SERVICE

MANUAL

4800 Ink Jet Printer

 4800
Continuous Ink Jet
Printer

SERVICE MANUAL

Linx Printing Technologies plc

MP65209–1
4800 Service Manual Oct 97
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MP65209–1
Oct 97 (ii) 4800 Service Manual
 Linx Printing Technologies plc

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

01 Issued with manual Feb 1998 27

02 Issued with manual Aug 1998 28

03 Issued with manual Sep 2000 29

04 30

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09 35

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11 37

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MP65209–1 Amdt 03
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Amdt 03 MP65209–1
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 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 October 1997

© 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® 4800 Continuous Ink Jet Printer. The
information contained in this manual is relevant to Version 1.0 software or later versions.
Products described in this manual are subject to continuous development, and reviews of
this manual will be made accordingly in subsequent amendments, editions 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
Cambs
PE17 4LE
United Kingdom
Tel: + 44 (0) 1480 302100
Fax: + 44 (0) 1480 302116

This service manual has been written and compiled by Roger Livesey.

MP65209–1 Amdt 01
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Contents
Amendment Record ........................................................................... iii
Contents ........................................................................................... vii
List of Figures ............................................................................ xiii

SECTION 1: GENERAL ................................................. 1—1

1.1 Introduction ............................................................................ 1—1
1.2 Technical Data ........................................................................ 1—1
1.2.1 Cabinet .......................................................................... 1—1
1.2.2 Power Requirements ....................................................... 1—1
1.2.3 Low Voltage Power Supply Unit ....................................... 1—1
1.2.4 EHT Power Supply Unit .................................................. 1—2
1.2.5 Environmental ............................................................... 1—2
1.2.6 Ink System ..................................................................... 1—2
1.2.7 Memory Capacity ........................................................... 1—2
1.2.8 Printhead ....................................................................... 1—3
1.2.9 Printing Performance Data ............................................. 1—3
1.2.10 Regulatory Approvals ................................................... 1—4
1.3 Abbreviations and Glossary ..................................................... 1—5

SECTION 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—3
2.4.1 Precautions .................................................................... 2—4
2.4.2 First Aid ......................................................................... 2—4
2.5 Test Printing ........................................................................... 2—5

SECTION 3: TECHNICAL DESCRIPTION ...................... 3—1

3.1 Introduction ............................................................................ 3—1
3.2 Printhead Components ........................................................... 3—2
3.2.1 Printhead Types ............................................................. 3—3
3.2.2 Piezo Crystal .................................................................. 3—3
3.2.3 Charge Electrode ............................................................ 3—3
3.2.4 Deflector Plates............................................................... 3—3
3.2.5 Phase and TOF Sensors .................................................. 3—4
3.2.6 Safety Sensors................................................................ 3—4
3.2.7 Charge Strobe ................................................................ 3—4
3.2.8 Printhead Connections ................................................... 3—5
3.2.9 Quality ........................................................................... 3—5
3.2.10 Last Chance Filter ........................................................ 3—5
3.2.11 Printhead Replacement................................................. 3—5
3.2.12 Jet/Nozzle Alignment ................................................... 3—6

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3.3 Printhead Principles of Operation ............................................ 3—6

3.3.1 Overview ........................................................................ 3—6
3.3.2 The Ink Jet ..................................................................... 3—7
3.3.3 Modulation .................................................................... 3—7
3.3.4 Drop Charge .................................................................. 3—9
3.3.5 Historic Correction ......................................................... 3—9
3.3.6 Drop Deflection .............................................................. 3—9
3.3.7 Phasing .......................................................................... 3—9
3.3.8 Time Of Flight (TOF) ..................................................... 3—11
3.3.9 Viscosity Control .......................................................... 3—11
3.3.10 Guard Drops .............................................................. 3—12
3.3.11 Starting Up and Shutting Down ................................. 3—13
3.4 Cabinet ................................................................................. 3—14
3.5 User Interface ........................................................................ 3—16
3.5.1 Keyboard and Display .................................................. 3—16
3.5.2 Control Panel LEDs ...................................................... 3—17
3.6 Electrical Components .......................................................... 3—18
3.6.1 Mains Filter .................................................................. 3—18
3.6.2 Mains Input Fuses ....................................................... 3—18
3.6.3 Low Voltage Power Supply Unit (LVPSU) ....................... 3—18
3.6.4 EHT Power Supply Unit ................................................ 3—19
3.6.5 Ink System Pump ......................................................... 3—19
3.6.6 Printhead Positive Air Pump ......................................... 3—19
3.6.7 Cooling Fan ................................................................. 3—19
3.7 Ink System ............................................................................ 3—20
3.7.1 General Description ...................................................... 3—20
3.7.2 Manifold Assembly ....................................................... 3—22
3.7.3 Manifold Connections .................................................. 3—24
3.7.4 Standard Gutter Restrictor ........................................... 3—25
3.7.5 High Flow Gutter Restrictor .......................................... 3—25
3.7.6 In-Line Gutter Check Valve ........................................... 3—26
3.7.7 Ink and Solvent Flows .................................................. 3—26
3.7.8 Startup and Shutdown Routines .................................. 3—31
3.7.9 Clear Nozzle (Diagnostics Menu) (as figure 3-36) ........... 3—59
3.7.10 Nozzle Flush (Diagnostics Menu) ................................ 3—60
3.8 Electronics and Software ....................................................... 3—62
3.8.1 Circuit Diagrams .......................................................... 3—62
3.8.2 IPM PCB ...................................................................... 3—62
3.8.3 Display PCB ................................................................. 3—65
3.8.4 Photocell PCB............................................................... 3—65
3.8.5 Software ....................................................................... 3—66
3.9 External Signals ................................................................... 3—70
3.9.1 Primary Photocell ......................................................... 3—70
3.9.2 Auxiliary Photocell ....................................................... 3—71
3.9.3 Shaft Encoders ............................................................. 3—72
3.9.4 Alarm Output ............................................................... 3—73
3.9.5 Print Ready Signal ....................................................... 3—73
3.9.6 RS–232 and RS–485 Interfaces ..................................... 3—74
3.9.7 D-type Connector Assembly .......................................... 3—75
3.10 Drawing List ....................................................................... 3—75

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SECTION 4: THE SETUP MENU ................................... 4—1

4.1 Introduction ............................................................................ 4—1
4.2 The Current Message Screen ................................................... 4—1
4.3 Password Access ...................................................................... 4—1
4.4 Total Menu Options ................................................................ 4—2
4.5 Option Availability .................................................................. 4—3
4.6 Selecting and Changing Menu Options ................................... 4—4
4.7 Option Description .................................................................. 4—4
4.7.1 Password ........................................................................ 4—4
4.7.2 Print Height ................................................................... 4—4
4.7.3 Normalise Height ............................................................ 4—5
4.7.4 Print Width .................................................................... 4—6
4.7.5 Print Delay ..................................................................... 4—7
4.7.6 Print Count .................................................................... 4—7
4.7.7 Reverse Message ............................................................. 4—8
4.7.8 Bold Ratio ...................................................................... 4—8
4.7.9 Set Time ........................................................................ 4—8
4.7.10 Set Date ....................................................................... 4—8
4.7.11 Julian Date Format ...................................................... 4—9
4.7.12 Photocell ...................................................................... 4—9
4.7.13 Shaft Encoder ............................................................ 4—10
4.7.14 Conduit Length .......................................................... 4—12
4.7.15 Head Height ............................................................... 4—12
4.7.16 Print Head Code ......................................................... 4—13
4.7.17 Ref Modulation ........................................................... 4—14
4.7.18 Ink Selection .............................................................. 4—14
4.7.19 Calibrate Print Head ................................................... 4—15
4.7.20 Alarm ......................................................................... 4—16
4.7.21 Change Password ....................................................... 4—17
4.7.22 Change Language....................................................... 4—17
4.7.23 Remote Setup Menu (RS–232) .................................... 4—18
4.7.24 Remote Setup Menu (RS–485) .................................... 4—24
4.7.25 Diagnostics ................................................................ 4—24
4.7.26 Solv Add Time ............................................................ 4—24
4.8 Passwords ............................................................................. 4—25

SECTION 5: MAINTENANCE ........................................ 5—1

5.1 The Diagnostics Menu ............................................................. 5—1
5.1.1 Password Access ............................................................. 5—1
5.1.2 Total Menu Options........................................................ 5—2
5.1.3 Option Availability ......................................................... 5—2
5.1.4 Option Description ......................................................... 5—3
5.2 Maintenance Instructions...................................................... 5—22
5.2.1 Introduction ................................................................. 5—22
5.2.2 Maintenance Terminology ............................................ 5—22
5.2.3 Antistatic Precautions .................................................. 5—23
5.2.4 Ink System Cableform Assembly—Solvent Damage ....... 5—23
5.2.5 Good Practice ............................................................... 5—24
5.2.6 4800 CE Approval Checklist ......................................... 5—24
5.2.7 1400 Hour Scheduled Maintenance Checklist ............... 5—25

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5.2.8 Maintenance Instruction Documents ............................ 5—25

1400 Hour Scheduled Maintenance .............................. 5—27
Printhead Cleaning for Pigmented Inks ......................... 5—35
Draining the Ink System .............................................. 5—39
Ink Tank Dip Tube Replacement ................................... 5—43
Solvent Tank Dip Tube Replacement ............................ 5—47
3-Way Fluid Connector Filter Replacement ................... 5—51
Main Ink Filter Replacement ......................................... 5—55
IPM PCB Calibration .................................................... 5—63
Feed Valve Test ............................................................. 5—67
Purge and Gutter Valves Tests ...................................... 5—69
Solvent Flush Valve Tests ............................................. 5—75
Solvent Top-up Valve Tests ........................................... 5—79
Blocked Gutter Clearance Procedure ............................. 5—83
Jet Alignment and Nozzle Cleaning .............................. 5—87
Modulation Range Checks ............................................ 5—95
Nozzle O-ring Replacement ........................................... 5—97
Calibrated Nozzle Replacement ................................... 5—101
System Flush Procedure ............................................. 5—105
Ink Conversion Calibration ......................................... 5—117
Positive Air Pump Fitting Instructions ........................ 5—125
Alarm Beacon Fitting (Printer Mounted) ...................... 5—129
Alarm Beacon Fitting (Gantry Mounted) ..................... 5—133
Pump Motor Brush Assembly Replacement ................. 5—135
Solvent Bottle Adaptor Fitting Instructions ................. 5—141

SECTION 6: ERROR & FAULT MESSAGES ................... 6—1

6.1 Introduction ............................................................................ 6—1
6.2 Summary of Error & Fault Messages ....................................... 6—1
6.3 Error & Fault Message Designations ........................................ 6—2
6.4 Error & Fault Reporting Configuration .................................... 6—3
6.5 System Failures ...................................................................... 6—7
6.6 Print Failures ........................................................................ 6—13
6.7 System Warnings .................................................................. 6—17

SECTION 7: FAULT DIAGNOSIS ................................... 7—1

7.1 Introduction ............................................................................ 7—1
7.2 Where to Start ......................................................................... 7—1
7.3 Identifying Faults .................................................................... 7—2
7.3.1 Identifying Faults by Print Sample.................................. 7—2
7.3.2 Identifying Faults by Symptom ....................................... 7—5

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7.4 Problem Solving ...................................................................... 7—9

7.4.1 Problem Solving – Print Samples (FC1 to FC11) .............. 7—9
FC1 High Viscosity ....................................................... 7—10
FC2 Low Viscosity ........................................................ 7—11
FC3 Modulation Problems ............................................ 7—12
FC4 Phasing Errors ...................................................... 7—14
FC5 Gutter Clipping ..................................................... 7—16
FC6 Printhead Cover Catch .......................................... 7—17
FC7 Charge Faults ....................................................... 7—19
FC8 Character Generation Faults ................................. 7—20
FC9 Shaft Encoder Faults ............................................ 7—20
FC10 Deflector Voltage Faults ....................................... 7—21
FC11 Other Faults........................................................ 7—21
7.4.2 Problem Solving – Ink System Mechanical Faults (FC12 to
FC21).................................................................................... 7—22
FC12 Pressure Loss ...................................................... 7—22
FC13 Leaking Feed Valve .............................................. 7—23
FC14 Inactive Feed Valve .............................................. 7—23
FC15 Inactive Purge Valve ............................................. 7—24
FC16 Leaking Purge Valve or Gutter Valve .................... 7—24
FC17 Leaking Gutter Valve ........................................... 7—24
FC18 Leaking Solvent Top-Up Valve .............................. 7—25
FC19 Solvent Contamination........................................ 7—25
FC20 New Pump Requiring Priming .............................. 7—25
FC21 Solvent Pick-up Pipes Clogged with Dust ............. 7—25
7.4.3 Problem Solving – Ink System Electrical Faults (FC22 to
FC27).................................................................................... 7—26
FC22 Pressure Loss ...................................................... 7—26
FC23 Ink Low Warning ................................................. 7—26
FC24 Solvent Low Warning ........................................... 7—26
FC25 Inoperative Feed Valve ......................................... 7—27
FC26 Incorrect Valve Operation .................................... 7—27
FC27 Incorrect Viscosity Control .................................. 7—28
7.4.4 Problem Solving – Printhead Electrical Faults (FC28 to FC31)
7—29
FC28 Modulation Problems .......................................... 7—29
FC29 Charge Problems ................................................. 7—30
FC30 No Strobe LED .................................................... 7—31
FC31 No Drop Deflection .............................................. 7—31
7.4.5 Problem Solving – Printhead Mechanical Faults (FC32 to
FC36).................................................................................... 7—32
FC32 Jet Alignment Problems ...................................... 7—32
FC33 Modulation Problems .......................................... 7—34
FC34 Charge Problems ................................................. 7—35
FC35 Gutter Problems .................................................. 7—35
FC36 Vibration Problems .............................................. 7—36
7.4.6 Problem Solving – Electronics System Faults (FC37 to FC38)
7—40
FC37 Poor Print ........................................................... 7—40
FC38 Power Failures ..................................................... 7—40

