervals are
reset in the System Times option of the DIAGNOSTICS sub-menu (SETUP menu).
See also: Chapter 5: Maintenance > The Diagnostics Menu > System Times option.
MP65557–1 Amdt 01
6.7.9 “3.12 Printhead Cover Off”
WARNING: LETHAL VOLTAGE. DANGEROUS VOLTAGES EXIST IN THE

PRINTHEAD. EXTREME CARE MUST BE TAKEN WHEN WORKING ON THE
PRINTHEAD WITH THE COVER TUBE REMOVED AND WITH LK6 FITTED. THE
CORRECT ELECTRICAL SAFETY PRECAUTIONS MUST BE FOLLOWED.
This warning is reported if the printhead cover tube is removed. The +8 kV EHT supply to
the positive deflector plate is automatically switched off and printing is suspended when
the cover tube is removed, and is resumed a few seconds after the cover tube is refitted.
The red strobe LED is also switched on when the cover tube is removed.
See also: System Warning “3.13 Cover Override Link Fitted” below.
Chapter 3: Technical Description > Printhead Components > Safety Sensors >
Printhead Cover Sensor.
6.7.10 “3.13 Cover Override Active”
WARNING: LETHAL VOLTAGE. WHEN LINK LK6 IS FITTED, AND UNDER

NORMAL OPERATING CONDITIONS, THE EHT WILL STILL BE PRESENT ON
THE DEFLECTOR PLATES AND 300 VOLTS D.C. WILL BE PRESENT ON THE
CHARGE ELECTRODE AFTER THE PRINTHEAD COVER TUBE HAS BEEN
REMOVED. THE CORRECT, STANDARD ELECTRICAL SAFETY PRECAUTIONS
MUST BE TAKEN WHILE WORKING ON THE PRINTHEAD WITH THE COVER
TUBE REMOVED AND LINK LK6 FITTED. LINK LK6 MUST NOT BE FITTED
PERMANENTLY AND THE PRINTER MUST NOT BE LEFT UNATTENDED
WHILE THE LINK IS FITTED. THERE IS A DANGER OF DEATH OR INJURY
FROM ELECTRIC SHOCK IF THE CORRECT ELECTRICAL SAFETY
PRECAUTIONS ARE NOT TAKEN.
This warning is reported if link LK6 (Cover Override) is fitted on the IPM PCB.
Software readable link. When this link is fitted, the EHT and charge voltage remain on
while the printhead cover tube is removed (that is, they are not automatically disabled),
which allows printing to continue for fault diagnosis purposes. The red strobe LED also
remains lit. After removing the printhead cover tube and then fitting the link (or refitting
the printhead cover tube), a period of approximately 6 seconds elapses before printing
recommences.
See also: System Warning “3.12 Printhead Cover Off” above.
Chapter 3: Technical Description > Electronics and Software > IPM PCB > Test
Points and Links > LK6 (Cover Override).
Chapter 4: Setup Menu > Printhead Setup option > Cover Override option.
6.7.11 “3.14 Power Off Override Active”

This warning is reported if link LK13 (Power Off Override) is fitted on the IPM PCB.
When this link is fitted, the auto power down mains on/off switch cannot be switched off
by the software.
See also: Chapter 3: Technical Description > Electronics and Software > IPM PCB > Test
Points and Links > LK13 (Power Off Override).
Amdt 01 MP65557–1
6.7.12 “3.15 Safety Override Active”
WARNING: LETHAL VOLTAGE. WITH PRINTHEAD OVER TEMPERATURE OR

EHT TRIP FAULT CONDITIONS, AND WITH LINK LK4 FITTED, THE 300 VOLTS
D.C. WILL STILL BE PRESENT.
THE CORRECT, STANDARD ELECTRICAL SAFETY PRECAUTIONS MUST BE
TAKEN WHILE WORKING ON THE PRINTHEAD WITH LINK LK4 FITTED.
LINK LK4 MUST NOT BE FITTED PERMANENTLY AND THE PRINTER MUST
NOT BE LEFT UNATTENDED WHILE THE LINK IS FITTED. THERE IS A
This warning is reported if link LK4 (Safety Override) is fitted on the IPM PCB.
When this link is fitted, the printhead Over Temperature sense and the EHT Trip sense
signals will not disable the 300 V, ink system pump, feed valves and EHT. However, the
EHT Trip sense will disable the EHT internally on the EHTPSU regardless of LK4 being
fitted. The link can be fitted, but with caution, to aid fault diagnosis.
6.7.13 “3.16 Gutter Override Active”

This warning is reported if link LK12 (Gutter Sense Override) is fitted on the IPM PCB.
The purpose of the gutter sense is to detect the presence of ink flow in the gutter. If ink
flow is not detected in the gutter for any reason (for example, a misaligned jet), the
software shuts down the jet. Absence of ink in the gutter is detected within approximately
10 seconds. With this link fitted, the software starts and maintains the jet regardless of the
gutter sense status.
6.7.14 “3.17 Gate Array Test Mode Active”

This warning is reported if link LK11 (Built In Self Test) is fitted on the IPM PCB.
When this link is fitted, it places the gate array (IC58) in test mode, which generates a
staircase waveform with historic correction.
6.7.15 “3.18 Low Pressure”

Each time the jet is started a pressure and filter check is carried out—the pressure is set to
235 bits and the pressure ADC is used to check that this pressure is actually reached. If the
difference between the pressure DAC setting (Set Pressure) and the pressure ADC reading
(Read Pressure) is greater than a predetermined value (currently 5 bits), this warning is
reported. The jet continues to run.
The primary function of this test is to detect ink system faults or pressure loss. The test
pressure is well above normal running pressures, so it is possible that printing may still
take place with a partially blocked filter, hence the jet is not shut down.
When this warning is reported no solvent addition is permitted; pressure only is used to
control the TOF. This may result in the ink viscosity increasing and the pressure being
increased to the maximum running pressure. The effect would be poor print quality.
Possible Causes:
• The main ink filter or the ink pick-up tube in-line filter are blocked (most probable)
• Some other loss of pressure in the ink system
• Faulty pump
• Faulty pump drive circuit
MP65557–1 Amdt 01
6.7.16 “3.20 No Time Of Flight”
This warning can occur when the jet has been running for at least 5 minutes. It indicates
that the printer has been unable to obtain a valid TOF in the time allowed.
Possible Causes:
• The software is not receiving TOF signals
• Incorrect or no signal from the TOF sensor caused by a partially blocked nozzle or jet
misalignment
• Noise (EMC) interference
6.7.17 “3.26 User Data Corrupt”

Internal software error. On startup, checks are made for invalid data, and if found this
event is reported. If this event occurs, contact your local Linx Service Centre.
6.7.18 “3.29 No Message Stored”

This warning informs the operator that the message store is empty. In this circumstance,
the Messages Stored item in the System Configuration menu (Setup menu > Diagnostics)
also indicates 0.
6.7.19 “3.30 Message Name Exists”

This warning is displayed if the name the operator has entered for a new message is the
same as the name of an existing message. The operator simply needs to enter a different
(unused) message name. No default names are shown to the operator.
6.7.20 “3.31 Message Memory Full”

This warning informs the operator that the maximum permissible number of 50 messages
has been created, or the memory is full before it reaches 50 messages. To create another
new message, an existing one must first be deleted from the message store.
6.7.21 “3.32 Remote Error”

This warning informs the operator that the printer has received the ‘Set Remote Error’
command (121) through the remote communications interface. If this event occurs, contact
your local Linx Service Centre.
6.7.22 “3.33 Synchronisation”

This warning can be enabled to inform the operator that a secondary trigger state change
has occurred during the print. This does not affect the print, and the warning is cleared at
the start of printing.
Amdt 01 MP65557–1
CHAPTER 7: TROUBLESHOOTING
7.1 Introduction
The Troubleshooting Flow Charts contained in this section have been designed to
assimilate the vast range of knowledge that exists regarding failures of printers, and to
present this knowledge in a clear and easy-to-follow fashion. They do not negate the need
for a Linx-trained service engineer as there will always be the occasion when there is no
flow chart for a particular problem. The flow charts must only be used by a Linx-trained
service engineer, who has been given the opportunity to practise with them in a classroom
environment.
7.2 How to Use the Flow Charts

The flow charts must be followed by reading the instructions in the first box and
completing the action as required before moving to the next appropriate box. At various
stages throughout a flow chart a decision needs to be made. The result of the decision
decides the next path. An example is shown in Figure 7-1, which shows the simplicity of
the system.
Cannot make a 68145

cup of tea
Has kettle got

water in it?
YES Is kettle switched on?
NO NO YES
Fill kettle with water Switch on kettle
Wait for kettle to boil
Make tea
Figure 7-1. Simple Flow Chart Example

It can be seen that if the steps are not followed correctly, it would be impossible to make a
cup of tea. Therefore, it is essential to read and follow carefully the instructions in each
box.
An explanation of how a flow chart is designed, what the different shaped boxes mean,
and how to use a flow chart are shown in Figure 7-2.
MP65557–1
FCXXX Each flow chart is identified
with a code number, which
can be referenced in the
Start 68491
Index.
A Terminator box is the start

point for each flow chart. It
contains the flow chart title
or the relevant event
message code number.
Always note and follow the

direction of the arrows.
Rectangular boxes contain

specific instructions.
These must be completed
before moving to the
next box. A decision box requires you to
answer a question (usually the
answer is Yes or No) and follow
the appropriate path.
Good record keeping is essential
The rectangle with side bars directs you to
here as a wrong answer can be
another procedure. This procedure will
retraced and amended.
typically be in either the Maintenance
Manual or another flow chart.
When the breakout procedure has been
completed, return to this point to continue
unless otherwise directed.
Location
Decision YES
Title
NO
This symbol instructs you to

perform an action a number
of times. When this has
Test been completed, continue
Sometimes a number with the flow chart as
of instructions are directed.
to be repeated.
Until
This termination box directs you

to the final flow chart FC999. This termination box
It assumes the fault has been indicates that you must
found and rectified. If other return to the last flow chart
faults exist you will have to you were working through
restart from flow chart FC001. before this one.
This repeats until all faults have
been rectified.
Final Test Return
Figure 7-2. How to Use a Flow Chart
MP65557–1
7.3 First Steps
The first flow chart in the series is ‘Troubleshooting Start’, for which the reference is
FC001. This flow chart must always be followed first no matter what the fault. It
ensures that all the parameters are set for the troubleshooting session.
7.4 Fault Recording

All details of the printer and the fault should be recorded on a Flow Chart Record Sheet,
an example of which is given in Figure 7-3. This sheet gives you the ability to understand
the troubleshooting process, so that when the fault has been identified and rectified it is
possible to evaluate how to avoid the fault reoccurring.
7.5 When Flow Charts Seem Inappropriate

Sometimes the flow charts seem inappropriate and they appear not to help in diagnosing
the fault. If this is suspected, it is advisable to retrace the flow charts already followed to
establish if a wrong decision has been made or a reading has been taken incorrectly. Also,
it must always be taken into consideration that if a component has been replaced, it may
itself be faulty. If there is doubt about the condition of the replaced component, it can be
tested in a known working printer.
7.6 Miscellaneous Faults

There will be occasions when the flow charts are not appropriate for the particular fault.
In such a case it will be necessary to resort to the generic fault diagnosis techniques, which
were taught during the Linx training course.
MP65557–1
49237
4900 Troubleshooting Flow Chart Record Sheet

Printer 4900 Printhead
Serial Number Serial Number
Setup menu: Setup menu:
Print Width Primary Trigger
Print Delay Shaft Encoder
Ink Type Selection Head Height
Setup menu > Setup menu >
Printhead Setup: Change Configuration:
Type UNIC
Conduit Length Code
Printhead Code
Fault observations:
Flow Chart FC001 Result
Flow Chart Result
Flow Chart Result
Flow Chart Result
Flow Chart Result
Flow Chart Result
Flow Chart Result
Flow Chart Result
Flow Chart Result
Flow Chart Result
Flow Chart Result
Conclusion Components replaced
Final test of system Precautionary measures
Figure 7-3. Flow Chart Record Sheet
MP65557–1
7.7 List of Flow Charts
49238
List of Troubleshooting Flow Charts