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SECTION 8: ILLUSTRATED PARTS LIST ...................... 8—1

8.1 Introduction ............................................................................ 8—1
8.2 Abbreviations .......................................................................... 8—1
4800 Printer ................................................................................. 8—3
4800 Top Cover Assembly ....................................................... 8—5
4800 Cabinet Assembly ........................................................... 8—7
4800 Rear Cabinet .................................................................. 8—9
4800 Ink System (1) ............................................................. 8—11
4800 Ink System (2) .............................................................. 8—13
4800 Ink System (2) (continued) ............................................ 8—15
4800 Electronics Assembly .................................................... 8—17

INDEX .......................................................................... 9—1

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List of Figures

Figure Page

SECTION 2: SAFETY ................................................................... 2—1

Figure 2-1. Test Printing into a Non-Metallic Container .............................................. 2—5

SECTION 3: TECHNICAL DESCRIPTION....................................... 3—1

Figure 3-1. The Mk.5 Midi Printhead in operation ...................................................... 3—2
Figure 3-2. Modulation of the ink jet using a piezo crystal .......................................... 3—7
Figure 3-3. Correct drop breakoff observed in the charge electrode ............................. 3—8
Figure 3-4. Charge and Modulation synchronization (Phasing) ................................. 3—10
Figure 3-5. Guard Drops .......................................................................................... 3—12
Figure 3-6. 4800 cabinet base unit .......................................................................... 3—14
Figure 3-7. 4800 European keyboard ....................................................................... 3—16
Figure 3-8. LVPSU output details ............................................................................. 3—18
Figure 3-9. Static Ink System .................................................................................. 3—21
Figure 3-10. Ink System Manifold Assembly ............................................................. 3—22
Figure 3-11. Section view of the Venturi ................................................................... 3—23
Figure 3-12. 4800 Manifold connections .................................................................. 3—24
Figure 3-13. High Flow Gutter Restrictor ................................................................. 3—25
Figure 3-14. In-Line Gutter Check Valve .................................................................. 3—26
Figure 3-15. Primary circuit ..................................................................................... 3—27
Figure 3-16. Secondary circuit (normal running after start purge) ............................ 3—28
Figure 3-17. Solvent Addition .................................................................................. 3—30
Figure 3-18. Printhead Dependent Parameters table ................................................ 3—32
Figure 3-19. Normal Startup summary table ............................................................ 3—34
Figure 3-20. Normal Startup Stage 2: Feed Line Flush ............................................. 3—35
Figure 3-21. Normal Startup Stage 3: Feed Line Flush ............................................. 3—36
Figure 3-22. Normal Startup Stage 4: Start Purge .................................................... 3—37
Figure 3-23. Quick Start summary table .................................................................. 3—39
Figure 3-24. Clear Nozzle and Restart Stage 1: Clearing the Nozzle ........................... 3—40
Figure 3-25. Flush Shutdown summary table .......................................................... 3—43
Figure 3-26. Flush Shutdown Stage 1: Clearing the Nozzle of Ink ............................. 3—44
Figure 3-27. Flush Shutdown Stage 2: Clearing the Gutter and Feed Lines of Ink .... 3—45
Figure 3-28. Flush Shutdown Stage 3: Clearing the Purge Line of Ink ...................... 3—46
Figure 3-29. Flush Shutdown Stage 4: Priming the Nozzle with Solvent .................... 3—47
Figure 3-30. Flush Shutdown Stage 5: Flushing the Nozzle and Gutter .................... 3—48
Figure 3-31. Flush Shutdown Stage 6: Clearing the Nozzle of Solvent ....................... 3—49
Figure 3-32. Flush Shutdown Stage 7: Clearing the Gutter & Feed Lines of Solvent .. 3—50
Figure 3-33. Flush Shutdown Stage 8: Clearing the Purge & Feed Lines of Solvent ... 3—51
Figure 3-34. Flush Shutdown Stage 9: Final Gutter Clearing ................................... 3—52
Figure 3-35. Non-Flush Shutdown summary table ................................................... 3—53
Figure 3-36. Non-Flush Shutdown Stage 1: Clearing the Nozzle of Ink ...................... 3—54
Figure 3-37. Non-Flush Shutdown Stage 2: Clearing the Gutter Line of Ink .............. 3—55
Figure 3-38. Non-Flush Shutdown Stage 3: Clearing the Purge Line of Ink ............... 3—56
Figure 3-39. Non-Flush Shutdown Stage 4: Final Gutter Clearing ............................ 3—57
Figure 3-40. Fault Shutdown summary table ........................................................... 3—58
Figure 3-41. Quick Stop summary table ................................................................... 3—59
Figure 3-42. Nozzle Flush summary table ................................................................ 3—60
Figure 3-43. Ink Type Dependent Parameters table .................................................. 3—61
Figure 3-44. Primary Photocell – NPN Configuration ................................................. 3—70
Figure 3-45. Primary Photocell – PNP Configuration ................................................. 3—70
Figure 3-46. Auxiliary Photocell – NPN Configuration ............................................... 3—71
Figure 3-47. Auxiliary Photocell – PNP Configuration ................................................ 3—71
Figure 3-48. 5 V and 24 V Single Ended Shaft Encoder Inputs ................................. 3—72
Figure 3-49. RS–232 Interface Cable Pin Connections .............................................. 3—74
Figure 3-50. Correct Assembly of the ‘Wet’ D-type Connector ................................... 3—75

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SECTION 4: THE SETUP MENU ................................................... 4—1

Figure 4-1. Current Message screen ........................................................................... 4—1
Figure 4-2. Password screen ...................................................................................... 4—1
Figure 4-3. Setup screen ............................................................................................ 4—2
Figure 4-4. Setup menu option availability table ........................................................ 4—3
Figure 4-5. Normalise Height adjustment ................................................................... 4—5
Figure 4-6. Normalise Height adjustment to avoid clipping ......................................... 4—6
Figure 4-7. Table of raster/printhead type minimum delay default values .................. 4—7
Figure 4-8. Bold Ratio setting .................................................................................... 4—8
Figure 4-9. Julian Date format .................................................................................. 4—9
Figure 4-10. Table of raster/printhead type ideal pitch values .................................. 4—11
Figure 4-11. Printhead Code composition ................................................................. 4—13
Figure 4-12. Ink Type Settings Table ........................................................................ 4—14
Figure 4-13. Calibrate Print Head screen ................................................................. 4—15
Figure 4-14. Alarm screen ....................................................................................... 4—16
Figure 4-15. Change Password screen ...................................................................... 4—17
Figure 4-16. Change Language screen ..................................................................... 4—17
Figure 4-17. Remote Setup Menu screen (RS–232) ................................................... 4—18
Figure 4-18. Transfer Parameters screen ................................................................. 4—18
Figure 4-19. Serial Parameters screen ...................................................................... 4—19
Figure 4-20. Flow Control screen ............................................................................. 4—20
Figure 4-21. Message Delimiters screen ................................................................... 4—20
Figure 4-22. Print Control screen ............................................................................. 4—21
Figure 4-23. Print Mode screen ................................................................................ 4—22
Figure 4-24. Remote Setup Menu screen (RS–485) ................................................... 4—24
Figure 4-25. Transfer Parameters screen (RS–485) ................................................... 4—24

SECTION 5: MAINTENANCE ........................................................ 5—1

Figure 5-1. Diagnostics screen ................................................................................... 5—2
Figure 5-2. Diagnostics menu option availability table ............................................... 5—3
Figure 5-3. Monitor Jet screen ................................................................................... 5—8
Figure 5-4. System Times screen ............................................................................. 5—11
Figure 5-5. System Configuration screen ................................................................. 5—12
Figure 5-6. Raster Type screen ................................................................................ 5—12
Figure 5-7. Data screen ........................................................................................... 5—13
Figure 5-8. Enabled Options screen ......................................................................... 5—13
Figure 5-9. Pressure Refs screen .............................................................................. 5—14
Figure 5-10. Clear Message Area screen ................................................................... 5—16
Figure 5-11. Save Cal Value screen .......................................................................... 5—19
Figure 5-12. Test pattern in the Current Message screen ......................................... 5—19
Figure 5-13. Editing the test pattern in the Edit Message screen .............................. 5—20
Figure 5-14. System Flush screen (prior to v1.1) ...................................................... 5—20
Figure 5-15. System Flush screen (v1.1) .................................................................. 5—21
Figure 5-16. Valve Test screen ................................................................................. 5—21

1400 Hour Scheduled Maintenance .................................................................. 5—27

Figure 1. Removing the Air Filter ............................................................................. 5—30

Printhead Cleaning for Pigmented Inks ............................................................ 5—35

Figure 1. Correct Area of the Printhead to Wash with Solvent ................................... 5—36
Figure 2. Correct Area of the Printhead to Clean with the Brush .............................. 5—37

Draining the Ink System .................................................................................. 5—39

Figure 1. Feed Damper with Drain Tube Connected ................................................. 5—40
Figure 2. System Flush Screen (Empty Tank option) ................................................ 5—40
Figure 3. System Flush Screen (Start Pump) ............................................................ 5—40
Figure 4. System Flush Screen (Stop Pump) ............................................................. 5—41

Ink Tank Dip Tube Replacement ...................................................................... 5—43

Figure 1. 4800 Ink Dip Tube and Filter Assembly ..................................................... 5—43

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Solvent Tank Dip Tube Replacement ................................................................ 5—47

Figure 1. 4800 Solvent Dip Tube and Filter Assembly ............................................... 5—47
Figure 2. Connecting the Solvent Pick-up Pipe to the Y-piece Connector ................... 5—49

3-Way Fluid Connector Filter Replacement ...................................................... 5—51

Figure 1. 3-Way Fluid Connector Disassembled ........................................................ 5—52

Main Ink Filter Replacement ........................................................................... 5—55

Figure 1. Enclosing One End of the Main Ink Filter with a Rubber Glove .................. 5—56
Figure 2. Correct Assembly of the Main Ink Filter Fluid Connections ........................ 5—56
Figure 3. Applying Thread Lubricant to the Main Ink Filter Fluid Connections ......... 5—57
Figure 4. Correct Tightening of the Main Ink Filter Fluid Connections ...................... 5—57
Figure 5. Both Ends of the Main Ink Filter Enclosed with Rubber Gloves ................. 5—58
Figure 6. Clearing the Main Ink Filter Outlet of Debris ............................................. 5—59
Figure 7. Filter Purge Option in the Diagnostics Menu ............................................. 5—60

IPM PCB Calibration ........................................................................................ 5—63

Figure 1. DAC Cal Mode option in the Diagnostics menu .......................................... 5—64
Figure 2. Save Cal Value menu ................................................................................ 5—65

Feed Valve Test ................................................................................................ 5—67

Figure 1. Flush Shutdown Option in the Diagnostics Menu ...................................... 5—67
Figure 2. Set Pressure Option in the Diagnostics Menu ............................................ 5—67

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

Figure 1. Quick Start Jet Option in the Diagnostics Menu ........................................ 5—69
Figure 2. Monitor Jet Screen .................................................................................... 5—70
Figure 3. Testing for a Leaking Purge or Gutter Valve ............................................... 5—71
Figure 4. Purge/Gutter Test Fluid Connector Fitted in the 3-Way Fluid Connector ... 5—72
Figure 5. Testing for a Leaking Purge or Gutter Valve (closed) ................................... 5—73

Solvent Flush Valve Tests ................................................................................ 5—75

Figure 1. Flush Shutdown Option in the Diagnostics Menu ...................................... 5—75
Figure 2. Solvent Flush Option in the Valve Test Menu ............................................ 5—76
Figure 3. Set Pressure Option in the Diagnostics Menu ............................................ 5—77
Figure 4. Creating Bubbles to Test the Solvent Flush Valve ...................................... 5—77

Solvent Top-up Valve Tests .............................................................................. 5—79

Figure 1. Creating Bubbles to Test the Solvent Top-up Valve .................................... 5—79
Figure 2. Set Pressure Option in the Diagnostics Menu ............................................ 5—80
Figure 3. Valve Test Screen in the Diagnostics Menu ................................................ 5—81

Blocked Gutter Clearance Procedure ................................................................ 5—83

Figure 1. Gutter Clear Fluid Connector Fitted in the 3-Way Fluid Connector ............ 5—84
Figure 2. Set Pressure Option in the Diagnostics Menu ............................................ 5—85
Figure 3. Valve Test Screen in the Diagnostics Menu ................................................ 5—85

Jet Alignment and Nozzle Cleaning .................................................................. 5—87

Figure 1. Correct Alignment of the Jet into the Gutter .............................................. 5—88
Figure 2. Correct Alignment of the Jet from the Nozzle ............................................. 5—88
Figure 3. Nozzle Clear Routine—Applying Solvent to the Nozzle ................................ 5—89
Figure 4. Suspending the Nozzle in a Beaker of Solvent ............................................ 5—90

Modulation Range Checks ................................................................................ 5—95

Figure 1. Ref Modulation Option in the Setup Menu ................................................. 5—95
Figure 2. Under Modulation—Expected Deterioration when Reference Mod is < Vm1 5—95
Figure 3. Over Modulation—Expected Deterioration when Reference Mod is > Vm2 .. 5—95

Nozzle O-ring Replacement .............................................................................. 5—97

Figure 1. Correct Alignment of the Jet into the Gutter .............................................. 5—98
Figure 2. Correct Alignment of the Jet from the Nozzle ............................................. 5—99

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Calibrated Nozzle Replacement ...................................................................... 5—101

Figure 1. Correct Alignment of the Jet into the Gutter ............................................ 5—102
Figure 2. Correct Alignment of the Jet from the Nozzle ........................................... 5—103
Figure 3. Correct fitting of the Flag Label on the conduit ........................................ 5—104

System Flush Procedure ................................................................................ 5—105

Figure 1. Primary System Flush Menu ................................................................... 5—112
Figure 2. System Flush Screen with “Disconnect Bleed Line” Message .................... 5—112
Figure 3. System Flush Screen with “Fill Ink Tank with 1.5l Solvent” Message ....... 5—113
Figure 4. System Flush Screen with “Short Cycle Running” Message ...................... 5—113
Figure 5. System Flush Screen with “Disconnect Bleed Line” Message .................... 5—114
Figure 6. System Flush Screen with “Fill Ink Tank with 1.0l Solvent” Message ....... 5—114
Figure 7. System Flush with “Flush Cycle Running” Message ................................. 5—114

Ink Conversion Calibration ............................................................................ 5—117

Figure 1. Approved ink conversion table ................................................................. 5—120
Figure 2. Ink conversion correction factors table .................................................... 5—121
Figure 3. Ink conversion calibration data table ....................................................... 5—122

Positive Air Pump Fitting Instructions ........................................................... 5—125

Figure 1. Fitting the Printhead Positive Air Pump ................................................... 5—126
Figure 2. Printhead Positive Air Tube ..................................................................... 5—127

Alarm Beacon Fitting (Printer Mounted) ......................................................... 5—129

Figure 1. Alarm Beacon Mounting Bracket Fitted to the Stalk Assembly ................. 5—130
Figure 2. Fitting the Alarm Beacon to the Rear of the Printer ................................. 5—131
Figure 3. Alarm Option Settings for Testing the Alarm Beacon ............................... 5—132

Alarm Beacon Fitting (Gantry Mounted) ......................................................... 5—133

Figure 1. Alarm Option Settings for Testing the Alarm Beacon ............................... 5—134

Pump Motor Brush Assembly Replacement ..................................................... 5—135

Figure 1. Motor Assembly Parts’ Identification ........................................................ 5—136
Figure 2. Removing/Refitting the Motor Casing ...................................................... 5—137
Figure 3. Motor End Shield Assembly .................................................................... 5—138
Figure 4. Motor Assembly with Cup Magnet Setting Jig Fitted ................................ 5—139

SECTION 6: ERROR & FAULT MESSAGES ................................... 6—1

Figure 6-1. Error Message designations table ............................................................. 6—2
Figure 6-2. Accessing the Print Status screen ............................................................ 6—3
Figure 6-3. Error List screen ...................................................................................... 6—4
Figure 6-4. Error Information screen ......................................................................... 6—4
Figure 6-5. Error Message configuration screen ......................................................... 6—5
Figure 6-6. Fault Information screen ......................................................................... 6—6
Figure 6-7. Fault Message configuration screen ......................................................... 6—6
Figure 6-8. Print Failure screen ............................................................................... 6—13

SECTION 7: FAULT DIAGNOSIS ................................................... 7—1

Figure 7-1. The Effects of viscosity and modulation on drop break-up ........................ 7—9
Figure 7-2. Gutter clipping ...................................................................................... 7—16
Figure 7-3. Printhead cover catch ............................................................................ 7—17
Figure 7-4. Correct alignment of the jet into the gutter ............................................ 7—33
Figure 7-5. Vibration problems: product tilting along axis of conveyor travel ............ 7—37
Figure 7-6. Vibration problems: product tilting across axis of conveyor travel ........... 7—37
Figure 7-7. Vibration problems: high frequency vibration ......................................... 7—38
Figure 7-8. Vibration problems: testing for product or printhead vibration ............... 7—38
Figure 7-9. Vibration problems: high impact knock or excessive vibration ................ 7—39

SECTION 8: ILLUSTRATED PARTS LIST ...................................... 8—1

Figure 8-1. Part description abbreviations table ......................................................... 8—1

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SECTION 1: GENERAL

1.1 Introduction
The Linx 4800 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 Cabinet
Construction
Base tray unit: Stainless steel grade 304
Top cover: Blue painted polyurethane reaction injection moulding
The integrity of the earthed metal panels and chassis has been tested in accordance with
the “continuity of protective bonding circuits” as defined in EN60204: 1992.

Dimensions
External height: 231 mm
External width: 458 mm
External depth: 574 mm

Weight
Printer weight: 21 kg (excluding ink, solvent and packaging)

1.2.2 Power Requirements

Voltage: Single-phase, 90 V (3 A) to 240 V (1 A) a.c., 50/60 Hz
Power rating: 200 VA
This equipment is a Class 1 earthed appliance as defined by EN60204. Electrical
connections at the rear of the cabinet comply with the extra low voltage safety
requirements as defined by EN60204.

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 EN60950.

1.2.3 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%, 8.0 A
+12 V d.c. ±5%, 4.5 A
–16 V d.c. ±5%, 0.5 A
+24 V d.c. ±5%, 3.5 A

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1.2.4 EHT Power Supply Unit

Input: 0 V to +24 V d.c. ±5%, <1.2 A
Outputs: +300 V d.c. ±5%, 10 to 46 mA max.
0 V to +5 kV d.c. ±5%, 10 µA
0 V to –5 kV d.c. ±5%, 10 µA

1.2.5 Environmental
Operating temperature: +5 °C to +45 °C ambient
Humidity: Up to 90% relative humidity, non–condensing
Water/Dust: Cabinet sealed to IP55
Ink system enclosure sealed to IP54 with respect to the
electronics when top cover is correctly fitted
Ink system fluid seals to IP68
Acoustic emission: Less than 70 dBA

1.2.6 Ink System

Construction
Ink system enclosure: Stainless steel grade 304, self contained, integral to chassis
(i.e. non-removable)
Ink tank: MDPE black
Solvent tank: MDPE natural

Capacity
Ink tank: 1600 ml approx.
Solvent tank: 1600 ml approx.

Pressure
Pressure range: Up to 65 p.s.i. (4.48 bar) normal operating pressure
Maximum pressure: 90 p.s.i. (6.2 bar) maximum under fault conditions

Level Control
Ink tank sense low: Warning reported at approx. 750 ml
Solvent tank sense low: Warning reported at approx. 750 ml

Performance
Solvent consumption: <6 ml/h at 20 °C ambient using LM1240 MEK black ink

1.2.7 Memory Capacity

Message storage capacity: 5 messages
Logo storage capacity: Up to 100 logos

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1.2.8 Printhead
Types
Micro: Mk.3B (37 µm)
Midi: Mk.5 (62 µm and 70 µm)
Macro: Mk.3B (110 µm)

Construction
Printhead: Machined Acetal body
Cover tube: Stainless steel grade 304
Conduit adaptor: Stainless steel grade 303
Conduit min. bend radius 50 mm

Dimensions
Conduit length: 2 m or 4 m
Conduit diameter: 20 mm

Throw Distance (recommended)

Micro: 3.5 mm
Midi (62 µm): 10.5 mm
Midi (70 µm): 10.5 mm
Macro: 20 mm

1.2.9 Printing Performance Data

Raster Information
Lines of print: Maximum of one line of 16 High characters, or up to two
lines of 5 High or 7 High characters.
Rasters available: Paired raster set (printer model dependent) of:
5 S HI SPEED, 7 GEN STD, 7 HI SPEED, 7 HIGH
QUALITY, 16 GEN STD, 16 N HI SPEED, 16 S HI SPEED.

Character Height Range

Minimum character height: 1.5 mm (Micro printhead) using 7 GEN STD raster
Maximum character height: 11.2 mm (Midi 62 µm printhead) using 16 S HI SPEED
raster

Maximum Speed (single line print at ideal pitch with Midi 62

µm printhead)
Optima model: 1.88 m/s
High Speed model: 5.00 m/s
Super High Speed model: 6.28 m/s

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Maximum Number of Characters per Second

Optima model: 1000 (Micro printhead)
High Speed model: 1667 (Midi 62 µm printhead)
Super High Speed model: 1904 (Midi 62 µm printhead)

Further information can be found in the Linx CIJ print performance data pamphlet for each of
the four printhead types.

1.2.10 Regulatory Approvals

Safety
Approved in accordance with TÜV/GS requirements.

Machinery Directive
89/392/EEC as amended by 91/368/EEC as amended by 93/44/EEC.

Low Voltage Directive

73/23/EEC.

EMC Directive
89/336/EEC as amended by 92/31/EEC.

European Safety Standards

EN292–1, –2: 1991 Safety of Machinery
EN60079–10: 1996 Electrical Apparatus for Explosive Gas Atmospheres –
Classification of Hazardous Areas
EN60204: 1992 Specification for General Requirements
EN60529: 1992 Enclosure Protection Specification (IP code)
EN60950: 1992 Information Technology Equipment Specification

Electromagnetic Compatibility

European EMC Standards

EN50081–1: 1992 EMC Emissions
EN50082–1: 1992 EMC Immunity
EN50082–2: 1995 EMC Immunity

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1.3 Abbreviations and Glossary

a.c. Alternating current
ADC Analogue to Digital Converter
CMOS Complimentary Metal Oxide Semi-Conductor
CPU Central Processing Unit
CW Continuous Wave
d.c. Direct current
DAC Digital to Analogue Converter
DC Drop Control
DVM Digital Volt Meter
EHT Extra High Tension (voltage)
EMC Electromagnetic Compatibility
EPDM Ethylene Propylene Diene Monomer
FC Fault Code
GAL Gate Array Logic
HDPE High Density Polyethylene
IP International Protection
IPM Integrated Processor Module
LCD Liquid Crystal Display
LK Link
LVPSU Low Voltage Power Supply Unit
MDPE Medium Density Polyethylene
MEK Methyl Ethyl Ketone
NiCad Nickel–Cadmium
NMI Non-Maskable Interrupt
NVR Non-Volatile RAM
PCB Printed Circuit Board
PET Polyethylene Terephthalate
Pixel The smallest size of spot on the screen that makes up the
displayed message
PL Plug (connector with male pins/contacts)
Print Go A logic signal generated by the photocell trigger, or internally,
which initiates printing of one message.
Print registration The position of a printed message on a substrate
PROM Programmable Read Only Memory
PSU Power Supply Unit
PU Polyurethane
PVC Polyvinyl Chloride
r.f. Radio frequency
RAM Random Access Memory

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Raster A variable line of drops printed at 90 degrees to the direction of

production line travel, to create characters which are made up of
five or more rasters
ROM Read Only Memory
SK Socket (connector with female pins/contacts)
Substrate Surface (product) on which printing is done
TOF Time Of Flight
TP Test Point

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 SECTION 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 section 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 section before attempting to operate it 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 which 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.

Specific Warning Symbols

The above specific warning symbol is used to alert the reader to the mandatory
requirement to wear safety glasses when there is a risk of exposure to inks or solvents.

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 The above specific warning symbol is used to alert the reader to the risk of exposure to,
and the hazards of, lethal voltages.

The above specific warning symbol is used to alert the reader to the risk of fire due to the
highly flammable nature of a substance.

The above 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 above 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 which may cause damage to the printer
itself, 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 above hand symbol may be shown beside an important NOTE to indicate that the
reader should pay particular attention to the information given.

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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 is accessible, together with the
300 volts d.c. supply.
To avoid the danger of electric shock, when the printhead cover tube is removed printing is
stopped, the charge electrode voltage is limited to less than 10 volts instead of the normal
300 volts and the ±5 kV supply to the deflector plates is switched off.