Flow chart Title Notes
FC001 Troubleshooting Start Always start here
FC002 Jet To examine the jet
FC003 Modulation To examine modulation
FC004 Charge To examine drop charging
FC005 Phase To examine phase synchronization
FC006 Low Pressure To test primary ink circuit. Can be used
when event "3.18 Low Pressure" occurs
FC007 Ink Quality To test ink quality
FC008 Low Viscosity Ink To evaluate the cause of the ink viscosity
being too low for the machine to operate
FC009 High Viscosity Ink To evaluate the cause of the ink viscosity
being too high for the machine to operate
FC010 EHT Deflection To test the EHT system
FC011 Print To ascertain the cause of print problems
FC012 Print Quality To ascertain the cause of print quality
problems
FC200 2.00 Printhead Over Temperature For when the displayed event occurs
FC201 2.01 EHT Trip For when the displayed event occurs
FC202 2.02 Phase Failure For when the displayed event occurs
FC203 2.03 Time of Flight Failure For when the displayed event occurs
FC204 2.04 300V Power Supply For when the displayed event occurs
FC205 2.05 Ink Tank Empty For when the displayed event occurs
FC206 2.06 Solvent Tank Empty For when the displayed event occurs
FC207 2.07 Internal Spillage For when the displayed event occurs
FC209 2.09 Misaligned Ink Jet For when the displayed event occurs
FC211 2.11 Pressure Limit Reached For when the displayed event occurs
FC212 2.12 Viscosity For when the displayed event occurs
FC213 2.13 Hardware Safety Trip For when the displayed event occurs
FC999 Final Test When the problem has been solved
Figure 7-4. List of Troubleshooting Flow Charts
MP65557–1
FC001
Troubleshooting 49239
Start
Check installation data in

the Setup menu.
Enter this on the
Flow Chart Record Sheet.
Load the maximum

size test pattern and,
if possible, start the jet
and take a print sample.
Read explanation of the

Note any printer event message in the
failures or warnings on the Maintenance Manual.
If the printer returned a

failure code, power the
printer down and then up
again before continuing.
Clean the printhead.

This action is only
required if the printhead
is excessively dirty or it
is not possible to view
the Charge LED.
In the Setup menu, set:

Primary Trigger to Leading
Edge
Shaft Encoder to Off.
In the Diagnostics menu,

select the Quick Start Jet
option.
Proceed to appropriate
Troubleshooting Flow Chart
Figure 7-5. FC001 Troubleshooting Start
MP65557–1
FC002
Jet 49240
Flow Chart
Does Set Pressure =
Read Pressure NO FC006
(±6 bits)? Low Pressure
YES
Maintenance Manual
Is jet going
Chapter 5
straight into NO
the gutter? Jet Alignment and
Nozzle Cleaning
YES
Return Final Test
Figure 7-6. FC002 Jet
MP65557–1
FC003
Modulation 49241
View the drop breakup in the

charge electrode and assess
which image the drop
breakup looks like most.
YES Return
NO
NO NO
Note the presence

of satellites
YES YES YES
Test Modulation signal

Increase Modulation and Decrease Pressure and
output from IPM PCB
observe drop breakup. observe drop breakup.
(TP1).
Is an Is an
improvement improvement Is signal present?
observed? observed?
YES
NO
NO YES NO
NO
Maintenance Manual
Replace Printhead. Chapter 5 Replace IPM PCB.
Modulation Range
YES
Final Test
Figure 7-7. FC003 Modulation
MP65557–1
FC004
Charge 49242
From the Diagnostics menu, select the

Start Print option to put the printer into the
Ready to Print state.
Place a piece of paper at the printhead
outlet and select the Test Print option.
Check continuity of
Is a message printed? NO Charge coaxial cable.
Is cable
YES continuity NO
good?
YES
Test Charge output

from the IPM PCB at the Test IPM Charge output
printhead using the while activating Replace printhead.
Calibrate function. Test Print (TP9).
Calibrate if necessary.
Is a signal
present when
printing?
YES
NO
Replace IPM PCB.
Return Final Test
Figure 7-8. FC004 Charge
MP65557–1
FC005
Phase 49243
Flow Chart
FC007
Ink Quality
Test continuity of Is the Phase

Phase coaxial cable.
NO value good?
YES Return
Is the Phase
cable continuity NO Replace printhead.
good?
YES
Is electrical
noise present? NO Replace IPM PCB.
(TP3)
YES
Remove source of
electrical noise.
Final Test
Figure 7-9. FC005 Phase
MP65557–1
FC006
Low Pressure 49244
Maintenance Manual
Maintenance Manual
Chapter 5 Is the printer
Chapter 5
IPM PCB Calibration NO due for scheduled YES
maintenance? Scheduled
(pressure transducer
Maintenance
calibration)
Final Test
Test the pressure

Is it possible transducer and
Check ink flow from pump associated electronics.
outlet.
YES to calibrate the NO
pressure? Replace components
as necessary.
Is there good
Check ink flow from main Check vacuum at pump
filter outlet.
YES ink flow from NO inlet.
the pump?
Is there good Is there good

YES ink flow from vacuum at the NO
the filter? pump inlet?
Examine the manifold Test the pump and

and associated piping. associated electronics.
Replace components NO YES Replace components
as necessary. as necessary.
Examine the ink

pick-up tube and
Replace filter. associated piping.
Replace components
as necessary.
Check maintenance manual

amendments to ensure that
scheduled maintenance is being
completed to latest specification.
Confirm maintenance interval is
appropriate for installation.
Final Test
Figure 7-10. FC006 Low Pressure
MP65557–1
FC007
Ink Quality 49245
Ensure printer is in the

Jet Running state.
In the Diagnostics menu,

set the TOF Correction
option to Off.
Start the printer printing

using the Start Print option
in the Diagnostics menu.
YES
Repeat four
times at...
Take a print sample.

...Phase number
=
0, 4, 8, 12.
Test Charge output

from the IPM PCB at the
printhead using the Is one of the print
NO samples good?
Calibrate function.
Calibrate if necessary.
YES
Was charge In the Diagnostics menu,

calibration required? set the TOF Correction
option back to On.
NO
Replace the ink. Return
Final Test
Figure 7-11. FC007 Ink Quality
MP65557–1
FC008
Low Viscosity Ink 49246
Ensure pressure
transducer is
correctly calibrated.
Maintenance Manual
Chapter 5
Solvent Add
Valve Tests
Replace ink.
Maintenance Manual
Chapter 5
Solvent Flush
Valve Tests
Maintenance Manual
Chapter 5
Purge and Gutter
Valves Tests
Ensure there is
no blockage in
the feed line.
If all systems are considered to be

functioning correctly, then monitor
the printer for a further 2 hours.
If the printer correctly adds solvent, assume
that the initial problem was caused by the
operator adding solvent into the ink tank.
Final Test
Figure 7-12. FC008 Low Viscosity Ink
MP65557–1
FC009
High Viscosity Ink 49247
Maintenance Manual
Chapter 5
IPM PCB Calibration
calibration)
Flow Chart
Is TOF OK? NO FC203
Time Of Flight Failure
YES
Is there
Replenish solvent tank. NO solvent in the solvent
tank?
YES
Maintenance Manual
Chapter 5
Test solvent level sensor.
Solvent Add
Valve Tests
If all systems are considered to be

functioning correctly, then monitor the printer
for a further 2 hours.
If the printer correctly adds solvent, assume
that the initial problem was caused by the
operator adding ink to the solvent tank.
Therefore, the condition of the solvent needs
to be checked.
Final Test
Figure 7-13. FC009 High Viscosity Ink
MP65557–1
FC010
EHT Deflection 49248
Ensure printhead and

cover tube are clean.
Ensure printhead cover
tube is correctly fitted.
Initiate printing using
Diagnostics > Test Print.
Examine the printhead

output, the printhead
and the printhead cover
tube for signs that ink
drops were diverted
from the main ink jet.
Were ink drops

NO diverted?
YES
Ensure calibration code

is entered correctly.
Check that printhead cover
tube detection is
functioning correctly.
Test EHT control signal
into EHT module (TP65).
Test continuity of EHT
cable (22 MΩ).
NO
Test for correct voltage

on EHT plate.
Did the
tests highlight a
problem?
Was voltage
YES NO as expected?
Replace faulty component

as necessary.
YES
Final Test Return
Figure 7-14. FC0010 EHT Deflection
MP65557–1
FC011
Print 49249
From the Diagnostics menu,

select the Start Print option
to put the printer into the
Ready to Print state. Flow Chart
Place a piece of paper at the IS TOF OK? NO FC203
printhead outlet and select
the Test Print option. Time Of Flight Failure
YES
Is ink Does printer

Test trigger, trigger setup
ejected from the YES print when NO and associated electronics.
printhead? triggered?
NO YES
Clean printhead. Does printer Test line speed sensor,

Check for obstructions. print at correct NO line speed setup and
rate? associated electronics.
Repeat Test Print
twice more.
YES
Flow Chart
Still faulty? NO Is print sample good? NO FC012
Print Quality
YES
Does
Remove Battery link LK2
print count NO and retest.
Still faulty?
increment?
YES YES
Flow Chart YES

Replace the software. Still faulty?
FC010
EHT Deflection
YES YES
Still faulty? Replace IPM PCB.
NO
NO NO
Final Test
Figure 7-15. FC0011 Print
MP65557–1
FC012
Print Quality 49250
Maintenance Manual
Chapter 5
IPM PCB Calibration Problem solved?
calibration)
NO
Flow Chart
FC010 Problem solved?
EHT Deflection
NO
Flow Chart
FC007 Problem solved?
Ink Quality
NO
YES
Maintenance Manual
Chapter 5
Problem solved?
Modulation Range YES
Checks
NO
YES
Replace the software.
YES
Final Test
Figure 7-16. FC0012 Print Quality
MP65557–1
FC200
2.00 Printhead Over Temperature 49251
Is printhead
NO ambient temperature YES
> 60 oC?
Place printer and printhead

Disconnect Printhead in environment where
connector the temperature is
PL5 from IPM PCB. within operational
range for 1 hour.
Does error
still exist?
NO
YES
Printer must be located

in environment < 60 oC.
Examine connector PL5

for obvious damage
and repair if possible.
Replace IPM PCB.
Does error
still exist?
YES
Replace printhead.
NO
Final Test
Figure 7-17. 2.00 Printhead Over Temperature
MP65557–1
FC201
2.01 EHT Trip 49252
Flow Chart
FC002
Jet
Flow Chart
FC003
Ensure event Modulation
settings are correct.
Examine printhead Ensure link LK6
cover detection system is removed.
and replace faulty
components as necessary.
Remove printhead
from printhead cover
tube and then refit it.
NO YES
Was
Was event
event "3.13 Cover
"3.12 Printhead Cover YES Override Active"
Off" displayed?
displayed?
NO
Disconnect the EHT

module output cable.
YES
NO
Take a print sample.
Ensure the environment is

within operational parameters.
Ensure cleaning procedures
are being adhered to.
Ensure there is no vibration
Replace IPM PCB. being transmitted to printhead.
Does the If all else is OK, replace
printer fail? the EHT module.
Final Test
Figure 7-18. FC201 2.01 EHT Trip
MP65557–1
FC202
2.02 Phase Failure 49253
Flow Chart
FC002
Jet
NO Problem solved?
Flow Chart
FC003
Modulation
NO Problem solved?
Flow Chart
FC004
Charge
NO Problem solved?
Flow Chart YES

FC005
Phase
YES
NO Problem solved?
YES
Flow Chart
FC001 YES
Troubleshooting Start
Final Test
Figure 7-19. FC202 2.02 Phase Failure
MP65557–1
FC203
2.03 Time Of Flight Failure 49254
Flow Chart
FC002
Jet
Flow Chart
FC003
Modulation
Flow Chart
FC004
Charge
Flow Chart
FC005
Electrical noise is being Phase Electrical noise
generated on the is being generated
production line. within the printer.
Move printer to area where

there is no electrical noise
Ensure electrical supply and a good earth. Examine all earth
is free from noise, earthing NO If possible, change printer YES connections.
to the printer for one that is experiencing
is in place, and printhead Ensure printhead cover
no problems. screw has good earth
is isolated from other
earthing sources. continuity to printer.
Does problem
still exist? Replace in turn:
Ensure auxiliary 1. Power Supply
components are screened. 2. IPM PCB
3. Pump
4. Printhead
Retest system after each
replacement.
Refit original component if

Ensure there is no static no improvement.
on production line.
Final Test
Figure 7-20. FC203 2.03 Time Of Flight Failure
MP65557–1
FC204
2.04 300V Power Supply 49255
Ensure the printer is

powered down.
Remove link LK8 on IPM PCB.
Remove link LK9 on IPM PCB.
Power up the printer.
Does the
error still exist?
YES
NO
Power down printer.