WARNING: THIS PRINTER MUST BE EARTHED.

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.
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
DATA SHEETS AND THAT THEY ARE AVAILABLE ON SITE, IF NOT, CONTACT
YOUR DISTRIBUTOR.
The following paragraphs summarize the precautions to be taken and first aid procedures:

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 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 which 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, or
when inspecting or repairing the printer, or at any time when your hands may
come into contact with inks or solvents. 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 or with inks and solvents;
• smoking, eating and drinking should be prohibited in areas of storage and use;
• remove all spilt ink and solvent or build-up of ink deposits immediately, using
the correct solvent for the ink 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:

Eye Contact
Contact lenses should be removed. 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.

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 in the affected
person in the recovery position and seek medical advice.

Ingestion
If accidentally swallowed obtain immediate medical attention. Wash out mouth with
water and give 200 to 300 ml (half a pint) of water to drink. Keep at rest. Do NOT induce
vomiting.

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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) 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.)

48141

MIDI

Figure 2-1. Test Printing into a Non-Metallic Container

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 Linx Printing Technologies plc

SECTION 3: TECHNICAL
DESCRIPTION

3.1 Introduction
This section provides a technical description of the function of the various sub-systems,
modules and components which comprise the Linx 4800 Ink Jet Printer. The following
topics are covered in this section:
• Printhead
• Cabinet
• User Interface
• Electrical Components
• Ink System
• Electronics and Software
• External Signals

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3.2 Printhead Components

The following identifies the main components of the printhead and describes their basic
functions together with various other aspects of the printhead. Figure 3-1 shows the
location of the printhead components.

6244

Conduit
Printhead
to control unit
and ink system
in Operation

Over temperature
sensor MIDI

Nozzle

Charge electrode

Phase sensor
Deflector plates

Time Of Flight sensor

Gutter

Print pattern
being created

e l
T rav
f
no
c tio
D ire

Figure 3-1. The Mk.5 Midi Printhead in operation

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3.2.1 Printhead Types

Linx printers have three types of printhead: Micro, Midi and Macro. The basic design of
these three types is similar, but the size of the nozzle aperture is different in each case; the
micro being the smallest and the macro being the largest, with the midi approximately
midway between them:
Micro: Mk.3B (37 µm)
Midi: Mk.5 (62 µm and 70 µm)
Macro: Mk.3B (110 µm)
Also, the flight distance of the jet from the nozzle to the gutter is different for each type of
printhead, being shortest for the micro and longest for the macro. Allowing for these
obvious differences, the three printhead types follow the same basic design.

3.2.2 Piezo Crystal

The printhead operation requires ink to be supplied under pressure from the ink system
via the pump, through the main ink filter to the ink gun. Here the ink is oscillated by the
effect of a piezoelectric crystal so that the jet, which is forced from the nozzle, will break up
into a jet of evenly spaced and evenly sized drops. The amplitude of the voltage applied to
the piezo crystal is dependent on:
• the type of printhead;
• the individual characteristics of the particular printhead;
• the type of ink being used.
The piezo crystal voltage (modulation voltage) is calibrated when each printhead is
manufactured, and the value is identified on the printhead conduit label as the reference
modulation voltage for the particular printhead.
The modulated ink jet is emitted from the nozzle orifice (a precisely machined hole in a
small jewel), and the jet is directed towards the gutter at the end of the flight path of the jet.
The oscillation caused by the modulation is transmitted through the ink and causes the ink
jet to distort and eventually to break up into uniform drops. This break-up occurs at the
frequency of the oscillating modulation voltage applied to the piezo crystal. The drop
breakoff is calculated to occur within the charge electrode slot.

3.2.3 Charge Electrode

The charge electrode is used to apply a charge to individual ink drops. Drops which are
required for printing will be charged, while drops that are not required for printing will
not be charged, and will travel to the gutter, returning to the ink system for reuse.
The charge timing is such that the precise point of drop breakoff occurs approximately in
the middle of the charge pulse. When the drop breaks off, it is no longer connected to the
stream and retains the charge it has been given. Timing the breakoff point to be in the
centre of the charge pulse ensures that the drop has attained the full charge, and thus
increases the certainty of the printed position of the drop.

3.2.4 Deflector Plates

An electrostatic field is generated across two deflector plates and when the stream of drops
enter the field charged drops are deflected in proportion to the amount of charge they
carry, while uncharged drops are unaffected by the field. The combination of the speed of
the drops travelling through the field and the charge given to them is accurately calculated
to ensure that each drop is positioned correctly on the substrate on which the pattern is to
be printed.
The uncharged non-printing drops are not deflected and enter the gutter. A vacuum acting
on the gutter draws the ink drops back through the system to the ink tank for reuse.

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3.2.5 Phase and TOF Sensors

The printhead has two sensors mounted just before and just after the deflector plates.
These sensors are used to monitor the jet to ensure that the printer is operating correctly.
The first sensor (nearest the charge electrode) is called the phase sensor; the second sensor
(nearer the gutter) is called the Time Of Flight (TOF) sensor. During startup, and at
intervals during printing, the printer needs to monitor the jet performance. This is
achieved by charging a series of drops with a low charge which induce a signal as they
pass the phase and TOF sensors.
These signals are used by the printer for two functions. The first is to monitor the charge
position to ensure that the drops are attaining the correct 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 gives a counter reading which is called the Time Of Flight measurement.
The phase and TOF readings are checked routinely during printing and between patterns
in order to maintain consistent print quality.

3.2.6 Safety Sensors

To ensure safe operation of the printhead, the design includes two safety sensors.

Printhead Cover Sensor

This sensor is a Hall effect switch which is used to detect the presence of the printhead
cover and is buried within the printhead body. The cover includes a small magnet which
activates the Hall effect switch when the cover is fitted to the printhead. Activation of the
Hall effect switch enables the print process by switching on the charging and deflector
plate EHT circuits. As soon as the cover magnet is moved away from the sensor by
approximately 3 mm (which is insufficient to allow access to any of the potentially
dangerous components) the Hall effect switch is deactivated, thus disabling the charge and
EHT circuits.

Temperature Sensor
The other safety sensor is the temperature sensor, which is fitted because the solvent base
of some inks used is highly inflammable. The sensor is set at approximately 75 degrees
Celsius, which is lower than the ignition point of the normal ink solvent bases. If a local
temperature in excess of 75 °C is detected by the sensor, the printer is immediately shut
down in a controlled way. In addition, a Print Failure error message “2.00 Printhead
Temperature” is displayed to warn of the printhead over temperature condition.

3.2.7 Charge Strobe

A red light emitting diode (LED) is located in the centre of the charge electrode slot, so that
it is behind the jet breakup point, when viewed from the front of the printhead. The LED is
strobed at the same frequency as the modulation signal which has the effect of making the
jet appear to be stationary when viewed with an eyeglass. This feature allows the details of
the jet breakup to be examined which can be useful for diagnostic purposes.
The LED supply is enabled when the printhead cover is removed, and so 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.
NOTE: There is a slight delay when the Hall effect switch is bypassed with the service
override link. The LED will remain on for a few seconds even though the
charge and EHT circuits have been enabled.

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3.2.8 Printhead Connections

The printhead is connected to the printer by a number of electrical connectors and
Swagelok fluid union fittings. These are identified by colour code, labelled letter
identification, or polarised sockets and plugs. One of three different configurations of links
is fitted to one of the electrical connectors to distinguish between the three different
printhead types. The printer is thus able to identify the type of printhead that has been
fitted, and to compare this information with the parameters that have been entered for the
printhead. This reduces the possibility of an incompatibility between the printhead type
and the parameters specified.

3.2.9 Quality
During manufacture, each printer undergoes a series of performance and quality tests to
establish the individual characteristics of each printhead. These characteristics are:
• the printhead type;
• the Time Of Flight reference;
• the charge calibration correction;
• the operating pressure.
These parameters are all established to give consistent print quality. The parameters are
then grouped together to form the printhead code for the particular printhead. This code is
identified on the printhead conduit label, which is located near where the conduit connects
to the printer.
Refer to the Print Head Code option in Section 4: “The Setup Menu” for details of how the
code is created.

3.2.10 Last Chance Filter

This assembly consists of an integral union fitting and 18 micron stainless steel in-line feed
filter (“last chance” filter). It is fitted to Micro, Midi and Macro printheads and its purpose
is to provide increased protection for the printhead from ink borne particles which could
cause a blocked nozzle. The filter is permanently fitted in the feed line between the
printhead union fittings and as such is part of the printhead assembly (it is not available as
a spare part). Plastic sleeving is used to cover the printhead union fitting/last chance filter
connection, to ensure that the feed line can only be disconnected on the printer side of the
connection. This ensures that the printhead is protected by the filter when it is
disconnected.
NOTE: When reconnecting the last chance filter union fitting it should be tightened
using a torque setting of 27 N.m.

3.2.11 Printhead Replacement

Whenever a printhead is replaced, the code for the new printhead must be entered using
the Print Head Code option in the Setup menu. The modulation value must also be
entered using the Ref Modulation option in the Setup menu.
Prior to removing the printhead for replacement it should be flushed to remove any ink
residue in the nozzle, and feed, purge and gutter lines.

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3.2.12 Jet/Nozzle Alignment

The alignment of the jet is critical to the performance of the printhead. There are three
requirements:
1. The jet must pass centrally through the charge electrode slot to ensure correct
charging.
2. The jet must pass centrally over the phase and TOF sensors to ensure the
signals are detected.
3. The undeflected jet must enter the gutter cleanly, i.e. without clipping the
edges.
It is also necessary to ensure that the jet, when viewed from the side of the printhead, is not
too close or too far away from the two sensors. If it is too close, it will clip the sensors; if
too far away, the signal strength will be diminished. It is not possible, in the field, to adjust
the position of the charge electrode, the sensors or the gutter. It is sometimes possible to
achieve a small amount of movement of the nozzle to correct jet misalignment.

3.3 Printhead Principles of Operation

3.3.1 Overview
The following gives a brief overview of the basic principles of operation of the ink jet
printhead before studying each part of the process in detail.
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 or rasters and each raster has a certain
number of drops which 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 a jet of electrically conductive ink under pressure is forced out from a
nozzle and excited to produce a constant stream of ink drops. This stream is directed along
the length of the printhead 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 an electrode (charge electrode) situated at the point where the jet breaks up
and the drops form. The electrostatic charge causes a flow of electrons onto the drop as it
breaks from the jet. The printing drop will now possess a negative electric charge.
This electrically charged drop travels with the main stream of drops until it enters between
two deflector plates. One plate is at a negative potential producing a repulsing force upon
the drop and the other plate is at a positive potential producing an attracting force upon
the drop. These simultaneous forces act upon the drop, causing it to deflect from its
original straight path. The drop will be deflected by an amount proportional to the charge
on the drop, the potential across the two deflector plates and the time the drop spends
within the influence of the plates.
To ensure that the printing drops are being correctly charged a regular test is performed of
the charging function by measuring the drop charge at the Phase sensor.
A measurement of jet speed is also carried out. This employs both the Phase and the Time
Of Flight sensors 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. This 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.

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3.3.2 The Ink Jet

The jet of ink is produced by forcing ink under pressure through an orifice in an industrial
sapphire (jewel) which is located in the printhead nozzle assembly. The orifice size, in
micrometres (µm), is dependent on the type of printhead: Micro 37 µm; Midi 62 µm, and
70 µm; and Macro 110 µm.
By convention, the pressure within the LINX ink jet system is referred to in “points” of
pressure. The maximum pressure that the ink system can develop under normal operating
conditions is 255 points. The absolute pressure figure (in bar) will vary with jewel size,
temperature, pump wear, etc. Therefore, 255 points always represents maximum, but the
maximum actual pressure in the system can be any figure up to 4.5 bar.
The desired pressure within the system is termed the “Set Pressure” and the actual
pressure within the system is termed the “Read Pressure”.

3.3.3 Modulation
The jet of ink is broken into evenly sized 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 into the fluid. This is achieved in the Linx
printheads by oscillating a piezo crystal in contact with the fluid (figure 3-2).

Ink feed line.

Ink delivered under
pressure from ink system
Piezo crystal oscillates

;
due to modulation signal

;;
6245

Nozzle chamber

;;
Modulation signal

;
Nozzle

Break-up of ink jet occurs in

charge electrode caused by
excitation from piezo crystal

NOTE: Charge electrode

shown enlarged and rotated
through 90 degrees for ease
of representation

Figure 3-2. Modulation of the ink jet using a piezo crystal

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If a voltage is applied to a piezo crystal it will flex and the degree of flexing will depend
upon the amplitude of the voltage applied. Two opposite polarity bimorph piezo crystals
are used in the printhead nozzle chamber, bonded together in such a way that they will
distort in sympathy with a fixed frequency sine wave. This gives a direct and very
controllable degree of modulation to the fluid. As the edges are fixed, the crystal deflects
and thus displaces a small volume of ink.
The frequency of the sine wave (the modulation frequency) determines the rate of drop
production. This is a fixed value for each printhead type. The amplitude of the sine wave
(the modulation voltage) determines exactly where the ink jet will form into drops. This
modulation voltage is an in-house calibrated value between 0 and 255 volts which is
unique to every printhead and is recorded on each printhead conduit label. The recorded
value on the printhead conduit label must correspond with the reference modulation value
entered into the printer.
As previously stated, the modulation amplitude determines the point at which the ink jet
forms into drops. This point will vary depending on the viscosity of the ink; if the ink is
thicker the drop breakoff point occurs later than if the ink is thinner. The actual desired
point of breakoff is within the charge electrode where printing drops are required to be
charged.
A strobe LED, situated behind the charge electrode, enables the drop breakoff inside the
charge electrode to be observed with the aid of a suitable eyeglass. The LED is strobed at
the same frequency as the modulation signal giving the appearance that the drops are
frozen in flight. When viewing the charge electrode with the aid of an eyeglass of x10 or
x20 magnification, the example shown in figure 3-3 should be observed:

6246

Jet nozzle

Jet stream
affected by
piezoelectric Charge
crystal electrode

Drop breakup
beginning to occur

Actual point of jet breakup.

This must occur within the central
region of the charge electrode to
achieve optimum drop charging

Charged
drops

Figure 3-3. Correct drop breakoff observed in the charge electrode

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3.3.4 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 charge voltage on it.
To charge a drop a positive voltage of between 0 V and 300 V is applied to the charge
electrode for the period of time (1/modulation frequency) that it takes to form one
complete drop. By capacitive coupling 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.
If the following drop is to be printed then 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 should therefore pass straight to the gutter) then a small correction voltage of
12.5% of the previous charge voltage is applied. This is known as “historic correction” (see
below).

3.3.5 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 itself 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 all non-printing drops.
For example, a printing drop has 100 V placed on 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 V is placed on the charge
electrode, for the time period of the non-printing drop’s production, to stabilize its charge
at zero.

3.3.6 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 5 kV (typically 2.5 kV to 3 kV) which establishes an electrostatic field.
The negatively charged drops are deflected in this field by an amount proportional to the
field strength, the charge on the drop, and the velocity of the drop (TOF).
If a drop is to be non-printing, i.e. pass straight into the gutter, then that drop is given zero
charge which results in zero deflection.

3.3.7 Phasing
As previously mentioned, for correct charging of the drops to occur the charge voltage
must remain on the charge electrode for the period from when the drop starts to form until
the drop breaks off from the main ink stream. 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.

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An example illustration of drops being charged at the correct and incorrect times is shown
in figure 3-4. Note how the amplitude of the phase signal varies when the charge signal is
applied at different times in relation to the modulation signal.

6247

Phase position 0
MOD

CHG

Modulation and Charge

not in phase.
Drops charged too early.

Phase signal too small.

Phase position 4
MOD

CHG

Modulation and Charge

not in phase.
Drops charged too early.

Phase signal too small.

Phase position 8
MOD

CHG

Modulation and Charge

in phase.
Drops charged correctly.

Phase signal correct.

Phase position 12
MOD

CHG

Modulation and Charge

not in phase.
Drops charged too late.

Phase signal too small.

Figure 3-4. Charge and Modulation synchronization (Phasing)

The operation is carried out by first charging eight consecutive drops (ten consecutive
drops for a micro printhead) to 12 volts. 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, then the
magnitude of the phase signal will be large enough to trigger the phase electronics and the
print control would be deemed to be in phase.

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The phasing process synchronizes the charge and modulation to one of sixteen positions 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 will be charged 1/16
of the time period later with relation to the drop breakoff. Again the phase signal strength
is assessed.
This process is repeated for each of the sixteen phase positions until an in-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 after every printed message or every
25 ms, whichever is the shorter time.

3.3.8 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 is 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 packet of TOF drops are charged by
applying 12 volts to the charge electrode. This packet of drops travels past the phase
sensor 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 situated in front of
the gutter. 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 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.
• if actual TOF = Reference TOF (± 1/2%) — System pressure left unchanged;
• if actual TOF > Reference TOF — System pressure is increased;
• if actual TOF < Reference TOF — 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 handles the received signal.

3.3.9 Viscosity Control

As previously stated the viscosity of the ink will change 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 the viscosity
reaches a predetermined level, solvent is added to the ink tank from the solvent tank. This
predetermined level is when the Set Pressure exceeds a value known as the “Solvent Add
Reference Pressure”. Solvent Add is derived from a reference pressure which is a
calibrated value unique to each printhead, and is part of the printhead code located on the
conduit label.
For each of the printhead types, the Solvent Add value is derived as follows:
• Micro Solvent Add = Reference Pressure + 5;
• Midi 62 µm & 70 µm Solvent Add = Reference Pressure + 4;
• Macro Solvent Add = Reference Pressure + 3.

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Solvent will be added to the ink when all of the following five conditions have been
satisfied:
1. Set Pressure > Solvent Add.
2. Actual TOF = Reference TOF.
3. Solvent level OK (i.e. the printer solvent level is above the minimum required
and there is no solvent low warning).
4. Pressure check OK (i.e. the pressure generation circuits functioned correctly at
jet startup and the pressure fail error does not exist).
5. Warm-up time expired (i.e. the jet has been running for 45 minutes).
When solvent has been added to the ink the viscosity of the ink will be lowered. Within 20
minutes this thinner ink arrives at the printhead causing the Set Pressure to decrease as the
thinner ink flows from the nozzle. If, after twenty minutes, the Set Pressure value is still
above the Solvent Add value then more solvent will be added to the ink tank.
To ensure that too much solvent is not inadvertently added to the ink the printer will only
allow 8 (MEK and Pigmented ink types) or 25 (3XXX and ethanol ink types) consecutive
solvent additions, 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 the
error “2.03 Time Of Flight”.

3.3.10 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. This also means that it would not normally
be possible to have drops touching on the substrate, which would ideally produce a higher
quality print.
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 3-5. Guard Drops

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3.3.11 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 which 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 continuously 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 as there is a constant
replacement of ink in the nozzle.
A problem arises on shutdown when ink is left in the printhead nozzle; as it is fast drying it
will soon cause a blockage in the nozzle. To overcome this, special procedures to clear the
nozzle are necessary.
On shutdown, the ink is removed from the nozzle and the gun by suction through a purge
line. 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 manually clean the printhead after
shutdown.
On startup a series of actions occur automatically:
• the electronic circuitry is checked;
• the feed and purge valves are opened to allow the ink to circulate through the
printhead;
• the pump pressure is increased to maximum and the purge valve is shut off
with the consequence that the ink jet is established at high pressure;
• pressure is reduced to normal operating pressure and the ink jet is excited
through the modulation process to cause drop break-up;
• the phasing and modulation are checked automatically for optimum
positioning;
• 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 ready state;
• on receiving a signal from the “print go” sensor (photocell) the printer will
print the message previously entered, which is automatically updated for
dates, sequential numbers, etc.
All these procedures should operate automatically and it should not, under normal
operating conditions, be necessary to remove the printhead cover and carry out any
maintenance during shutdown or startup. However, it may be necessary, under certain
fault conditions, to remove the printhead cover and manually clean the printhead with
solvent.
NOTE: 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.
Detailed descriptions of the startup and shutdown routines are contained in the “Ink
System” sub-section later in this section.

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3.4 Cabinet
The purpose of the cabinet is to house and support the modules which comprise the
printer, and to protect them from contamination. The basic printer cabinet is designed to
meet an International Protection rating of, and is sealed to, IP55 in respect of water and
dust.
The cabinet is a two piece structure consisting of a top cover and a base tray unit. The
polyurethane (PU) top cover moulding is secured at the front and rear to the stainless steel
base unit. The top cover hooks under two locating lugs at the front of the base unit, and is
lowered into place and secured by three top accessible fixings with security heads.
The top cover houses the keyboard and liquid crystal display (LCD) used as the interface
between the operator and the printer. The keyboard is mounted directly behind the top
cover and is sealed using a concealed EPDM gasket.
The base unit houses the following main components: the ink system enclosure; electronics
system (IPM and Photocell PCBs); mains power on/off switch; mains filter; low voltage
power supply unit (LVPSU) and fuses; EHT power supply unit; printhead positive air
pump; printhead protection enclosure; cooling fan and air filter.
Figure 3-6 is a plan view of the 4800 printer base unit showing the locations of the main
components:

Printhead
conduit Ink system
Printhead ventilation
protection duct Mains power
Cover securing
enclosure on/off switch
lugs (3 off) Vent
Mains power
48002 cable

Photocell PCB Solvent Ink Mains

tank tank filter

Fuses

Low voltage
Printhead power supply
positive air pump unit
(if fitted)

EHT power Ink system

supply unit pump

Air filter
Ink system
housing
valves

Air filter
removing
tab

IPM PCB

Cooling fan
Cover locating
lugs (2 off)

Figure 3-6. 4800 cabinet base unit

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The back plate of the base unit allows entry of the printhead conduit (sealed to IP55) and
the non-user-removable mains power supply cable (sealed to IP65). The mains power
supply cable enters the rear of the printer below the on/off switch. External connectors for
RS–232, the photocell, the shaft encoder and the alarm relay output are also provided on
the back plate. All the connectors are IP67 rated.
The ink system is further protected by, and housed within, a self contained stainless steel
enclosure. The enclosure is integral to the printer base unit and therefore cannot be
removed as a complete functional assembly. The lid of the ink system is formed by the
moulded top cover when fitted. When the top cover is correctly fitted the ink system
enclosure is sealed to IP54 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.
The air intake for the cooling fan is on the underside of the base unit together with a user-
replaceable air filter. The ink system air outlet vent is on the rear of the base unit.
The cabinet also provides fixing points on the rear face for the alarm beacon.

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3.5 User Interface

3.5.1 Keyboard and Display
The user interface consists of a keyboard and display. The keyboard includes a full
QWERTY, tactile membrane keypad which is used to input the required message. The
display is a “black on white” Liquid Crystal Display (LCD) with cold cathode back-
lighting. Figure 3-7 is an illustration of the standard European keyboard.
48001

enter
del

~
#
)

ø
+

]
=

?
ã
Ñ

/
@
'
!
(

õ
–

[
Ø

>
-

.
ñ

µ
;
¿
P
)

Å
0

<
,
ú

ö
¨
L
O
Ï
(

Ä
9

M
ó

Î
K
Change Setup

è
Check Status

I
*

ê
8
: MESSAGE 1

N
Í

Ì
J
ë
&

U
ö
7
4800
:
:

B
á
F2
F4

ü
H
ç
Y
^

ÿ
6

V
§

ò
G
Change Message
CURRENT MESSAGE

å
T
New Message

ô
5

C
ß

é
F
à
$

R
æ
4

space
Ô

X
:
:

ù
D
F1
F3

â
E
£

ä
3

Z
£

Ö
S
warning

Æ
W
"
power

û
2

¦
ready

\
Ã
fail

A
º
Ç
Q
!

É
1

shift
Ü

ctrl
caps
esc
start

stop

F1

F4
F2

F3

Figure 3-7. 4800 European keyboard

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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
which will not change from one print to the next; a time field will display the actual time
(or the time offset by a specific amount) and will change accordingly from one print to the
next. Refer to the 4800 Ink Jet Printer User Manual for details of message creating and
editing.

3.5.2 Control Panel LEDs

Power
The green Power LED remains on while the printer is powered up. It is not under software
control.

Ready
The green software controlled Ready LED will light 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.

Warning
The red software controlled Warning LED will light when there are one or more active
System Warning errors on the printer. These errors can be viewed (and cleared) via the
Check Status option in the CURRENT MESSAGE screen. Once the last remaining error has
been cleared the LED will be extinguished.

Fail
The red software controlled Fail LED will light when a System Failure or a Print Failure
occurs and will remain lit until the printer is powered down.

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3.6 Electrical Components

The electrical components housed within the printer cabinet comprise the following:
• Mains Filter;
• Mains Fuses;
• Low Voltage Power Supply Unit (LVPSU);
• EHT Power Supply Unit;
• Ink System Pump;
• Printhead Positive Air Pump;
• Cooling Fan.

3.6.1 Mains Filter

The mains filter is mounted on the inside rear face of the cabinet on the right-hand side,
below the mains supply on/off 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 electrical
noise from being transmitted from the printer to the mains supply wiring.

3.6.2 Mains Input Fuses

There are two mains input fuses mounted on a bracket which in turn is mounted on the
rear face of the LVPSU.
The fuses are antisurge, rated at 4 A for both 110 V and 240 V a.c. operation.