Refit link LK8 and link LK9.
Disconnect Charge cable.
Disconnect Modulation cable.
Power the printer up.
Replace EHTPSU.
Does the
error still exist?
YES NO
Replace IPM PCB. Replace printhead.
Final Test
Figure 7-21. FC204 2.04 300V Power Supply
MP65557–1
FC205
2.05 Ink Tank Empty 49256
YES
Is the ink level low?
NO YES
Switch the printer off. Add one bottle of ink.

Examine and replace ink Switch the printer off and
level sensor and wiring as then on again to reset the
necessary. hardware.
Is event
Fault cleared? "3.03 Ink Low" still
present?
NO
YES
Test ink sensor

electronics and replace
IPM PCB as necessary.
NO
Final Test
Figure 7-22. FC205 2.05 Ink Tank Empty
MP65557–1
FC206
2.06 Solvent Tank Empty 49257
YES
Is the solvent
NO level low?
YES
Examine and replace

solvent level sensor and Add one bottle of solvent.
wiring as necessary.
Is event
Fault cleared? "3.04 Solvent Low"
still present?
NO YES
Test solvent sensor

electronics and replace
IPM PCB as necessary.
NO
Final Test
Figure 7-23. FC206 2.06 Solvent Tank Empty
MP65557–1
FC207
2.07 Internal Spillage 49258
Is there ink
YES or solvent in the NO
ink tray?
Clean the ink tray.

Remove and clean
the sensor. Disconnect Ink System
Examine the ink system connector PL11.
to determine the cause
of the leak, and repair.
YES
Does error still exist? YES Does error still exist?
NO
Test the leak detect wiring

Replace IPM PCB. for short circuit to earth
and repair as necessary.
NO
Final Test
Figure 7-24. FC207 2.07 Internal Spillage
MP65557–1
FC209
2.09 Misaligned Ink Jet 49259
Ensure jet is running.
Is the jet
entering the centre of YES
the gutter?
NO
Connect pin 12 to pin 13
on the Printhead connector
PL5.
Monitor TP60.
Flow Chart
FC002 TP60 > 4 VDC?
Jet
NO YES
Replace printhead. Replace IPM PCB.
Final Test
Figure 7-25. FC209 2.09 Misaligned Ink Jet
MP65557–1
FC211
2.11 Pressure Limit Reached 49260
Is event
NO "3.18 Low Pressure" YES
present?
Flow Chart Flow Chart

FC003 FC006
Modulation Low Pressure
NO Problem solved?
Flow Chart
FC004
Charge
NO Problem solved?
Maintenance Manual
Chapter 5
IPM PCB Calibration
calibration)
YES
Problem solved?
NO
YES
Flow Chart
FC001 YES
Final Test
Figure 7-26. FC211 2.11 Pressure Limit Reached
MP65557–1
FC212
2.12 Viscosity 49261
Adjust pressure +/– to

bring jet break-up into the
charge electrode and
achieve good TOF.
Is it
possible to achieve
good TOF?
YES
NO
Maintenance Manual
Chapter 5
Modulation Range
Checks
Viscosity?
Flow Chart
Low or High or
FC203
lower higher
than Time Of Flight Failure
than
expected expected
Flow Chart Flow Chart

FC008 FC009
Low Viscosity Ink High Viscosity Ink
Final Test
Figure 7-27. FC212 2.12 Viscosity
MP65557–1
FC213
2.13 Hardware Safety Trip 49262
Flow Chart
FC201
EHT Trip
NO Problem solved?
Flow Chart
FC200
Printhead Over
Temperature
NO Problem solved?
YES
Flow Chart
FC001 YES
Final Test
Figure 7-28. FC213 2.13 Hardware Safety Trip
MP65557–1
FC999
Final Test 49263
Clean the printhead and

ensure the cover tube is
clear of any obstruction.
Start jet using

green [start] key.
Printer
starts and NO
prints OK?
YES
Flow Chart
FC001
Note any conclusions on

Evaluate any
precautionary measures
to be taken to avoid
a reoccurrence
of the problem.
Set printer back on

line and run, observing
its operation for
at least ½ hour.
Clean the working area.

Dispose of all liquid
and solid waste in
the proper manner.
Clean the printer.
Complete all relevant

administration.
Report conclusions and

preventative actions to
whoever is responsible
for the printer.
Finish
Figure 7-29. FC999 Final Test
MP65557–1
CHAPTER 8: TRAINING
DOCUMENTATION
Course One: Printer Operation

Course Overview
Purpose
This training course is intended for anyone who is required to operate a Linx 4900 printer
on a production line.
It is designed to enable a service engineer to train personnel, in the necessary skills
needed, to maintain normal line operation of the printer on a day-to-day basis. To achieve
this the courses make use of the Simply the Linx 4900 pocket guide and the 4900 Ink Jet
Printer Operating Manual.
The training provided here is for a printer that has been previously commissioned and has
a number of suitable messages already stored in it. The service engineer should also
ensure that he is fully aware of the customer’s requirements for printing, and that the
default options are correctly set for the application.
It is essential that the printer is set to the correct/appropriate password level prior to
commencing this course.
Objectives
This training course guide is to be used to train operators following the installation of the
Linx 4900 printer.
The course is designed to enable the trainee to set up the printer safely on a variety of
production lines, together with any associated ancillary components. In addition, the
trainee will be able to start and stop the printer, select and print messages, create and edit
messages, and carry out the more advanced routine maintenance tasks and simple
troubleshooting. The trainee will also be conversant with the safety implications and be
aware of the location in the manuals of basic first aid instructions.
This course is therefore suitable for the Line Supervisor or more advanced Line Operator.
Modules
01. Introduction
02. Continuous Ink Jet Printing
03. Getting Started and Printing Messages
04. Navigating the 4900
05. Creating and Editing Messages
06. Stopping Print and Shutting Down
07. Looking After Your Printer
08. Routine Maintenance
09. Line Installation
10. Review
MP65557–1
Equipment List
Equipment Quantity
Linx 4900 Printer 1
Simply the Linx 4900 pocket guide 1 per trainee
4900 Ink Jet Printer Operating Manual 1 per printer
Safety glasses 1 pair per trainee
Safety gloves sufficient for course
Eyewash 1 bottle
Fire extinguisher 1
Hand cleanser sufficient for course
Magnifier or eyeglass 1
Ink and solvent bottles 1 of each
Paper towels sufficient for course
Paper for printing onto as required (optional)
Ensure that all local Health and Safety regulations are complied with.
MP65557–1
Module 01 – Introduction
Aims
• To establish the credibility of the course, the trainer and the course materials
• To establish a relaxed atmosphere in which to learn
• To make the trainees aware of the relevant health and safety aspects
Key Points
• Outline the course objectives
• Cover the health and safety aspects of working with a CIJ printer, inks and solvents
Activities
Introduce yourself and the training course to the trainees.
Explain domestic arrangements (timings, breaks, lunch, facilities, etc.).
Distribute a copy of the Simply the Linx 4900 pocket guide to each of the trainees and
explain its use.
Explain the use of the 4900 Ink Jet Printer Operating Manual.
Outline the course objectives.
Explain the warnings and cautions. Use the 4900 Ink Jet Printer Operating Manual to
illustrate the relevant points, and cross-reference with the Simply the Linx 4900 pocket
guide.
Explain the safety implications (hazards and their prevention, and accident management)
for the following:
• Ink/solvent flammability
• Eye and skin contact
• Inhalation
• Ingestion
Stress the importance of keeping the printer covers fitted.
Equipment
Ink and solvent bottles
Personal safety equipment
Fire extinguisher
MP65557–1
Module 02 – Continuous Ink Jet Printing
Aims
• To give some awareness of what continuous ink jet printing is and, in particular, how
the Linx printer achieves its purpose
Key Points
• Continuous ink jet printing is a non-contact printing method for printing small
variable characters and images
• The Linx printer achieves this by creating a stream of ink drops, from which
individual drops are electrically charged and deflected out of the printhead onto the
product in a predetermined manner
Activities
Ask the trainees if they can give examples of where continuous ink jet printers might be
used. Examples could be food products for legislation reasons, pills, motor parts for
product traceability, and cable for marking the product length. In fact, there are very few
products manufactured today that do not require a mark for one reason or another, and
many of these applications are satisfied by marking the product using continuous ink jet
technology.
State that ink jet is usually selected for its capacity to print a large number of characters
every second, and so can cope with production line speeds up to 6 m/s.
Indicate the ‘About Continuous Ink Jet Printing’ section in the 4900 Ink Jet Printer Operating
Manual, where further information can be found if required.
Explain that, under normal operating conditions, when the printhead cover tube is
removed, all harmful voltages are removed and the printhead can be handled and viewed
safely.
Point out the passage of the ink from the nozzle to the gutter.
Explain that, as the drops are formed they may be given an electric charge that causes them
to be deflected by the deflector plates onto the passing product.
Explain that, as the uncharged drops receive no charge they are not deflected and pass
directly into the gutter at the bottom of the printhead.
Point out the Phase and Time Of Flight sensors and explain that they are used to control
the charge and speed of the drops.
Equipment
Magnifier or eyeglass
Safety glasses
MP65557–1
Module 03 – Getting Started and Printing Messages
Aims
• To ensure that there is understanding as to what is required for the printer to be used
successfully on the production line
• To ensure that the trainees are able to bring the printer to a state where it can be run
on line
Key Points
• Powering up the printer
• Use of the two power switches
• The keyboard and display
• Printing a message
• Using the Simply the Linx 4900 pocket guide
• Selecting a message
Activities
Refer to ‘Switching the printer on’ in the Simply the Linx 4900 pocket guide. Invite the
trainees to find the two power switches, to switch the printer on, and observe the startup
screen.
Refer to ‘Introducing the printer display’ in the Simply the Linx 4900 pocket guide and
explain the use of each of the items in the display.
Refer to ‘When you want to start printing’ in the Simply the Linx 4900 pocket guide.
Briefly explain what is happening during start up.
Point out when the status changes to ‘Printing’ in the PRINT STATUS screen and
demonstrate printing onto a product. (You may have to improvise/explain the installation
at this point.)
Point out that print Count in the PRINT STATUS screen increments each time the message
is printed.
Explain that the message displayed in the CURRENT MESSAGE screen when the printer
was switched off, will be available for immediate printing the next time the printer is
switched on.
Refer to ‘Selecting a message to print’ in the Simply the Linx 4900 pocket guide.
Invite each of the trainees to select a message from the list of stored messages.
Ensure that all trainees can select and print messages.
MP65557–1
Module 04 – Navigating the 4900
Aims
• To ensure that the trainees become familiar with, and can confidently use the cursor
control keys
• To ensure that the trainees become familiar with the menu structure
Key Points
• Using the Up, Down, Left and Right cursor control keys
• Understanding the menu structure
Activities
Introduce the cursor control keys.
Explain the principal menu options.
MP65557–1
Module 05 – Creating and Editing Messages
Aims
• To ensure that the trainees can access and use the New Message and Edit Message
functions, and their sub-menu options to create and edit messages
Key Points
• Using the New Message and Edit Message functions
• Placing fields using the cursor keys
• Saving and printing newly created messages
• Adjusting the position and appearance of the message
• Editing messages
Activities
Invite the trainees to access the NEW MESSAGE screen and create a new message.
Demonstrate entering text into the message using the various menu options.
Demonstrate how, after entering text, the message can be saved and printed.
Invite each of the trainees to create a new message and input their name, then save and
print each message.
Invite the trainees to adjust the appearance of their message by varying the Print Width
and Print Delay.
Explain how other fields, such as the time and date, can be added to a message and
moved into position using the cursor control keys.
Discuss with the operators what message they will be printing on the production line. Ask
the trainees to enter the message into the printer and to print it.
Explain how to edit the message and change the data within it.
Remember to save the message before attempting to print it.
MP65557–1
Module 06 – Stopping Print and Shutting Down
Aims
• To show the difference between stopping print and stopping the jet
• To emphasise that the 4900 is a completely automatic printer requiring minimum
intervention
Key Points
• Pressing the [F1] Stop Print key stops the printing but the jet continues to run
• The [stop] key instigates a full shutdown sequence
• The full shutdown sequence stops the jet, flushes the nozzle with solvent and leaves
the printer in a condition ready for a clean and reliable startup next time
• The [stop] key is the preferred method for switching off the printer
• The power switch should only be used if the printer has failed as displayed in the
status line, or in the event of a hazardous situation (e.g. fire)
Activities
Refer to ‘To stop and restart printing’ in the Simply the Linx 4900 pocket guide.
Invite a trainee to demonstrate the correct key to stop and restart the print.
Point out how the function key options change in the CURRENT MESSAGE screen as the
printer status changes.
Demonstrate to the trainees that when printing is stopped the jet is still running
(emphasise the importance of wearing safety glasses during this operation).
At this point, it may be an opportunity to demonstrate the ink drop formation and the ink
jet (optional).
Refer to ‘To stop printing & shut down’ in the Simply the Linx 4900 pocket guide.
Invite one of the trainees to shut down the printer, noting the AUTO POWER DOWN
screen and the message change in the display status line.
Explain what is happening as the printer shuts down. Observe the printer switching itself
off and explain that the whole operation is automatic with no user intervention required.
Equipment
Safety glasses
Magnifier or eyeglass
MP65557–1
Module 07 – Looking After Your Printer
Aims
• To demonstrate to the trainees that minimum intervention is required for basic printer
operation, and if a few simple rules are adhered to, the printer will give trouble-free
operation
• To demonstrate the correct method of filling the printer with ink and solvent, as
required
Key Points
• System Event (warning) messages and appropriate actions
• Ink and solvent low warnings
• Ink and solvent dos and don’ts
• Ink and solvent addition
• Event message log
Activities
Demonstrate a warning on the printer (a simple one is to remove the printhead from its
cover tube) and point out the warning in the display status line.
Explain that all printer events (warnings) are logged and demonstrate where these events
can be viewed.
Explain that the display status line should be examined whenever close to the printer to
ensure that no attention is needed.
Explain that if the printer is reporting an “Ink Low” or “Solvent Low” warning, this is a
continuous reminder that a tank needs refilling.
Refer to ‘Ink & solvent precautions’ in the Simply the Linx 4900 pocket guide.
A ‘Quick Quiz’ can be given to cover all the relevant safety aspects concerning working
with the printer.
Ensure that there is complete understanding of all the points. In particular, point out the
gloves and glasses symbols reminding operators that protective equipment is to be worn
when handling ink and solvents.
Point out the first aid instructions in ‘First aid for inks and solvents’ in the Simply the Linx
4900 pocket guide.
Refer to ‘Adding ink & solvent’ in the Simply the Linx 4900 pocket guide.
Point out the adhesive label on the solvent filler cap, which shows the solvent type to be
used. Emphasise that this must be compared to the markings on the solvent bottle itself
and be the same. Also point out the ‘Use-by’ date on the bottle.
Repeat the above activity for the ink filler cap and ink bottle.
Demonstrate, using an empty bottle, how the bottle should be placed into the filler tube.
Point out the serrated teeth, which are designed to pierce the foil on the bottle neck.
Advise caution that the bottle must not be removed too early.
Emphasise that only one bottle of ink or solvent is to be added at any one time.
MP65557–1
Module 08 – Routine Maintenance
Aims
• To make the trainees aware of the regular maintenance activities necessary to ensure
trouble-free operation of the Linx 4900 printer
Key Points
• How and when to clean the printhead
• How and when to clean or replace the air filter
• Accessing the MONITOR JET and EVENT LIST screens
• Use of the Nozzle Flush and Nozzle Clear functions
Activities
Refer to the ‘Diagnostics & Maintenance’ section of the 4900 Ink Jet Printer Operating
Manual and demonstrate cleaning the printhead and printhead cover tube. Emphasise that
the manual states that the printhead requires cleaning only once every week.
Indicate the location of the air filter and demonstrate its removal. Demonstrate the cleaning
procedure and state the cleaning interval.
Demonstrate and explain the MONITOR JET menu (optional).
Emphasize that correct nozzle alignment is very important and must not be mechanically
adjusted.
Explain the causes of a blocked nozzle and demonstrate the use of the Nozzle Flush
function. Show the jet of solvent coming from the nozzle.
Demonstrate the Nozzle Clear procedure and encourage each trainee to try it himself/
herself.
Emphasise that, in the case of a nozzle not being correctly aligned, only the Nozzle Flush
and Nozzle Clear functions must be used to rectify the fault. No one should attempt to
physically move the nozzle without first seeking advice from a person trained to do so, or
a Linx or Linx distributor service engineer.
Emphasise that moving the nozzle with non-approved tools will void any warranty or
service contracts in force.
Equipment
Safety glasses
Safety gloves
MP65557–1
Module 09 – Line Installation
Aims
• To ensure that the trainees are able to install and change the setup parameters for
typical product sensors and line speed detectors
Key Points
• A product sensor sends a signal to the printer to start a message printing onto the
product after a delay
• A line speed detector sends a number of pulses to the printer, which interprets them
as a line speed
• Correct setup is essential to ensure correct printing
• Product sensors and line speed detectors are optional components
• All line setup functions are accessed from the SETUP menu
• Security
Activities (all activities are optional based upon installation