3.6.3 Low Voltage Power Supply Unit (LVPSU)

The LVPSU is mounted on the base unit of the cabinet, on the rear right-hand side and to
the right of the ink system enclosure.
It is a switch mode unit which provides the necessary voltage rails to power various
systems within the printer.
The input voltage range of the unit is between 85 V and 264 V a.c., 50/60 Hz. A 10-way
Molex connector receives the mains live on pins 1 and 6, neutral on pins 3 and 8, and earth
on pins 5 and 10.
There are four outputs of +5.1 V, +12 V, –16 V and +24 V d.c. In addition, 6 outputs of 0 V
are provided (all commoned), together with a power fail control signal. If the input power
is interrupted causing the outputs to fall outside their tolerance of ≤ ±5%, the control signal
will open circuit the four outputs.
Figure 3-8 provides details of the outputs including connector pin numbers:

48003
Output Max. Current 16-way Molex Pin
(V) (A) Number
+5.1 8 2, 10
+12 4.5 5, 13
–16 0.5 6, 14
+24 4.5 8, 16
0 — 3, 4, 7, 11, 12, 15
Power Fail — 1, 9

Figure 3-8. LVPSU output details

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Aug 98 3 — 18 4800 Service Manual
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3.6.4 EHT Power Supply Unit

The EHT Power Supply Unit is mounted on the base unit of the cabinet, on the rear left-
hand side and to the left of the ink system.
This unit generates the high voltages required for the printhead deflector plates and charge
electrode, and is powered by +24 V d.c. from the LVPSU.
Two variable EHT outputs of up to +5 kV and –5 kV at 10 µA are provided, which are used
to establish the electrostatic field between the deflector plates in the printhead. These EHT
outputs are routed from the unit via two Highvol style connectors (positive EHT red,
negative EHT white).
A further output of +300 V at a maximum of 46 mA is used to supply the printhead charge
electrode.
Apart from the two EHT outputs, all other voltages and signals are routed in and out of the
unit via a 12-way minifit junior Molex connector.

3.6.5 Ink System Pump

This unit is a pump and motor assembly mounted through an aperture in the front wall of
the ink system enclosure.
Its purpose is to pump ink round 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.
The unit is controlled by a 24 volts pulse-width modulated signal fed from the control
circuits on the IPM PCB.
Magnetic coupling from the motor to the pump ensures separation of the ink from the
drive parts. The gears are made from polyetheretherketone (PEEK) which provides
reduced wear and long life.

3.6.6 Printhead Positive Air Pump

The printhead positive air pump is mounted on the inside of the left-hand wall of the base
unit.
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 in the printhead. The air flow into the printhead is
greater than that through the gutter, thereby producing a positive air pressure inside the
printhead which helps to keep the printhead free of dust and other airborne debris.
The air supply pipe is fitted to all Mk.5 Midi and Mk.3B Micro and Macro printheads.
However, the pump is not fitted as standard to the 4800 printer but is available as an
option (refer to the Linx Parts and Prices catalogue or contact your Linx distributor).

3.6.7 Cooling Fan

The cooling fan is mounted below the IPM PCB on the air filter housing. It is a 24 V device
supplied directly from the LVPSU and operates all the time the printer is switched on.
The air filter, located beneath the fan in its own housing, may be removed for cleaning or
replacement by pulling the tab attached to the filter, on the right-hand side of the printer
base unit. The filter should be cleaned using compressed air blown through in the reverse
direction to the normal air flow.

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 Linx Printing Technologies plc

3.7 Ink System

3.7.1 General Description
The Ink System is contained in a stainless steel enclosure which is integral to the base unit
of the cabinet, and therefore is not removable for maintenance or replacement. The cabinet
top cover has two openings through which the ink and solvent tanks can be filled, via
internal filler tubes. The filler tubes are sealed by removable protective caps—black for ink
and white for solvent.
Within the module the ink system comprises (refer to figure 3-9. Static Ink System):
• the ink tank;
• 40 micron disposable pre-pump filter;
• pump and motor assembly;
• 5 micron polypropylene disposable main ink filter (10 micron for pigmented
inks);
• integral damper/filter;
• 18 micron stainless steel in-line feed filter (“last chance” filter)—see Printhead
Components earlier in this section;
• solvent tank;
• solvent dip tube incorporating an 80 micron stainless steel in-line filter;
• 10 micron solvent pick-up filter;
• ink manifold and interconnecting pipes.
The pump has an internal system of gears and is magnetically coupled to the pump motor.
The overall control of the pump is achieved by a 24 V (depending on the requested
pressure) pulse width modulated drive signal supplied by the IPM PCB via PL6.
The moulded plastic ink and solvent tanks have nominal capacities of 1600 ml. The
capacity of the solvent tank is slightly less than the ink tank due to one corner being
chamfered to accommodate the ink system vent tube. Both tanks are fitted with level
sensors to detect when the level of fluid falls below a predetermined point. If either sensor
detects a low fluid level, a System Warning error 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 for
a long time (8 hours for the Micro and Midi printheads, 3 hours for a Macro printhead), the
system reports the Print Failure fault message “2.06 Ink Tank Empty”. This is to prevent
the ink from running out completely.
The ink flows from the tank to the pump through the pre-pump filter which removes larger
foreign debris from the ink. The main ink filter provides the primary filtration within the
ink system to remove remaining foreign particles from the ink before it reaches the
manifold and the printhead. The disposable main ink filter and pre-pump filter should be
replaced every 1400 jet-running hours, and the damper should be replaced annually, in
accordance with the “1400 Hour Scheduled Maintenance” procedure provided in Section 5:
“Maintenance”.
Ink is fed to and from the printhead via the Feed, Purge and Gutter lines, which each use a
stainless steel compression union fitting to connect the printhead to the ink system. The
tubing is colour-coded: red for the Feed line, blue for the Purge line, and white for the
Gutter line. All three union fittings are located within the ink system module.

Amdt 02
Aug 98 3 — 20 4800 Service Manual
4800 Service Manual

Nozzle
Chamber

Purge Line Gutter

Restrictor
Printhead
Gutter Restrictor not used
In-Line on macro printheads
Feed
Pressure Filter
18µ Union 48008
Transducer Fitting
Pressure
connections Transducer 18
1 = Red/Green T-
2 = Black/Grey 0V
3 = White/Black T+

Linx Printing Technologies plc

4 = Red/White +5V
15 1 OFF 2 OFF 3 OFF 4 OFF 5 OFF
25
3 — 21

Venturi Feed Purge Gutter Solvent Solvent

Add Flush
24 16 21 6 20 11 7 12 8 13 9 14 10
Solvent 22
Pick-Up
Filter 23
Main Ink Damper 10µ
Filter
5µ/10µ

Vent Vent

Pump
Pre-Pump
Filter
40µ

INK SOLVENT
Amdt 02
Aug 98

Figure 3-9. Static Ink System

 Linx Printing Technologies plc

3.7.2 Manifold Assembly

The manifold assembly is the heart of the ink system and its purpose is to regulate the
pressure and distribution of the ink and solvent in the system. Various components are
used to achieve this and they each form part of the complete manifold assembly. The main
component is the manifold block which is manufactured from white acetal and has
interconnecting internal bores drilled in it. These bores exit the manifold block at ports to
which are connected a pressure transducer, vacuum venturi, valves and interconnecting
pipes.
Figure 3-10 shows the ink system manifold assembly components:

48005

Purge
valve
Gutter
valve
Solvent Add
valve
Solvent Flush Feed
valve valve

Pressure
Transducer
1
2
3
4
5

Manifold
Block

Venturi

Figure 3-10. Ink System Manifold Assembly

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Aug 98 3 — 22 4800 Service Manual
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Pressure Transducer
The actual pressure of the ink in the system is monitored by the pressure transducer which
is fitted to the manifold; this is the “Read Pressure” measurement.

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 “Clear
Nozzle” later in this section.

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. Figure 3-11 is a sectional illustration of the venturi:

Ink flow from the pump

at Set Pressure
48004 Small bore
drilling

Groove around circumference of

venturi to allow equalization of
vacuum at both tappings Area of low pressure
around the ink flow
due to turbulance

Suction connected Suction connected

through the manifold to through the manifold
the Solvent Add valve to the Gutter valve

Large bore
drilling

Ink and air returned Venturi housing

to the ink tank

Figure 3-11. Section view of the Venturi

Valves
The five solenoid-operated 3-way valves are used to control the flow of ink and solvent
through the system. The valves are: Feed valve, Purge valve, Gutter valve, Solvent Add
(Top-up) valve, and Solvent Flush valve.
These valves are sealed and cannot be disassembled.
The electrical connections to the valves are provided via a 25-way “D” type connector
(PL11) on the edge of the IPM PCB.

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 Linx Printing Technologies plc

3.7.3 Manifold Connections

The pipe connections to the manifold are made using barb fittings. The barbs are sealed by
interference fit to the manifold and cannot be removed. They are, therefore, not
replaceable items. Refer to Service Bulletin SB0395 for further information.
Figure 3-12 shows the manifold, its components and the various ports. Details of the
manifold pipe connections and the colour-coding of the wires to the valves are provided.

23

48006
VALVE ELECTRICAL CONNECTIONS
VALVE WIRE COLOURS
22
FEED BROWN/ORANGE
PURGE WHITE/PINK
GUTTER GREY/PINK
18
SOLVENT ADD VIOLET/PINK
SOLVENT FLUSH RED-BLUE/PINK

19 17

1 2 3 4 5

FEED PURGE GUTTER SOLVENT SOLVENT

25 ADD FLUSH

6 7 8 9 10

20
11 12 13 14
21

15 16

24

MANIFOLD PIPE CONNECTIONS

PIPE ROUTING PIPE LENGTHS

PORT 1 (FEED VALVE) TO PORT 10 215 mm NATURAL PIPE (1/8 in. OD)
PORT 2 (PURGE VALVE) TO PORT 8 170 mm NATURAL PIPE (1/8 in. OD)
PORT 3 (GUTTER VALVE) TO GUTTER FLUID CONNECTOR (CAP) 450 mm NATURAL PIPE (1/8 in. OD)
PORT 4 (SOLVENT ADD VALVE) TO 19 ('Y' PIECE) 40 mm NATURAL PIPE (1/8 in. OD)
PORT 5 (SOLVENT FLUSH VALVE) TO 17 ('Y' PIECE) 40 mm NATURAL PIPE (1/8 in. OD)
PORT 6 TO FEED FLUID CONNECTOR (CAP) 450 mm RED PIPE (1/8 in. OD)
PORT 7 TO INK TANK 300 mm NATURAL PIPE (1/8 in. OD)
PORT 9 TO PORT 15 215 mm NATURAL PIPE (1/8 in. OD)
PORT 11 TO PURGE FLUID CONNECTOR (CAP) 450 mm BLUE PIPE (1/8 in. OD)
PORT 12 TO PORT 16 120 mm NATURAL PIPE (1/8 in. OD)
PORT 13 TO PORT 14 90 mm NATURAL PIPE (1/8 in. OD)
PORT 18 ('Y' PIECE) TO 22 (SOLVENT PICK-UP FILTER) 120 mm NATURAL PIPE (1/8 in. OD)
PORT 20 TO DAMPER (BLEED CAP END) 330 mm NATURAL PIPE (1/8 in. OD)
PORT 21 TO DAMPER OUTLET 330 mm NATURAL PIPE (1/8 in. OD)
PORT 23 (SOLVENT PICK-UP FILTER) TO SOLVENT TANK 120 mm NATURAL PIPE (1/8 in. OD)
PORT 24 (VENTURI) TO INK TANK (RETURN LINE) 500 mm NATURAL PIPE (6 mm OD)
PORT 25 TO MAIN INK FILTER 190 mm NATURAL PIPE (6 mm OD)

Figure 3-12. 4800 Manifold connections

Amdt 02
Aug 98 3 — 24 4800 Service Manual
 Linx Printing Technologies plc

3.7.4 Standard Gutter Restrictor

The normal running pressure of the Midi and Micro printheads is substantially higher than
that of the Macro printhead. Therefore, the amount of air being drawn into the gutter with
the ink in Midi and Micro printheads is greater. This larger volume of air flowing with the
ink in the gutter return line causes the solvent in the ink to evaporate quicker, thereby
increasing solvent consumption. This in turn causes an increase in the volume of vented
solvent fumes.
By fitting a restrictor in the gutter return line to control the airflow, a significant reduction
in solvent consumption can be made and thus a decrease in the volume of vented solvent
fumes.
The gutter restrictor is fitted as standard inside the gutter return line of Midi and Micro
printheads only (i.e. not Macro and 70 µm printheads), and as such is part of the printhead
assembly. It is held in place with a clip and is located on the printhead side of the gutter
line union fitting, within the printer cabinet.

3.7.5 High Flow Gutter Restrictor

With Midi printheads only and in extreme circumstances, if the printhead is inverted
during normal running, ink can overflow from the gutter causing printer failure. This is
due to the gutter suction being unable to successfully overcome the increased gravity, and
the ink is therefore not drawn away from the gutter efficiently. For such applications a
High Flow Gutter Restrictor can be fitted, as an optional replacement for the standard
gutter restrictor, to further increase the ink flow in the gutter return line.
Before fitting a High Flow Gutter Restrictor it is advisable to check the jet alignment with
respect to the gutter to make sure that this is not causing the gutter overflow problem.
The High Flow Gutter Restrictor is very similar to the standard restrictor except that the
hypodermic needle has a reduced length allowing greater ink flow. It is fitted in the gutter
line using barb fittings. The new part can be identified by a second indent ring around the
body of the restrictor.