setup)
Trigger the product sensor and explain how the signal is transmitted to the printer.
Explain the correct positioning of the printhead.
Select the Photocell option in the SETUP menu and explain the settings, particularly those
that are typically used on the production line.
Explain line speed detection, if fitted.
Select the Shaft Encoder option in the SETUP menu and explain the settings, particularly
those that are typically used on the production line.
If a shaft encoder is fitted, emphasise the need to correctly calculate the number of pulses
per millimetre, as this can seriously influence the further positioning of the message
(optional).
If the production lines also uses other ancillary equipment, such as an alarm, then this also
requires explanation. Point out its location in the SETUP menu. Explain its use and
functions as necessary (optional).
Discuss password entry and refer to the relevant section in the 4900 Ink Jet Printer
Operating Manual.
Outline the importance of using the correct level of password for the user’s requirements.
MP65557–1
Module 10 – Review
Aims
• To answer any questions that arise
• To ensure all Aims have been adequately met
Key Points
• Agreement of Aims
• Decide upon any future training requirements
Activities
Ask if there are any questions.
Review the Objectives from Module 01 and get agreement from the trainees that they are
happy that these have been met.
If there is any confusion, run through the particular points again.
If necessary, arrange a convenient time to cover again any areas where there is still
confusion. These needs may only be relevant to individual trainees.
MP65557–1
CHAPTER 9: ILLUSTRATED PARTS
LIST
9.1 Introduction
This chapter illustrates and identifies the assemblies and parts of the 4900 Continuous Ink
Jet Printer. Location diagrams are provided, with each part being identified by an item
number. These item numbers are referenced to the list of part numbers for the assembly,
which are given in tabular form on the relevant facing pages.
The information contained in this chapter corresponds to the Linx Parts and Prices manual,
Issue 5, amendment state 0.
9.2 Abbreviations
The table shown below explains the abbreviations used in the ‘Description’ column of the
parts lists:
48085
A Ampere MIL Military
AF Across Flats MM Millimetre
AMP Amplifier MOD Modification
ASSY Assembly NAT Natural
AUX Auxiliary NPT National Pipe Thread
BKT Bracket O/P Output
BSP British Standard Pipe OD Outside Diameter
BSPT British Standard Taper Pipe PAN Pan Head
BTN Button PCB Printed Circuit Board
C/F Cableform P/CELL Photocell
CER Ceramic P/H Printhead
CONN Connector PLT Plated
CSK Countersunk POZ Pozidriv
DEG Degree PSU Power Supply Unit
DIA Diameter PTFE Polytetrafluoroethylene
EHT Extra High Tension PVC Polyvinyl Chloride
EPDM Ethylene Propylene Diene Monomer R/I Remote Interface
EURO European REP Replacement
F Female RETRO Retrofit
GSKT Gasket RHS Right-Hand Side
HD Head S/A Self Adhesive
HEX Hexagonal SCR Screw
I/F Interface S/E Shaft Encoder
INT Internal SEC Security
I/P Input SKT Socket
IPM Integrated Processor Module SQ Square
I/S Ink System SPRF Shake Proof
ID Inside Diameter SQ Square
IN Inch SS Stainless Steel
LCD Liquid Crystal Display ST Steel
LG Long STD Standard
LHS Left-Hand Side STRT Straight
LRG Large TBA To be announced
M Metre TES Teflon Encapsulated Silicon
M Male THRU Through
M/F Metric Fine V Volt
M/FOLD Manifold WSH Washer
MA Milliamp
Figure 9-1. Part Description Abbreviation Table
MP65557–1
8
1
Nov 2003
10
3 2
9—2
1
LINX PRINTING TECHNOLOGIES plc,

BURREL ROAD, ST IVES, CAMBRIDGESHIRE
5 PE27 3LA UK
6 TITLE: 4900 TOP COVER ASSEMBLY
DRAWING NO.: PLATE 4900–1
7
SHEET: 1 OF 1

MP65557–1
4900 Top Cover Assembly
Item Part Description Pack Availability Comments
MP65557–1
Number Quantity Terms
1 FA71068 4900 DISPLAY ASSEMBLY 1 Ex-stock Display PCB Assembly complete with LCD.
2 FA74152 MOULDED INK CAP 1 Ex-stock Used in 4800, 4900 and 6800 printers.
3 FA74153 MOULDED SOLVENT CAP 1 Ex-stock Used in 4800, 4900 and 6800 printers.
4 FA72148 4900 COVER ASSEMBLY EUROPEAN 1 4 weeks Cover, seal, cover hinge, hinge screws, filler bosses, filler boss retainers, screws,
badge, keypad, blank keypad insert, earth tag, nut and earth label.
4 FA16011 4900 COVER ASSEMBLY GREEK 1 4 weeks Cover, seal, cover hinge, hinge screws, filler bosses, filler boss retainers, screws,

4 FA16012 4900 COVER ASSEMBLY JAPANESE 1 4 weeks Cover, seal, cover hinge, hinge screws, filler bosses, filler boss retainers, screws,
4 FA16014 4900 COVER ASSEMBLY RUSSIAN 1 4 weeks Cover, seal, cover hinge, hinge screws, filler bosses, filler boss retainers, screws,
5 FA16015 4900 BADGE 1 Ex-stock
6 FA16002 4900 DISPLAY CABLEFORM 1 Ex-stock
9—3
7 FA70101 4900 DISPLAY PCB ASSEMBLY 1 Ex-stock Display PCB only - no display.
8 FA73037 NUT M3 NYLOC - PACK 20 Ex-stock
9 FA16016 4900 EMC/IP55 SEAL 1 Ex-stock
10 FA74084 PILLAR 6 OD X 18 X M3 NYLON—PACK 10 Ex-stock Display PCB spacers.
FA13408 EARTH STRAP CABLE FORM 1 Ex-stock Display PCB to Chassis cableform. Replaces AS13355.
FA74098 LABEL EARTH WARNING—PACK 10 Ex-stock

FA74195 SCR M4 x 10 PAN HD POX SS - PACK 20 4 weeks
Nov 2003
13
Nov 2003
12
11
9—4
10
9
3
8
4 LINX PRINTING TECHNOLOGIES plc,
5 PE27 3LA UK
6 TITLE: 4900 FRONT CABINET ASSEMBLY
7 DRAWING NO.: PLATE 4900–2
SHEET: 1 OF 1

MP65557–1
4900 Front Cabinet Assembly
MP65557–1
1 FA71069 4900 IPM PCB ASSEMBLY 1 Ex-stock

2 FA74146 IPM MOUNTING BRACKET 1 Ex-stock Used in 4900 and 6800 printers.
2 FA73068 SNAP RIVET 2.1 - 3 - PACK 50 Ex-stock
3 FA13356 IP55 FAN ASSY 1 Ex-stock Used in the 4800, 4900 and 6800 printers.
3 FA73067 SCR M3X30 LG PAN HD POZ SS - PACK 50 Ex-stock
4 FA16000 TOP COVER SECURING LATCH 1 Ex-stock

4 FA16005 4900 COVER REMOVAL TOOL 1 Ex-stock
5 FA67050 POSITIVE AIR UPGRADE INTERNAL 1 Ex-stock Upgrade for 4900 and 6800 printers to provide positive air via internal air pump for
Mk7 printhead.
6 FA16004 IP65 PUSH BUTTON SWITCH 1 Ex-stock
FA79023 4900 INTERNAL LABEL PACK 1 Ex-stock Contains internal hazard warning labels.
7 FA15007 EHT POWER SUPPLY 1 Ex-stock

FA73037 NUT M3 NYLOC - PACK 20 Ex-stock
8 FA13178 AIR FILTER for IP55 1 Ex-stock Used in the 4900 and 6800 printers.
9—5
9 FA73172 M4 STEEL SERRATED FLANGE NUT - PACK 50 Ex-stock Used to secure the keyboard in the cover and the pump assembly to the chassis.
10 FA10674 LOW VOLTAGE PSU 1 Ex-stock Used in the 4800, 4900 and 6800 printers.
FA16003 4900 PSU MOUNTING BRACKET 1 Ex-stock

FA74086 SCREW M4X6 LG PAN HD POZ SS—PACK 50 Ex-stock
11 FA470024 MAINS ROCKER SWITCH 1 Ex-stock Mains power on/off switch. Used in 4800 and 4900 printers.
FA461012 MAINS FILTER 1 Ex-stock Used in 4900 and 6800 printers.
FA74115 RUBBER FOOT—PACK 4 Ex-stock Foot contains threaded insert for easy fitting. Used on 4800, 4900 and 6800
printers.
FA74101 SCREWLOCK 4.7—PACK 20 Ex-stock Screw thread sealant.
FA73078 SCR M3X16 LG PAN HD POZ SS—PACK 50 Ex-stock
FA74093 WSH SPRF INT M3 SS—PACK 50 Ex-stock
FA74097 NUT FULL HEX M3 SS—PACK 50 Ex-stock

FA77042 SCR M3X6 LG PAN HD POZ SS—PACK 20 Ex-stock
FA77080 SCR M3X10 LG CSK HD POZ SS - PACK 10 4 weeks
Nov 2003
Nov 2003
1
2
4
5
6
9—6
7
9
PE27 3LA UK
10 TITLE: 4900 REAR CABINET ASSEMBLY
SHEET: 1 OF 1

MP65557–1
4900 Rear Cabinet Assembly
MP65557–1
3 FA470024 MAINS ROCKER SWITCH 1 Ex-stock Mains power on/off switch. Used in 4800 and 4900 printers.
4 FA13472 IEC MAINS LEAD - 230 V 1 Ex-stock Includes mains cable, 6800 connector cover, flex protecting elbow and Nyloc nut.
4 FA13473 IEC MAINS LEAD - 110 V 1 Ex-stock Includes mains cable, 6800 connector cover, flex protecting elbow and Nyloc nut.

4 FA10504 MAINS CABLE IEC 230V - FREE END 1 Ex-stock
4 FA10585 110 V MAINS CABLE 1 Ex-stock
5 FA10578 GASKET MAINS COVER 1 Ex-stock
6 FA73065 NUT NYLOC M16x1.5 BLACK - PACK 20 Ex-stock
7 FA74102 SCR M3X8 LG PAN HD POZ SS—PACK 50 Ex-stock
8 FA13150 CONN COVER-MAINS CABLE 1 Ex-stock Used in the 4900 and 6800 printers.
9 FA570039 FLEX PROTECTING ELBOW 1 Ex-stock
9—7
10 FA71060 VFC ALARM CONVERSION 1 Ex-stock To convert 4900 printers (Connector PL10) and 6800 printers (Connector PL11) to
VFC alarm.
10 FA13547 ALARM CABLEFORM 1 Ex-stock Internal cableform, 24 V Alarm replacement set. Used in the 4900 and 6800
printers.
FA549130 9 WAY D-TYPE PLUG IP67 1 Ex-stock Plug to connect to shaft encoder or photocell.
FA599058 CON D SHELL 9 WAY SHIELDED 1 Ex-stock Fits FA549130 or FA541010.

FA63025 PRODUCT DETECTOR/ENCODER MULTIPLEXER 1 Ex-stock Enables up to four printers to be triggered by two or three encoders/sensors, or up
to eight printers to be triggered by two encoders. Includes IP67 D-type cable
AS63040. See Linx 6800 Maintenance Manual MP65307 for details of use.
FA63040 PDEM CABLEFORM 2M D-D IP67 1 Ex-stock Cableform to connect two 6800 printers so that they can be triggered from the
same source.
FA74101 SCREWLOCK 4.7—PACK 20 Ex-stock Screw thread sealant.
Nov 2003
6
Nov 2003
11 9 8
5
10
15
7 4
12
13
3
2
14
9—8
16 17
18
19 1
20
21
PE27 3LA UK
TITLE: 4900 INK SYSTEM ASSEMBLY (1)
SHEET: 1 OF 1

MP65557–1
4900 Ink System Assembly (1)
MP65557–1
1 FA74147 COMPLETE PUMP ASSEMBLY 1 Ex-stock Used in 4900 and 6800 printers.
2 FA73172 M4 STEEL SERRATED FLANGE NUT - PACK 50 Ex-stock Used to secure the keyboard in the cover and the pump assembly to the chassis.
3 FA10577 PUMP GASKET 1 Ex-stock Used in the 4900 and 6800 printers.
4 FA73012 TUBE SUPPORT ELBOW 6mm - PACK 10 Ex-stock
5 FA73044 MAIN INK FILTER 10 MICRON 1 Ex-stock
5 FA69012 LUBRICANT SMALL - MAIN FILTER 1 Ex-stock

6 FA73011 FILTER TUBE INSERT SS - PACK 10 Ex-stock
7 FA200005 PRESSURE TRANSDUCER O-RING SEAL 1 Ex-stock
7 FA74140 PRESSURE TRANSDUCER BOOT - PACK 20 Ex-stock Used in 4800, 4900 and 6800 printers.
8 FA10301 VENTURI 1 Ex-stock
9 FA16006 4900 VENTURI 0-RING MANIFOLD ASSY 1 Ex-stock Manifold Assembly complete with Pressure Transducer, Venturi and Connector.
FA16010 4900 O-RING MANIFOLD ASSEMBLY 1 Ex-stock Manifold block fitted with 6 barbs.
10 FA74141 O-RING 9.25 x 1.78 CSD - PACK 10 Ex-stock
11 FA73003 CONN STRT 1/8 BSP SELF SEAL—PACK 10 Ex-stock
9—9
12 FA74125 SIDE-PORTED VALVE ASSEMBLY 1 Ex-stock Valve fitted with two barbs.
13 FA74151 SIDE PORT VALVE ASSEMBLY - 2 WAY 1 Ex-stock Used in 4900 and 6800 printers.
14 FA74121 VALVE C-CLIP PACK-PLASTIC BASE 20 Ex-stock For use with plastic base valves.
15 FA72050 FEED DAMPER ASSY 1 Ex-stock Integral filter and push fit barbs. Support elbow included.
16 FA20110 3-WAY FLUID CONECTOR 15 MICRON 1 Ex-stock All black fluid connector used on Ultima and Midi printheads. To provide easier
and faster mistake-proof printhead connection.
17 FA74163 3-WAY CONNECTOR REPLACEMENT FILTER 15/25 1 Ex-stock Black plastic filter. For use with FA20110 connector. Includes insert/extract tool
18 FA74136 GASKET: FLUID CONNECTOR 3-WAY - PACK 10 Ex-stock For use with FA20110 and FA20254 connectors.
19 FA74135 M3 x 28 CSK POZ SS SCREW - PACK 10 Ex-stock For use with FA20110 and FA20254 connectors.
20 FA74119 SCR M3 x 25 CSK POZ (PLASTIC BASE) PK 20 Ex-stock For use with plastic base valves.
21 FA13421 VALVE CABLEFORM ASSY 1 Ex-stock Used in the 4900 and 6800 printers.
FA74164 VALVE/VENTURI BLOCK ASSEMBLY 1 Ex-stock Used in 4900 and 6800 printers.
FA74120 VALVE GASKET PACK-PLASTIC BASE 20 Ex-stock For use with plastic base valves.
FA74164 VALVE/VENTURI BLOCK ASSEMBLY 1 Ex-stock Used in 4900 and 6800 printers.
FA74120 VALVE GASKET PACK-PLASTIC BASE 20 Ex-stock For use with plastic base valves.
Nov 2003
14
Nov 2003
13
12
12
15
11
16 10
17 9
18 8
9 — 10
7
19
1
5 LINX PRINTING TECHNOLOGIES plc,
2 BURREL ROAD, ST IVES, CAMBRIDGESHIRE
PE27 3LA UK
4 TITLE: 4900 INK SYSTEM ASSEMBLY (2)

3 DRAWING NO.: PLATE 4900–5
SHEET: 1 OF 1

MP65557–1
4900 Ink System Assembly (2)
MP65557–1
1 FA13484 SOLVENT TANK ASSEMBLY MK2 1 Ex-stock Includes tank, filler tube, dip tube and cap. Used in the 4900 and 6800 printers.
1 FA13007 SOLVENT TANK 1 4 weeks Used in the 4800, 4900 and 6800 printers.
2 FA13005 SOLVENT DIP TUBE ASSEMBLY 1 Ex-stock
2 FA73014 O RING 7.66 x 1.78 EPDM - PACK 10 Ex-stock
3 FA13483 INK TANK ASSEMBLY MK2 1 Ex-stock Includes tank, filler tube, dip tube and cap. Used in the 4900 and 6800 printers.
3 FA72083 INK TANK PLASTIC 1 4 weeks Used in the 4200CE, 4800, 4900 and 6800 printers.

4 FA73016 CONN STRT M 1/4BSP SELF SEAL -PACK 10 Ex-stock
5 FA72131 MK2 INK FILLER TUBE ASSY 1 Ex-stock For use with new cover assemblies.
6 FA73017 O RING 26.6 x 2.62 EPDM - PACK 10 Ex-stock Two are used to provide the seal between the filler tube and the ink or solvent
tank.
6 FA13004 INK DIP TUBE ASSEMBLY 1 Ex-stock
7 FA73011 FILTER TUBE INSERT SS - PACK 10 Ex-stock

8 FA73012 TUBE SUPPORT ELBOW 6mm - PACK 10 Ex-stock
9 FA74149 INK MANDREL AND FILTER 1 Ex-stock
9 — 11
10 FA365002 O-RING FILL TUBE BS223 FEP/SIL CORE 1 Ex-stock Used on openings of ink and solvent filler tubes. Used in the 4800, 4900 and 6800
printers.
11 FA350066 QUAD RING 50.17ID x 5.33 1 Ex-stock
12 FA74162 INK AND SOLVENT CAPS’ SEALS—PACK 10 Ex-stock Used in 4800, 4900 and 6800 printers.
15 FA350067 QUAD RING 43.82ID x 5.33 1 Ex-stock
16 FA365003 O RING 33.87ID X 3.5 EDP 1 Ex-stock
17 FA74150 SOLVENT MANDREL AND FILTER 1 Ex-stock

18 FA72132 MK2 SOLVENT FILLER TUBE ASSY 1 Ex-stock For use with new cover assemblies.
19 FA73015 INK SYSTEM C1 BARB FITTING NYLON - PACK 10 Ex-stock
FA73182 I/S DRAIN PLUG M12 - PACK 10 Ex-stock Ink tray drain plug.
FA13422 FLOAT SWITCH ASSEMBLY 1 Ex-stock Used in the 4800, 4900 and 6800 printers.
FA74094 INK/SOLVENT CAP LABELS - 1240/3103—PACK 5 sheets Ex-stock Each sheet contains one each of the following labels: 1240 ink, 3103 ink, blank
ink, 1512 solvent, 3500 solvent, blank solvent.
FA74095 INK CAP LABELS - VARIOUS—PACK 5 sheets Ex-stock Each sheet contains 19 labels for ink types other than those in FA74094, plus 16
blank ink labels.
Nov 2003
FA74096 SOLVENT CAP LABELS - VARIOUS—PACK 5 sheets Ex-stock Each sheet contains 19 labels for solvent types other than those in FA74094, plus
16 blank solvent labels.
12 11 10 9 8 Pump 7
Nov 2003
Printhead
6
View on arrow A
5
9 — 12
1 Logo PROM System PROM 2 3 4
PE27 3LA UK
TITLE: 4900 ELECTRONICS ASSY—IPM PCB
SHEET: 1 OF 1