48073

Figure 3-13. High Flow Gutter Restrictor

Due to the increased ink flow through the gutter line there may be a slight rise in solvent
consumption, especially when using Linx Marque Ink 3103.
This High Flow Gutter Restrictor is available as a spare part only; it is not fitted to Midi
printheads as standard.

Amdt 02
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 Linx Printing Technologies plc

3.7.6 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 (with Midi printheads only) a
check valve can be fitted in the gutter return line.

48007

FLOW

Figure 3-14. In-Line Gutter Check Valve

This check valve is available as a spare part only; it is not fitted to Midi printheads as
standard. It is also only approved for use in printers using the following inks:
• Linx Marque Ink Fast Dry Black 1240;
• Linx Marque Ink Black Reodourized Alkali Removable 1070.

3.7.7 Ink and Solvent Flows

The following ink and solvent flow descriptions should be read in conjunction with the ink
and solvent flow diagrams, figures 3-15, 3-16 and 3-17.

Normal Operation
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 3-15)

The ink flow in the primary circuit is from the ink tank, through the pre-pump filter to the
pump, and then under pressure through the main ink filter to the 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 back to the ink tank.

Secondary Circuit (figure 3-16)

The secondary ink flow circuit comes into operation when the Feed valve is switched on.
There is an internal manifold fluid connection which feeds ink from the primary circuit at
the venturi, through the integral damper/filter, to the switched on Feed valve. This allows
ink to be fed under pressure through the in-line feed filter (“last chance filter”), along the
feed line 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 unused drops
back into the system through the switched off Gutter valve, and returns them to the ink
tank via the venturi.

Amdt 02
Aug 98 3 — 26 4800 Service Manual
4800 Service Manual

Nozzle
Chamber

Purge Line Gutter

Restrictor
Printhead
Gutter Restrictor not used
In-Line on macro printheads
Feed
Pressure Filter
18µ Union
Transducer 48009
Fitting
Pressure
connections Transducer
1 = Red/Green T-
2 = Black/Grey 0V
3 = White/Black T+
4 = Red/White +5V
OFF OFF OFF OFF OFF
3 — 27

Venturi Feed Purge Gutter Solvent Solvent

Add Flush

Solvent
Pick-Up
Filter
Main Ink Damper 10µ
Filter
5µ/10µ

Vent Vent

Pump
Pre-Pump
Filter
40µ

INK SOLVENT
Amdt 01
Feb 98

Figure 3-15 . Primary circuit

Feb 98
Amdt 01

Nozzle
Chamber

Purge Line Gutter

Restrictor
Printhead
Gutter Restrictor not used
In-Line on macro printheads
Feed
Pressure Filter
18µ Union 48010
Transducer Fitting
Pressure
connections Transducer
1 = Red/Green T-
2 = Black/Grey 0V
3 = White/Black T+
4 = Red/White +5V
ON OFF OFF OFF OFF
3 — 28

Venturi Feed Purge Gutter Solvent Solvent

Add Flush

Solvent
Pick-Up
Filter
Main Ink Damper 10µ
Filter
5µ/10µ

Vent Vent

Pump
Pre-Pump
Filter
4800 Service Manual

40µ

INK SOLVENT

Figure 3-16. Secondary circuit (normal running after start purge)

 Solvent Addition (figure 3-17)
Solvent is automatically added to the ink if the viscosity becomes too high. This is
indicated by the Set Pressure exceeding the predetermined Solvent Add Reference
Pressure (P1). When this Solvent Add Pressure is exceeded a solvent addition occurs only
if ALL the following criteria are met:
• Read Pressure > Solvent Add Reference Pressure;
• TOF within ±0.5% of TOF Reference;
• warm-up period expired;
• solvent level OK;
• no “Low Pressure” System Warning.
NOTE: No solvent is added if there is a “Low Pressure” System Warning since 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. in both the primary and secondary ink circuits.
To add solvent, the Solvent Add valve is switched on. The vacuum from the venturi now
acts on the Solvent Add valve, as well as the normally switched off Gutter valve. The
vacuum draws solvent from the tank, through the switched on 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 solvent/ink mixture in the ink tank
is then fed to the printhead as normal, where the reduced viscosity ink improves the
performance of the printhead.
The 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 ink and printhead type dependent. Refer to the Ink Type Dependent
Parameters table at the end of the “Ink System” description.
After solvent is added, further solvent additions are inhibited for a predetermined time
(Solvent Mix Time) which is specified in the Printhead Type Dependent Parameters table
later in this section. This allows the solvent to mix in the ink tank and for the effects of the
solvent addition to be seen at the printhead.

Amdt 01
4800 Service Manual 3 — 29 Feb 98
Feb 98
Amdt 01

Nozzle
Chamber

Purge Line Gutter

Restrictor
Printhead
Gutter Restrictor not used
In-Line on macro printheads
Feed
Pressure Filter
18µ Union 48011
Transducer Fitting
Pressure
connections Transducer
1 = Red/Green T-
2 = Black/Grey 0V
3 = White/Black T+
4 = Red/White +5V
ON OFF OFF ON OFF
3 — 30

Venturi Feed Purge Gutter Solvent Solvent

Add Flush

Solvent
Pick-Up
Filter
Main Ink Damper 10µ
Filter
5µ/10µ

Vent Vent

Pump
Pre-Pump
Filter
4800 Service Manual

40µ

INK SOLVENT

Figure 3-17. Solvent Addition

 3.7.8 Startup and Shutdown Routines
There are two startup routines:
• Normal Startup;
• Quick Start.
There are four shutdown routines:
• Flush Shutdown;
• Non-Flush Shutdown;
• Fault Shutdown;
• Quick Stop.
Fault Shutdown and Quick Stop are used in emergencies and the function of these is to
shut-off the jet as quickly as possible.
The Flush Shutdown routine has three settings which are accessible only with the Service
Level password in the Diagnostics sub-menu of the Setup menu. The Flush Shutdown
option and its settings are as follows:
Off The printer will never do the flush part of the flush shutdown routine.
On The printer will always do the flush part of the flush shutdown routine.
Auto In this mode the decision as to whether a flush shutdown is performed or
not is dependent on the time since the previous flush shutdown, as
follows:
• for ethanol inks, if the time since the previous flush shutdown
is less than 40 minutes (80 minutes for a 4 metre printhead
conduit), a non-flush shutdown will be performed;
• for all other inks, if the time since the previous flush shutdown
is less than 15 minutes (30 minutes for a 4 metre printhead
conduit), a non-flush shutdown will be performed.
NOTE: For a successful overnight shutdown the printer should be run for greater than
the times specified above.
The following valve sequence descriptions explain the flow of ink and solvent through the
system during the various routines used at startup, shutdown and solvent flush. Ink and
solvent flow diagrams are provided and should be studied in conjunction with the text.
In addition, valve sequence summary tables are provided after each detailed description.
The valves are identified in these tables as follows:
Feed F
Purge P
Gutter G
Top Up (Solvent Add) T
Flush L
A character in bold type indicates that the valve is on; a character in normal type indicates
that the valve is off. For example: F P G T L indicates that the Gutter and Flush valves are
on and the remainder are off.
NOTE: The valve sequences and timings information given here is relevant to Version
1.0 software for the 4800 printer only unless otherwise stated.

4800 Service Manual 3 — 31 Oct 97

 The various pressures and flush times mentioned in the following valve sequence
descriptions are printhead/conduit length dependent. The following table lists the
pressures for the corresponding printhead types:
48012

PRESSURES

Condition Pressure Micro Midi 62 µm Macro Midi 70 µm

Normal Running (default) * P0 196 195 75 140
Solvent Add Offset ** – 5 4 3 4
Normal Startup P2 255 255 160 200
Pressure/Filter Check P3 235 235 235 235
Max Running P4 255 255 150 200
Flush Startup P5 150 150 80 150
Clear Gutter/Nozzle P6 255 255 255 255
First Solvent Add Offset ** – 3 3 3 3
First Solvent Add Offset ** – 7 7 7 7
First Solvent Add Offset ** – 11 11 11 11

INK AND SOLVENT CONTROL

Micro Midi 62 µm Macro Midi 70 µm

Solvent Mix Time (min) – 2 m [4 m] conduit 20 [40] 20 [40] 20 [40] 20 [40]
Ink Time Out (hour) 8 8 3 8

* The Normal Running pressure (P0) is the default pressure, 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 Normal Running Pressure (P0) to produce the
Solvent Add Pressure (P1). The First Solvent Add Offset (3, 7 or 11) is added to the Solvent
Add Pressure (P1) to produce the First Solvent Add Pressure (P7, P8 or P9 respectively).
See also the Ink Type Dependent Parameters table at the end of the “Ink System”
description.
Figure 3-18. Printhead Dependent Parameters table

Oct 97 3 — 32 4800 Service Manual

 Linx Printing Technologies plc

Normal Startup Sequence

When the printer is first switched on and a message is selected for printing, all the valves
will be switched off initially.

Stage 1: Pressure/Filter Check (figure 3-16)

On pressing the [start] key the pump starts running at pressure P3 to perform the
pressure/filter check. Ink is circulated round the primary circuit, i.e. through the venturi
and back to the ink tank. The flow through the venturi creates a vacuum, which is applied
to the gutter via the Gutter valve (off). There is a pause of 8 seconds to allow the pressure
to stabilize, and the pressure at the transducer (Read Pressure) to be compared with the
requested pressure (Set Pressure—in this case P3). If the filter (and pump) is satisfactory,
there will be less than 14 points difference between the two pressures. If the filter is
becoming blocked or the pump is becoming worn, the Read Pressure will be significantly
lower than the Set Pressure. If the difference is more than 14 points, the system displays a
System Warning error message “3.12 Low Pressure”.
NOTE: When a Low Pressure error message has been issued, the system will not top-
up with solvent, although normal pressure correction will take place.

Stage 2: Feed Line Flush (figure 3-20)

After the pressure/filter check, the pressure is set to the maximum value of 255. There is a
brief delay of 5 seconds to allow the pressure to stabilize, then the Gutter and Solvent Flush
valves are switched on for 2 seconds (3 seconds for the 4 metre printhead conduit) and
then switched off. During this time the vacuum is applied to the purge line drawing 2 ml
of solvent through the Solvent Add valve (off), the Solvent Flush valve (on) and the Feed
valve (off), and into the feed line.

Stage 3: Feed Line Flush (figure 3-21)

The pressure is then set to the Flush Startup value P5 and allowed to stabilize for 5
seconds. The Feed valve is then switched on and during the next 5 seconds (8 seconds for
the 4 metre printhead conduit) a jet of solvent is established at low pressure for 2 seconds,
followed by ink flow in the secondary circuit and an ink jet.

Stage 4: Start Purge (figure 3-22)

Pressure is then increased to the Normal Startup value P2. After a further 5 second delay
the Purge valve is switched on. The ink will now also flow through the printhead nozzle
chamber and back along the purge line. From here it passes through the Purge valve (on)
and returns to the ink tank. This action lasts for 10 seconds (15 seconds for the 4 metre
printhead conduit) and removes the residual solvent from the nozzle chamber and the
purge line, and purges any air bubbles from the feed line, the nozzle chamber and the
purge line. The Purge valve is then switched off.

Stage 5: Phase and TOF Checks (figure 3-16)

The printer control system now reduces the pressure from the Normal Startup value of P2
to the Normal Running value P0, as specified in the printhead code. The jet is run at this
reference pressure for 8 seconds during which time the control system performs phasing
checks, followed by TOF checks. The pressure is adjusted, if required, to keep the TOF
within ±0.5% of the Reference TOF. If for any reason the printer is unable to obtain a
satisfactory phase or TOF reading, it will carry out a Clear Nozzle routine followed by a
slightly different startup routine (see “Clear Nozzle and Restart”).
The printer will make a maximum of four attempts to start, and will use this Clear Nozzle
and Restart routine for the second, third and fourth attempts. After the fourth attempt, if
there is still no phase or TOF reading, the printer performs a full shutdown routine, and
displays an error message describing the nature of the problem.