MP65557–1
4900 Electronics Assembly—IPM PCB
MP65557–1
1 FA71069 4900 IPM PCB ASSEMBLY 1 Ex-stock

2 FA13386 300 V CABLEFORM 1 Ex-stock Used in the 4900 and 6800 printers.
3 FA74146 IPM MOUNTING BRACKET 1 Ex-stock Used in 4900 and 6800 printers.
4 FA74086 SCREW M4X6 LG PAN HD POZ SS—PACK 50 Ex-stock
5 FA73068 SNAP RIVET 2.1 - 3 - PACK 50 Ex-stock
6 FA67050 POSITIVE AIR UPGRADE INTERNAL 1 Ex-stock Upgrade for 4900 and 6800 printers to provide positive air via internal air pump for

Mk7 printhead.
7 FA13421 VALVE CABLEFORM ASSY 1 Ex-stock Used in the 4900 and 6800 printers.
8 FA13401 MAINS INTERNAL CABLEFORM ASSY 1 Ex-stock Used in the 4900 and 6800 printers.
9 FA16002 4900 DISPLAY CABLEFORM 1 Ex-stock
10 FA13547 ALARM CABLEFORM 1 Ex-stock Internal cableform, 24 V Alarm replacement set. Used in the 4900 and 6800
printers.
11 FA71060 VFC ALARM CONVERSION 1 Ex-stock To convert 4900 printers (Connector PL10) and 6800 printers (Connector PL11) to
VFC alarm.
9 — 13
12 FA16001 AUTO POWER ON CABLEFORM 1 Ex-stock
FA63025 PRODUCT DETECTOR/ENCODER MULTIPLEXER 1 Ex-stock Enables up to four printers to be triggered by two or three encoders/sensors, or up
to eight printers to be triggered by two encoders. Includes IP67 D-type cable
AS63040. See Linx 6800 Maintenance Manual MP65307 for details of use.
FA63021 WIDTH ADJUSTER UNIT - IP67 D 1 Ex-stock For use with all printers except 6200S and 6000S, Includes IP67 D-type cable
FA63032. For use with a shaft encoder.
Nov 2003
MP65557–1
Index
Symbols
Fitting Instructions 5—123
Output 3—70
3-Way Fluid Connector 3—9, 3—10, 3—22, 3—27
Filter Replacement 3—22, 5—32
"300V Power Supply" print failure message 3—58, 6—14, 7—22
4800 Translation (remote setup) option 4—31
A
Abbreviations 1—8
Accelerator keys
Event List menu 6—3
Monitor Jet screen 5—10
Remote Setup menu 4—29
System software version number 3—62
Actual TOF 3—8
Advisory Messages 6—1
Air Filter 3—2
Replacement 5—32
Alarm menu 4—24
Failure mode option 4—25
Ink and Solvent mode option 4—25
Invert mode option 4—25
Mode option 4—24
Print Disabled mode option 4—25
Warning mode option 4—25
Alarm Output 3—70
Alarm Test option 5—22
Alarms, External
Output 3—70
Conversion to 5—127
Output 3—70
Alignment
Jet 3—20, 5—81
Nozzle 3—20
Amendments iii
Antistatic Precautions 5—26
Approvals, Regulatory 1—6
ATEX Directive 94/9/EC 1—3
ATEX EU Declaration of Conformity Certificate 1—6
Auto Mains Power Off Bypass Kit 4—18
Fitting Procedure 5—153
Auto Phase option 5—20
Auto Power Down menu 4—18
Auto Power Down option 4—18
Idle Time (mins) option 4—20
Printer Idle option 4—20
B
Battery 3—57
Baud Rate (remote setup) option 4—31
Blocked Gutter Clearance Procedure 5—91, 5—95
Bold Ratio option 4—12
Buffer Threshold (remote setup) option 4—30
Built In Self Test 3—58, 6—21
Buzzer (internal alarm warning) 3—59
MP65557–1 Amdt 01
C
Calculating the Print Width 4—15
Calibrated Nozzle Replacement (Offset Calibration) 5—115
Calibration
Charge Amplifier 5—62
EHTPSU 5—63
IPM PCB 5—61
Pressure Transducer 5—62
Calibration menu 5—21
DAC Cal Mode option 5—21
DAC Cal Value option 5—21
EHT Cal Value option 5—21
Saved Cal Value option 5—21
Cautions (Safety) 2—2
CE Approval Checklist 5—27
Change Configuration menu 4—28
Code option 4—28
UNIC option 4—28
Change Language menu 4—27
Change Password menu 4—26
Changing Menu Options 4—5, 5—4
Changing the Orientation of Mk7 Right-Angled P/Hs 5—149
Charge (Troubleshooting FC004) 7—9
Charge Amplifier
Calibration 5—62
Output 3—55
Charge Calibration Factor 3—20, 4—23
Charge Electrode 3—7, 3—14
Charge Voltage 3—14, 3—55
Checksum Disabled (remote setup) option 4—30
Circuit Diagrams 3—54
Clear Nozzle option 5—8
Clear Remote Buffers (remote setup) option 4—35
Code (configuration) option 4—28
Conduit Length option 4—22, 4—23
Configuration Code 3—62, 4—28
Configuration option 5—15
Control Panel Keys vi
Control Panel LEDs 3—4
Conventions, Document vi
Cooling Fan 3—53
Correct Installation of Mk7 Printheads 5—143
"Corrupt Program Data" system failure message 6—8
Cover Override 3—58, 6—20
Cover Override option 4—23
"Cover Override Active" system warning message 3—58, 4—23, 6—20
Cover Tube Magnet (printhead) 3—8
Cross-references vi
Current Message Screen 4—1
D
D-Type Connector, correct assembly 3—74
Dairy Coder configuration 1—1
Damper 3—22
Replacement 3—22, 5—32
Data Bits (remote setup) option 4—31
"Date Format Version" system failure message 6—10
Deflector and Phase Plate (DPP) 3—7, 3—15
Deflector Plates 3—7, 3—15
Cleanliness 3—15
Density, Ink 3—8
Amdt 01 MP65557–1
Diagnostics menu 4—35, 5—1
Option Availability 5—2
Options 5—2
Password Access 5—1
Diagnostics menu options
Alarm Test option 5—22
Auto Phase option 5—20
Calibration menu 5—21
Filter Purge option 5—19
Generate Test Pattern option 5—22
Modulation Tracking option 5—18
Modulation, Actual reading 5—11
Phase (position) reading 5—12
Printhead Temperature reading 5—12
Read Pressure reading 5—10
Reference Modulation reading 5—12
Reference TOF reading 5—11
Set Pressure reading 5—10
Solvent Add Pressure reading 5—11
TOF, Actual reading 5—11
Nozzle Flush option 5—9
Phase (position) option 5—16
Phase Fault option 5—19
Phase Offset option 5—16
Phase Period option 5—19
Pressure Tracking option 5—17
Quick Start Jet option 5—6
Ref Pressures menu 5—16
Maximum Run option 5—17
Printhead Ref option 5—16
Solvent Add option 5—17
Set Modulation option 5—18
Set Pressure option 5—18
Start Jet option 5—5
Start Print option 5—7
Stop Jet option 5—5
Stop Print option 5—7
System Configuration menu 5—14
Enabled Options option 5—15
Head Type option 5—14
Language Group option 5—15
Message Type option 5—14
Messages Stored option 5—14
PCB Issue option 5—15
SW Links option 5—14
SW Version option 5—14
System Flush menu 5—23
System Times menu 5—12
Jet Running option 5—13
Power On option 5—13
Service (Hours) option 5—13
Test Print option 5—7
TOF Correction option 5—20
TOF Warm Up option 5—20
Valve Test menu 5—24
Display 3—4
Display PCB 3—62
Links 3—62
Test Points 3—62
MP65557–1 Amdt 01
Divide Ratio 4—15
Document Conventions vi
Draining the Ink System 5—41
Drop Charge 3—14
Drop Deflection 3—15
E
EHT Deflection (Troubleshooting FC010) 7—15
EHT Power Supply Unit 1—2, 3—51
Calibration 5—63
"EHT Trip" print failure message 6—12, 7—19
Electromagnetic Compatibility (EMC) 1—6
EMC Directive 1—6
European EMC Standards 1—6
USA EMC Standards 1—6
EMC Standards 1—6
Empty Tank Sequence 3—44
Enclosure Protection Standards 1—6
Environmental Specification 1—1
Escape Char (remote setup) option 4—30
European Safety Standards 1—6
Event List 6—3
Events' messages 6—1
External Alarms
24 Volts Alarm
Output 3—70
Mains (VFC) Alarm
Output 3—70
External Signals 3—63
Alarm Output 3—70
PDEM Cableform 3—68, 3—69
Primary Trigger 3—63
Secondary Trigger 3—64
Serial Interface 3—73
Shaft Encoders 3—66
F
Fail LED 3—4
Failure (alarm mode) option 4—25
Fault Info. 6—5
Fault Reporting Configuration 6—2
Fault Shutdown Sequence 3—39
Feed Dry Cycle Sequence 3—40
Feed Valve (Ink System) 3—22, 3—25, 3—27, 3—32
Testing for Leaks 5—67
Feed Valve (Printhead) 3—9, 3—27, 3—32
Feed Valve Replacement 5—135
Filter Replacement 5—139
Filter, Air 3—2
Replacement 5—32
Filter Purge option 5—19
Filter Purge Sequence 3—43
Final Test (Troubleshooting FC999) 7—30
First Aid 2—5
Eye Contact 2—5
Ingestion 2—5
Inhalation 2—5
Skin Contact 2—5
Flag Label (Printhead) fitting 5—111, 5—119
Flow Control (remote setup) option 4—32
Amdt 01 MP65557–1
Flow Control menu 4—32
Flow Control option 4—32
Xoff Char option 4—32
Xon Char option 4—32
Fluid Connector, 3-way 3—9, 3—10, 3—22, 3—27
Filter Replacement 3—22, 5—32, 5—49
Fluid Level Sensors 1—4, 3—21
Flush Cycle Sequence 3—42
"Font Version" system failure message 6—10
Fuses (Mains) 3—50
G
"Gate Array Test Mode Active" system warning msg. 6—21
Generate Test Pattern option 5—22
Glossary 1—8
Good Practice 5—26
Guard Drops 3—18
Gun Chamber 3—7
Gutter (clearing a blockage) 5—91
Gutter Check Valve (In-Line) 3—10
Gutter Dry Cycle Sequence 3—44
"Gutter Override Active" system warning message 6—21
Gutter Restrictor (Standard) 3—10
Gutter Sense Override 3—58, 6—21
Gutter Valve 3—25, 3—32
Testing for Leaks 5—69, 5—72
Testing for Operation 5—72
H
Hall Effect Switch 3—8
"Hardware Safety Trip" print failure message 6—16, 7—29
Hazards. See Safety
Head Height option 4—21
High Level trigger setting 4—14
High Viscosity Ink (Troubleshooting FC009) 7—14
Historic Correction 3—14, 3—15
I
Ideal Pitch values 4—16
In-Line Feed Filter 3—9, 3—27
In-Line Gutter Check Valve 3—10
Ink and Solvent (alarm mode) option 4—25
Ink Conversion Calibration (Offset Calibration) 5—109
Ink Density 3—8
Ink Dip (Pick-up) Tube 3—21, 3—22, 3—27
Filter 3—21, 3—22, 3—27
Replacement 3—22, 5—32, 5—45
Ink Flow 3—27
Ink Low (level) 1—4
"Ink Low" system warning message 3—21, 5—44, 6—18
Ink Quality (Troubleshooting FC007) 7—12
Ink System 1—3, 3—2, 3—21
ATEX Directive 94/9/EC 1—3
Capacity 1—4
Connections 3—26
Construction 1—3
Damper 3—22
Draining 5—41
Electrical Connections 1—3
Environmental 1—3
Feed Valve Test 5—67
Fluid Level Control 1—4
MP65557–1 Amdt 01
Gutter Valve Tests 5—69
Ink Dip (Pick-up) Tube 3—21, 3—22, 3—27
Ink Tank 3—21
IP Rating 1—3
Level Sensors 3—21
Main Ink Filter 3—22
Maximum Surface Temperature of valves' solenoids 1—3
Performance 1—4
Pressure 1—3
Pump/Motor Assembly 3—21
Purge Valve Test 5—69
Solvent Dip (Pick-up) Tube 3—22
Solvent Flush Valve Tests 5—73
Solvent Tank 3—21
Solvent Top-up (Solvent Add) Valve Tests 5—77
Valves 3—25, 3—52
Vent Pipe 5—32
Venturi 3—22
Ink Tank 3—21
Capacity 1—4
Construction 1—3
"Ink Tank Empty" print failure message 3—21, 6—14, 7—23
Ink Time Out 3—21
Ink Type Dependent Parameters 3—46
Ink Type Selection option 4—20
Ink Viscosity 3—8, 3—17
Inks and Solvents (Safety) 2—4
"Internal Failure" system failure message 6—7
"Internal Spillage" print failure message 6—15, 7—25
"Invalid Configuration" system failure message 6—10
Invert (alarm mode) option 4—25
IP Rating
Ink System 1—3
Printer Cabinet 1—1
IPM PCB 3—54, 3—55, 3—62
Calibration Procedure 5—61
Links 3—57
Links' locations 3—61
Replacement and Calibration 3—62
Test Points 3—55
Test Points' locations 3—61
J
Jet (Troubleshooting FC002) 7—7
Jet Alignment 3—20, 5—81
Julian Date Format option 4—13
K
Keyboard 3—4
Keys
Control Panel vi
Keyboard vi
L
"Language Version" system failure message 6—9
LCD (Liquid Crystal Display) 3—4
Leading Edge trigger setting 4—13
LEDs 3—4
Lethal Voltages 2—3
Links
Display PCB 3—62
IPM PCB 3—57
IPM PCB locations 3—61
Amdt 01 MP65557–1
"Logo Version" system failure message 6—10
Low Level trigger setting 4—14
Low Pressure (Troubleshooting FC006) 7—11
"Low Pressure" system warning message 3—18, 3—30, 5—10, 5—17, 6—21
Low Viscosity Ink (Troubleshooting FC008) 7—13
Low Voltage Power Supply Unit 1—2, 3—50
M
Main Ink Filter 3—22
Purging 5—32
Replacement 3—22, 5—32, 5—53
Output 3—70
Mains Filter 3—50
Mains Input Fuses 3—50
Mains Power Cable 3—49
Mains Power Requirements 1—2
Mains Power Supply Switch 3—50
Maintenance Instructions 5—25
24 Volts Alarm Beacon Fitting (Printer Mounted) 5—123
3-Way Fluid Connector Filter Replacement 5—49
Auto Mains Power Off Bypass Kit Fitting Procedure 5—153
Blocked Gutter Clearance Procedure 5—91
Calibrated Nozzle Replacement (Offset Calibration) 5—115
Changing the Orientation of Mk7 Right-Angled P/Hs 5—149
Correct Installation of Mk7 Printheads 5—143
Draining the Ink System 5—41
Ink Conversion Calibration (Offset Calibration) 5—109
Ink System Feed Valve Test 5—67
Ink Tank Dip Tube Replacement 5—45
IPM PCB Calibration 5—61
Jet Alignment and Nozzle Cleaning 5—81
Main Ink Filter Replacement 5—53
Mains (VFC) External Alarm Conversion 5—127
Modulation Range Checks 5—89
Positive Air Pump Fitting Instructions 5—131
Printer Installation Procedure 5—121
Printhead Cleaning for Pigmented Inks 5—37
Printhead Feed Valve Filter Replacement 5—139
Printhead Feed Valve Replacement 5—135
Printhead Valves Tests 5—65
Purge and Gutter Valves Tests 5—69
Scheduled Maintenance 5—29
Solvent Flush Valve Tests 5—73
Solvent Top-up (Solvent Add) Valve Tests 5—77
System Flush Procedure 5—95
Maintenance Terminology 5—25
Maximum Pressure 3—32, 3—52
Memory Capacity 1—6
"Memory Corrupt" system warning message 6—17
Menu Options
Selecting and Changing 4—5, 5—4
Message Count (Print Status) 6—2
Message Delimiters menu 4—32
"Message Memory Full" system warning message 6—22
"Message Name Exists" system warning message 6—22
Message Orientation option (v1.5 S/W & DC Config.) 4—11
Message Types 1—5
Micrometre (µm) 3—21
Minimum Print Delay default values 4—9
"Misaligned Ink Jet" print failure message 6—15, 7—26
MP65557–1 Amdt 01
Mod. Tracking Slope option 4—20
Mode (alarm setup) option 4—24
Mode (remote setup, Print Mode) option 4—34
Mode (remote setup, Transfer Parameters) option 4—30
Modulation (Troubleshooting FC003) 7—8
Modulation, Actual 3—12, 5—11
Modulation description 3—12
Modulation Frequency 3—12, 3—56
Modulation Range Checks 5—89, 5—92
Modulation, Reference 3—13, 3—20, 4—23, 5—12
Modulation, Reference reading 5—12
Modulation Tracking option 5—18
Modulation Voltage 3—13, 3—55
N
"No Fonts" system failure message 6—9
"No Message Stored" system warning message 6—22
"No Raster Data" system failure message 6—9
"No Time Of Flight" system warning message 6—22
"No UNIC Chip" system failure message 6—10
Normal Shutdown Sequence 3—36
Normal Start Sequence 3—34
Normalise Message Type option 4—7
Notes 2—2
Nozzle Alignment 3—20
Nozzle Assembly 3—7
Nozzle Cleaning 5—81
Hot Water Wash 5—87
Nozzle Soaking 5—85
Nozzle Washing 5—86
Solvent Wash 5—86
Nozzle Clear Sequence 3—41, 5—83
Nozzle Flush option 5—9
Nozzle Flush Sequence 3—45
Nozzle Realignment 5—88
Nozzle Replacement 3—20, 5—115
NPN/PNP (Photocells) 3—63
Number Of Buffers (remote setup) option 4—35
O
"Over Speed (Asynchronous Data)" syst. warning msg 6—19
"Over Speed (Print Trigger)" syst. warning msg. 6—18
"Over Speed (Synchronous Data)" syst. warning msg. 6—19
P
Parity (remote setup) option 4—31
Password Access 4—2, 5—1
Password option 4—5
Passwords 4—37
PDEM Cableform 3—68, 3—69
Phase (position) 5—12
Phase (position) option 5—16
Amdt 01 MP65557–1
Phase (Troubleshooting FC005) 7—10
"Phase Failure" print failure message 6—13, 7—20
Phase Fault option 5—19
Phase Offset option 5—16
Phase Packet 3—16
Phase Period option 5—19
Phase Sensor 3—7, 3—15
Phase Signal 3—16
Phasing 3—7, 3—15
Photocells 3—63
Piezoelectric Crystal 3—12
Pigmented Inks, Printhead Cleaning for 5—37
"Pixel RAM" system failure message 6—10
Positive Air Pump 3—53, 5—131
Power Cable 3—49
Power LED 3—4
Power Off Override 3—58, 4—18, 4—19, 4—22, 4—29, 6—20
"Power Off Override Active" system warning message 6—20
Power On Switch 3—50
Precautions (Safety) 2—4
"Pressure Limit Reached" print failure message 6—15, 7—27
Pressure, Reference 4—23
Pressure Relief Valve, Pump 3—21
Pressure Tracking option 5—17
Pressure Transducer 3—24
Calibration 5—62
Primary Circuit, Ink System 3—27
Primary Trigger 3—63
Primary Trigger and Shaft Encoder Configurations 3—68
Primary Trigger option 4—13
Remote trigger setting 4—14
Trailing Edge trigger setting 4—14
Primary Trigger Signal 3—56
Print (Troubleshooting FC011) 7—16
Print Control menu 4—33
Print Delay Char option 4—33
Print End Char option 4—33
Print Go Char option 4—33
Print Trigger Char option 4—33
Print Count option 4—10
Print Delay Char (remote setup) option 4—33
Print Delay option 4—9
Print Disabled (alarm mode) option 4—25
Print End Char (remote setup) option 4—33
Print Failures 6—11
2.00 Printhead Over Temperature 3—8, 5—12, 6—12, 7—18
2.01 EHT Trip 6—12, 7—19
2.02 Phase Failure 6—13, 7—20
2.03 Time Of Flight Failure 5—11, 6—14, 7—21
2.04 300V Power Supply 3—58, 6—14, 7—22
2.05 Ink Tank Empty 3—21, 6—14, 7—23
2.06 Solvent Tank Empty 3—21, 6—14, 7—24
2.07 Internal Spillage 6—15, 7—25
2.09 Misaligned Ink Jet 6—15, 7—26
2.11 Pressure Limit Reached 6—15, 7—27
2.12 Viscosity 3—18, 6—16, 7—28
2.13 Hardware Safety Trip 6—16, 7—29
Print Go Char (remote setup) option 4—33
Print Go/No Data (remote setup) option 4—35
Print Go/Pixel Ram (remote setup) option 4—35
MP65557–1 Amdt 01
Print Height option 4—6
Print Mode menu 4—34
Clear Remote Buffers option 4—35
Mode option 4—34
Number Of Buffers option 4—35
Print Go/No Data option 4—35
Print Go/Pixel Ram option 4—35
Print Quality (Troubleshooting FC012) 7—17
Print Status Screen 6—2
Event List 6—3
Fault Info. 6—5
Warning Info. 6—3
Print Trigger Char (remote setup) option 4—33
Print Width
Calculating 4—15
Example Calculation 4—16
Print Width option 4—8
Printer Cabinet 3—1
Construction 1—2
Cooling 3—2
Dimensions 1—2
Weight 1—2
Printer Configuration Code 3—62
Printer Configurations 1—1
Printer Installation Procedure 5—121
Printhead 1—4, 3—20
Construction 1—4
Correct Installation 5—143
Dimensions 1—4
Feed Valve Filter Replacement 5—139
Feed Valve Replacement 5—135
Feed Valve Test 5—65
Purge Valve Test 5—65
Right-Angled, Changing the Orientation 5—149
Types 1—4, 3—11
Printhead Cleaning for Pigmented Inks 5—37
Printhead Components 3—6
Printhead Connections 3—10
"Printhead Cover Off" system warning message 3—58, 5—125, 6—20
Printhead Cover Sensor 3—8
Printhead Cover Tube Magnet 3—8
Printhead Feed Valve Filter Replacement 5—139
Printhead Feed Valve Replacement 5—135
Printhead Flag Label fitting 5—111, 5—119
"Printhead Over Temperature" print failure message 3—8, 5—12, 6—12, 7—18
Printhead Replacement 3—20
Printhead Setup menu 4—21
Type option 4—22
Printhead Temperature 5—12
Printhead Temperature Sensor 3—8
Printhead to Substrate Distance 1—5
Printhead Types 1—4, 3—11, 3—62
Printhead Valves 3—9, 3—19, 3—27
Printing Performance Data 1—4
Printhead to Substrate Distance 1—5
Pump/Motor Assembly 3—21, 3—52
Purge Dry Cycle Sequence 3—40
Purge Valve (Ink System) 3—25, 3—32
Purge Valve (Printhead) 3—9
Amdt 01 MP65557–1
Q
Quality (printer) 3—20
Quick Start Jet option 5—6
Quick Start Sequence 3—34
Quick Stop 5—5
Quick Stop Sequence 3—39
R
"Raster Version" system failure message 6—9
Rasters 3—11
Read Pressure 3—55, 5—10
Ready LED 3—4
Ref Pressures menu 5—16
Reference Modulation 3—13, 3—20, 4—23, 5—12
Reference Pressure 3—17, 3—20, 3—33, 4—23
Reference TOF 3—8, 3—17, 5—11
Regulatory Approvals 1—6
"Remote Error" system warning message 6—22
Remote Setup Menu (RS232) 4—29
Flow Control option 4—32
Xoff Char option 4—32
Xon Char option 4—32
Print Delay Char option 4—33
Print End Char option 4—33
Print Go Char option 4—33
Print Trigger Char option 4—33
Clear Remote Buffers option 4—35
Mode option 4—34
Number Of Buffers option 4—35
Print Go/No Data option 4—35
Print Go/Pixel Ram option 4—35
Serial Parameters menu 4—31
Baud Rate option 4—31
Data Bits option 4—31
Parity option 4—31
Stop Bits option 4—31
Transfer Parameters menu 4—30
4800 Translation option 4—31
Buffer Threshold option 4—30
Checksum Disabled option 4—30
Escape Char option 4—30
Mode option 4—30
Restart Sequence 3—35
Reverse Message option (non-DC Configuration) 4—10
RS232 Cable Connections 3—73
S
Safety 2—1
First Aid 2—5
Inks and Solvents 2—4
Lethal Voltages 2—3
Precautions 2—4
Test Printing 2—6
Warnings and Cautions 2—1
MP65557–1 Amdt 01
Safety Functions 3—60
Safety Override 3—57, 6—21
"Safety Override Active" system warning message 6—21
Safety Standards 1—6
Scheduled Maintenance 5—29
Scheduled Maintenance Checklist 5—28
"Scheduled Maintenance Req'd" syst. warning msg. 5—13
"Scheduled Maintenance Req’d" syst. warning msg. 6—19
Secondary Circuit, Ink System 3—27
Secondary Trigger 3—64
Secondary Trigger Signal 3—56
Serial Interface 3—73
Baud Rate option 4—31
Data Bits option 4—31
Parity option 4—31
Stop Bits option 4—31
Set Date option 4—13
Set Modulation option 5—18
Set Pressure 3—8, 3—17, 3—55, 3—57, 5—10
Set Pressure option 5—18
Set Time option 4—13
Setup menu 4—1
Calculating the Print Width 4—15
Current Message Screen 4—1
Option Availability 4—3
Options 4—3
Password Access 4—2
Shaft Encoder Divide Ratio (Print Width) 4—15
Setup menu options
Alarm menu 4—24
Failure mode option 4—25
Ink and Solvent mode option 4—25
Invert mode option 4—25
Mode option 4—24
Print Disabled mode option 4—25
Warning mode option 4—25
Auto Power Down menu 4—18
Bold Ratio option 4—12
Change Configuration menu 4—28
Code option 4—28
UNIC option 4—28
Change Language menu 4—27
Change Password menu 4—26
Diagnostics menu 4—35. See also 'Diagnostics menu options'
Head Height option 4—21
Ink Type Selection option 4—20
Julian Date Format option 4—13
Message Orientation option (v1.5 S/W & DC Config.) 4—11
Mod. Tracking Slope option 4—20
Normalise Message Type option 4—7
Password option 4—5
Primary Trigger option 4—13
Print Count option 4—10
Amdt 01 MP65557–1
Print Delay option 4—9
Print Height option 4—6
Print Width option 4—8
Printhead Setup menu 4—21
Type option 4—22
Remote Setup Menu (RS232) 4—29
Reverse Message option (non-DC Configuration) 4—10
Set Date option 4—13
Set Time option 4—13
Shaft Encoder option 4—15
Solv Add Time option 4—35
Shaft Encoder and Primary Trigger Configurations 3—68
Shaft Encoder Divide Ratio (Print Width) 4—15
Shaft Encoder Modes 4—17
Shaft Encoder option 4—15
Shaft Encoders 3—66
"Shutdown Incomplete" system warning message 6—17
Shutting Down 3—19
Software 3—62
Solv Add Time option 4—35
Solvent Add Offset 3—33
Solvent Add Pressure 3—8, 3—17, 3—30, 3—33, 5—11
Solvent Addition, Automatic 3—30
Solvent Dip (Pick-up) Tube 3—21, 3—22, 5—74, 5—78
Filter 3—22
Solvent Drain Sequence 3—44
Solvent Flow 3—27
Solvent Flush Valve 3—22, 3—25, 3—32
Solvent Low (level) 1—4
"Solvent Low" system warning message 3—18, 3—21, 3—30, 5—17, 5—105, 5—106, 6—18
Solvent Tank 3—21
Capacity 1—4
Construction 1—3
"Solvent Tank Empty" print failure message 3—21, 6—14, 7—24
Solvent Time Out 3—21
Solvent Top-up (Solvent Add) Valve 3—22, 3—25, 3—30, 3—32
"Stack Overflow" system failure message 6—8
Standard Gutter Restrictor 3—10
Standards 1—6
Start Jet option 5—5
Start Print option 5—7
Starting Up 3—19
Status (Print Status) 6—2
Stop Bits (remote setup) option 4—31
Stop Jet option 5—5
Stop Print option 5—7
Strobe LED 3—7, 3—14, 6—20
"Synchronisation" system warning message 6—22
MP65557–1 Amdt 01
System Configuration menu 5—14
System Events 6—1
System Failures 6—7
1.00 Internal Failure 6—7
1.01 Stack Overflow 6—8
1.02 Corrupt Program Data 6—8
1.03 Unexpected Interrupt 6—8
1.04 Unexpected RST 6—8
1.05 Unexpected NMI 6—9
1.07 System RAM 6—9
1.12 Language Version 6—9
1.13 No Raster Data 6—9
1.14 Raster Version 6—9
1.16 No Fonts 6—9
1.17 Font Version 6—10
1.20 Logo Version 6—10
1.21 Pixel RAM 6—10
1.22 Date Format Version 6—10
1.34 Invalid Configuration 6—10
1.35 No UNIC Chip 6—10
System Flush
Empty Tank sequence 5—102
Flush Cycle 5—105
Solvent Drain sequence 5—106
System Flush Cycle Sequence 3—42
System Flush menu 5—23
System Flush Procedure 5—95
"System RAM" system failure message 6—9
System Times menu 5—12
System Warnings 6—17
3.00 Shutdown Incomplete 6—17
3.02 Memory Corrupt 6—17
3.03 Ink Low 3—21, 5—44, 6—18
3.04 Solvent Low 3—18, 3—21, 3—30, 5—17, 5—105, 5—106, 6—18
3.05 Over Speed (Print Trigger) 6—18
3.06 Over Speed (Synchronous Data) 6—19
3.07 Over Speed (Asynchronous Data) 6—19
3.11 Scheduled Maintenance Req’d 6—19
3.11 Scheduled Maintenance Required 5—13
3.12 Printhead Cover Off 3—58, 5—125, 6—20
3.13 Cover Override Active 3—58, 4—23, 6—20
3.14 Power Off Override Active 6—20
3.15 Safety Override Active 6—21
3.16 Gutter Override Active 6—21
3.17 Gate Array Test Mode Active 6—21
3.18 Low Pressure 3—18, 3—30, 5—10, 5—17, 6—21
3.20 No Time Of Flight 6—22
3.26 User Data Corrupt 6—22
3.29 No Message Stored 6—22
3.30 Message Name Exists 6—22
3.31 Message Memory Full 6—22
3.32 Remote Error 6—22
3.33 Synchronisation 6—22
Amdt 01 MP65557–1
T
Technical Data 1—1
Temperature Sensor, Printhead 3—8
Test Points
Display PCB 3—62
IPM PCB 3—55
IPM PCB locations 3—61
Test Print option 5—7
Test Printing (Safety) 2—6
Time Of Flight (TOF) description 3—17
"Time Of Flight Failure" print failure message 5—11, 6—14, 7—21
TOF, Actual 3—8, 3—17, 5—11
TOF Correction option 5—20
TOF measurement 3—7
TOF, Reference 3—8, 3—17, 5—11
TOF, Reference reading 5—11
TOF Sensor 3—7, 3—15
TOF signal 3—17
TOF Warm Up option 5—20
4800 Translation option 4—31
Buffer Threshold option 4—30
Checksum Disabled option 4—30
Escape Char option 4—30
Mode option 4—30
Troubleshooting 7—1
Miscellaneous Faults 7—3
Troubleshooting Start (Troubleshooting FC001) 7—6
Type (printhead) option 4—22
U
"Unexpected Interrupt" system failure message 6—8
"Unexpected NMI" system failure message 6—9
"Unexpected RST" system failure message 6—8
UNIC 3—54, 3—62, 6—10
UNIC option 4—28
"User Data Corrupt" system warning message 6—22
User Interface 3—4
V
Valve Sequences 3—32
Empty Tank Sequence 3—44
Fault Shutdown Sequence 3—39
Feed Dry Cycle Sequence 3—40
Filter Purge Sequence 3—43
Flush Cycle Sequence 3—42
Gutter Dry Cycle Sequence 3—44
Normal Shutdown Sequence 3—36
Normal Start Sequence 3—34
Nozzle Clear Sequence 3—41
Nozzle Flush Sequence 3—45
Purge Dry Cycle Sequence 3—40
Quick Start Sequence 3—34
Quick Stop Sequence 3—39
Restart Sequence 3—35
Solvent Drain Sequence 3—44
Valve Sequences' Summary Tables 3—32
Valve Test menu 5—24
Valves (Ink System) 3—25, 3—52
Venturi 3—22, 3—24
Venturi Manifold Assembly 3—22, 3—24
Viscosity Control 3—17
MP65557–1 Amdt 01
Viscosity, Ink 3—8, 3—17
"Viscosity" print failure message 3—18, 6—16, 7—28
Viscosity Settle Time 3—18, 3—30
W
Warning (alarm mode) option 4—25
Warning Info. 6—3
Warning LED 3—4
Warning Reporting Configuration 6—2
Warnings (Safety) 2—1
Width Adjuster Unit 3—67, 4—17
X
Xoff Char (remote setup) option 4—32
Xon Char (remote setup) option 4—32
Amdt 01 MP65557–1

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Linx 4900 Ink Jet Printer

Amdt Incorporated by Date of Amdt Incorporated by Date of

01 Issued with manual Jan 2006 27

This First edition published November 2003

LINX® is the Registered Trademark

Unauthorized use of the LINX Trademark is strictly forbidden.

About this Manual

Control Panel Keys

Menu and Screen Conventions

CHAPTER 1: GENERAL .............................................................. 1—1

CHAPTER 2: SAFETY .................................................................. 2—1

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

CHAPTER 4: SETUP MENU ........................................................ 4—1

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

CHAPTER 7: TROUBLESHOOTING ........................................... 7—1

CHAPTER 8: TRAINING DOCUMENTATION ............................... 8—1

CHAPTER 9: ILLUSTRATED PARTS LIST ................................. 9—1

INDEX .......................................................................................... 10—1

CHAPTER 1: GENERAL ................................................................................. 1—1

CHAPTER 2: SAFETY ..................................................................................... 2—1

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

CHAPTER 4: SETUP MENU ........................................................................... 4—1

5.4 Maintenance Instructions ....................................................................... 5—25

Printhead Cleaning for Pigmented Inks ................................................................................. 5—37

Draining the Ink System .......................................................................................................... 5—41

Ink Dip Tube Replacement ...................................................................................................... 5—45

3-way Fluid Connector Filter Replacement ........................................................................... 5—49

Main Ink Filter Replacement ................................................................................................... 5—53

IPM PCB Calibration ................................................................................................................ 5—61

Printhead Valves Tests ............................................................................................................ 5—65

Ink System Feed Valve Test .................................................................................................... 5—67

Purge and Gutter Valves Tests ............................................................................................... 5—69

Solvent Top-up (Solvent Add) Valve Tests ............................................................................ 5—77

Jet Alignment and Nozzle Cleaning ....................................................................................... 5—81

Modulation Range Checks ...................................................................................................... 5—89

Blocked Gutter Clearance Procedure .................................................................................... 5—91

System Flush Procedure ......................................................................................................... 5—95

Ink Conversion Calibration (Offset Calibration) .................................................................. 5—109

Calibrated Nozzle Replacement (Offset Calibration) .......................................................... 5—115

24-volt Alarm Beacon Fitting (Printer Mounted) ................................................................. 5—123

Positive Air Pump Fitting Instructions ................................................................................. 5—131

Printhead Feed Valve Replacement ..................................................................................... 5—135

Printhead Feed Valve Filter Replacement ............................................................................ 5—139

Changing the Orientation of Mk7 Right-Angled Printheads ............................................... 5—149

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

CHAPTER 7: TROUBLESHOOTING .............................................................. 7—1

CHAPTER 9: ILLUSTRATED PARTS LIST .................................................... 9—1

1.2 Technical Data

Dairy Coder (SS to DC Upgrade)

Figure 1-1. Printer Configurations

WARNING: THIS PRINTER MUST BE EARTHED/GROUNDED.

1.2.5 Low Voltage Power Supply Unit

1.2.6 EHT Power Supply Unit

Type and Classification

ATEX classification: II 3G IIA T4

Maximum Surface Temperature

Fluid Level Control

Straight and Right-Angled Printheads

1.2.9 Printing Performance Data

Ultima (62 µm)

Ultima plus (75 µm)

Printhead to Substrate Distance (recommended)

1.2.11 Regulatory Approvals