Amdt 02
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 Linx Printing Technologies plc

The following Normal Startup summary table is provided for quick reference:
48013
STARTUP
Action Description Micro Midi Macro 70 µm 2m 4m
Valve F P G T L (all off)
Pressure Pressure Check (P3) 235 235 235 235
Wait Pressure/Filter Check 8s 8s 8s 8s
Pressure Maximum 255 255 255 255
Wait Pressure Response 5s 5s 5s 5s
Valve FPGTL
Wait Gutter/Flush Startup ➨ ➨ ➨ ➨ 2s 3s
Valve F P G T L (all off)
Pressure Flush Startup (P5) 150 150 80 150
Wait Pressure Response 5s 5s 5s 5s
Valve FPGTL
Wait Solvent to Nozzle ➨ ➨ ➨ ➨ 5s 8s
Pressure Normal Startup (P2) 255 255 160 200
Wait Pressure Response 5s 5s 5s 5s
Valve FPGTL
Wait Purge/Start ➨ ➨ ➨ ➨ 10 s 15 s
Valve FPGTL
Pressure Normal Running (P0) 196 * 195 * 75 * 140 *
Wait Phase/TOF Checks 8s 8s 8s 8s

* These are the Reference Pressure default values (196 for a Mk.3 Midi printhead). The
actual Reference Pressure for each individual printhead is specified in the printhead code.
Figure 3-19. Normal Startup summary table

Amdt 02
Aug 98 3 — 34 4800 Service Manual
4800 Service Manual

Nozzle
Chamber

Purge Line Gutter

Restrictor
Printhead
Gutter Restrictor not used
In-Line on macro printheads
Feed
Pressure Filter
18µ Union 48014
Transducer Fitting
Pressure
connections Transducer
1 = Red/Green T-
2 = Black/Grey 0V
3 = White/Black T+
4 = Red/White +5V
OFF OFF ON OFF ON
3 — 35

Venturi Feed Purge Gutter Solvent Solvent

Add Flush

Solvent
Pick-Up
Filter
Main Ink Damper 10µ
Filter
5µ/10µ

Vent Vent

Pump
Pre-Pump
Filter
40µ

INK SOLVENT
Amdt 01
Feb 98

Figure 3-20. Normal Startup Stage 2: Feed Line Flush

Feb 98
Amdt 01

Nozzle
Chamber

Purge Line Gutter

Restrictor
Printhead
Gutter Restrictor not used
In-Line on macro printheads
Feed
Pressure Filter
18µ Union 48015
Transducer Fitting
Pressure
connections Transducer
1 = Red/Green T-
2 = Black/Grey 0V
3 = White/Black T+
4 = Red/White +5V
ON OFF OFF OFF OFF
3 — 36

Venturi Feed Purge Gutter Solvent Solvent

Add Flush

Solvent
Pick-Up
Filter
Main Ink Damper 10µ
Filter
5µ/10µ

Vent Vent

Pump
Pre-Pump
Filter
4800 Service Manual

40µ

INK SOLVENT

Figure 3-21. Normal Startup Stage 3: Feed Line Flush

4800 Service Manual

Nozzle
Chamber

Purge Line Gutter

Restrictor
Printhead
Gutter Restrictor not used
In-Line on macro printheads
Feed
Pressure Filter
18µ Union 48016
Transducer Fitting
Pressure
connections Transducer
1 = Red/Green T-
2 = Black/Grey 0V
3 = White/Black T+

Linx Printing Technologies plc

4 = Red/White +5V
ON ON OFF OFF OFF
3 — 37

Venturi Feed Purge Gutter Solvent Solvent

Add Flush

Solvent
Pick-Up
Filter
Main Ink Damper 10µ
Filter
5µ/10µ

Vent Vent

Pump
Pre-Pump
Filter
40µ

INK SOLVENT
Amdt 02
Aug 98

Figure 3-22. Normal Startup Stage 4: Start Purge

 Linx Printing Technologies plc

Quick Start Sequence

This method of starting the printer is similar to the Normal Startup but the feed and gutter
flush part of the sequence are omitted. The Quick Start function is initiated by selecting the
Quick Start Jet option from the DIAGNOSTICS menu. For further information on the
Quick Start Jet option refer to The Diagnostics Menu” part of Section 5 “Maintenance”.
When the printer is first switched on and a message is selected for printing, all the valves
will be switched off initially.

Stage 1: Pressure/Filter Check (figure 3-15)

On selecting the Quick Start option the pump starts running at pressure P3 to perform the
pressure/filter check. Ink is circulated round the primary circuit, i.e. through the venturi
and back to the ink tank. The flow through the venturi creates a vacuum, which is applied
to the gutter via the Gutter valve (off). There is a pause of 8 seconds to allow the pressure
to stabilize, and the pressure at the transducer (Read Pressure) to be compared with the
requested pressure (Set Pressure—in this case P3). If the filter (and pump) is satisfactory,
there will be less than 14 points difference between the two pressures. If the filter is
becoming blocked or the pump is becoming worn, the Read Pressure will be significantly
lower than the Set Pressure. If the difference is more than 14 points, the system displays a
System Warning error message “3.12 Low Pressure”.
NOTE: When a Low Pressure error message has been issued, the system will not top-
up with solvent, although normal pressure correction will take place.

Stage 2: Establishing the Jet (as figure 3-16)

After the pressure/filter check, the pressure is set to the Normal Startup value P2 and
allowed to stabilize for 5 seconds. The Feed valve is then switched on and during the next
5 seconds the ink jet is established followed by ink flow in the secondary circuit.

Stage 3: Start Purge (as figure 3-22)

The Purge valve is switched on and the ink will now also flow through the printhead
nozzle chamber and back along the purge line. From here it passes through the Purge
valve (on) and returns to the ink tank. This action lasts for 10 seconds and purges any air
bubbles from the feed line, the nozzle chamber and the purge line. The Purge valve is then
switched off.

Stage 4: Phase and TOF Checks (as figure 3-16)

The printer control system now reduces the pressure from the Normal Startup value of P2
to the Normal Running value P0, as specified in the printhead code. The jet is run at this
reference pressure for 8 seconds during which time the control system performs phasing
checks, followed by TOF checks. The pressure is adjusted, if required, to keep the TOF
within ±0.5% of the Reference TOF.

Amdt 02
Aug 98 3 — 38 4800 Service Manual
 The following Quick Start summary table is provided for quick reference:

48087
QUICK START
Action Description Micro Midi Macro 70 µm 2m 4m
Valve F P G T L (all off)
Pressure Pressure Check (P3) 235 235 235 235
Wait Pressure/Filter Check 8s 8s 8s 8s
Pressure Normal Startup (P2) 255 255 160 200
Wait Pressure Response 5s 5s 5s 5s
Valve FPGTL
Wait Pressure Response 5s 5s 5s 5s
Valve FPGTL
Wait Pressure Response 10 s 10 s 10 s 10 s
Valve FPGTL
Pressure Normal Running (P0) 196 * 195 * 75 * 140 *
Wait Phase/TOF Checks 8s 8s 8s 8s

* These are the Reference Pressure default values (196 for a Mk.3 Midi printhead). The
actual Reference Pressure for each individual printhead is specified in the printhead code.
Figure 3-23. Quick Start summary table

Clear Nozzle and Restart Sequence

If the printer has been unable to obtain a satisfactory phase or TOF reading during startup
it will carry out a shutdown routine, followed by a Clear Nozzle routine and a restart,
using the following sequence:

Stage 1: Clearing the Nozzle (figure 3-24)

In this condition the Feed valve will be switched on initially. The pressure is set to the
Normal Startup value P2 for 5 seconds, then the Feed valve is switched off and the Gutter
valve is switched on. Pressure is set to the Clear Gutter/Nozzle value P6 to provide
maximum vacuum to purge the nozzle and draw ink from the nozzle chamber back into
the tank via the Purge and Gutter valves. This purging lasts for 15 seconds, after which the
Gutter valve is switched off followed by a further 5 seconds delay.

Stage 2: Restarting the Jet (figures 3-22 and 3-16)

The following parts of the sequence are similar to “Stage 4: Start Purge (figure 3-22)” and
“Stage 5: Phase and TOF Checks (figure 3-16)” described earlier in “Startup Sequence”:
Pressure is increased to the Normal Startup value P2. After a further 5 second delay, the
Purge valve is switched on. The ink will now also flow through the printhead nozzle
chamber and back along the purge line. From here it passes through the Purge valve (on)
and returns to the ink tank. . This action lasts for 5 seconds and removes the residual
solvent from the nozzle chamber and the purge line, and purges any air bubbles from the
feed line, the nozzle chamber and the purge line. The Purge valve is then switched off.
The printer control system now reduces the pressure from the Normal Start value of P2 to
the Normal Running value P0, as specified in the printhead code. The jet is run at this
reference pressure for 8 seconds during which time the control system performs phasing
checks, followed by TOF checks. The pressure is adjusted, if required, to keep the TOF
within the acceptable of ±0.5% of the Reference TOF.
If the printer still cannot obtain a satisfactory phase or TOF reading, this Clear Nozzle and
restart routine is carried out twice more before a full shutdown is initiated.

Amdt 01
4800 Service Manual 3 — 39 Feb 98
Feb 98
Amdt 01

Nozzle
Chamber

Purge Line Gutter

Restrictor
Printhead
Gutter Restrictor not used
In-Line on macro printheads
Feed
Pressure Filter
18µ Union 48017
Transducer Fitting
Pressure
connections Transducer
1 = Red/Green T-
2 = Black/Grey 0V
3 = White/Black T+
4 = Red/White +5V
OFF OFF ON OFF OFF
3 — 40

Venturi Feed Purge Gutter Solvent Solvent

Add Flush

Solvent
Pick-Up
Filter
Main Ink Damper 10µ
Filter
5µ/10µ

Vent Vent

Pump
Pre-Pump
Filter
4800 Service Manual

40µ

INK SOLVENT

Figure 3-24. Clear Nozzle and Restart Stage 1: Clearing the Nozzle
 Linx Printing Technologies plc

Flush Shutdown Sequence

Initially the Feed valve 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.

Stage 1: Clearing the Nozzle of Ink (figure 3-26)

The system sets the pressure to the Normal Startup value P2 and 5 seconds is allowed to
elapse to allow the pressure to stabilize. The Feed valve is then switched off, the Gutter
valve is switched on for 1 second (1.5 seconds for the 4 metre printhead conduit), and the
pressure is set to the Clear Gutter/Nozzle value P6. This stops the jet and briefly applies
the venturi vacuum to the purge line, through the Gutter valve (on) and Purge valve (off),
drawing the ink back from the nozzle.

Stage 2: Clearing the Gutter and Feed Lines of Ink (figure 3-27)
The Gutter valve is switched off and the Solvent Add and Solvent Flush valves are
switched on for 30 seconds (45 seconds for the 4 metre printhead conduit). This causes the
venturi vacuum to have a dual effect. First, it acts on the gutter, drawing ink from the
gutter line through the Gutter valve (off) and back to the ink tank. Secondly, it acts on the
nozzle, drawing ink back along the feed line via the Feed valve (off), Solvent Flush valve
(on) and Solvent Add valve (on), to the ink tank.

Stage 3: Clearing the Purge Line of Ink (figure 3-28)

The Gutter valve is then also switched on for 20 seconds (30 seconds for the 4 metre
printhead conduit). This transfers the vacuum from the gutter line to the purge line which
removes all ink from the purge line, and the Purge and Gutter valves. At the same time all
ink continues to be removed from the feed line and the Feed, Solvent Flush and Solvent
Add valves.

Stage 4: Priming the Nozzle with Solvent (figure 3-29)

The following action primes the nozzle chamber with solvent in preparation for flushing
the nozzle and gutter.
The Solvent Add valve is switched off. With the vacuum still acting on the purge line
through the Purge and Gutter valves, 10 ml of solvent is drawn into the nozzle chamber
and the purge line via the Solvent Add, Solvent Flush and Feed valves. This nozzle
priming continues for 6 seconds (15 seconds for the 4 metre printhead conduit) and then
the Gutter and Solvent Flush valves are switched off. All valves are now in the off state
which prevents further solvent from being drawn through the nozzle chamber into the
purge line.

Stage 5: Flushing the Nozzle and Gutter (figure 3-30)

Pressure is set to the Flush Startup value of P5. After a delay of 5 seconds to allow the
pressure to stabilize, the Feed valve is switched on. This establishes a solvent jet which
flushes residual ink from the nozzle and the gutter line for a period of 7 seconds (13
seconds for the 4 metre printhead conduit).

Stage 6: Clearing the Nozzle of Solvent (figure 3-31)

The Feed valve is then switched off which stops the solvent jet and the pressure is
increased to the Clear Gutter/Nozzle (maximum) value of P6. At the same time the Gutter
valve is switched on for 1 second (1.5 seconds for the 4 metre printhead conduit) and then
switched off again. For this brief period the vacuum acts through the Gutter valve and
Purge valve (off), drawing solvent from the nozzle chamber back along the purge line,
thereby removing any residual pressure in the line. All valves are now in the off state.

Amdt 02
4800 Service Manual 3 — 41 Aug 98
 Linx Printing Technologies plc

Stage 7: Clearing the Gutter and Feed Lines of Solvent (figure 3-32)
All the valves remain in the off state for 5 seconds which applies the vacuum to the gutter
drawing the solvent back towards the ink tank via the Gutter valve.
The Solvent Add and Solvent Flush valves are then switched on for 40 seconds (70 seconds
for the 4 metre printhead conduit). This causes the venturi vacuum to have a dual effect.
First, it continues to act on the gutter, drawing solvent from the gutter line through the
Gutter valve (off) and back to the ink tank. Secondly, it acts on the nozzle, drawing solvent
(and some ink) back along the feed line via the Feed valve (off), Solvent Flush valve (on)
and Solvent Add valve (on), to the ink tank.

Stage 8: Clearing the Purge and Feed Lines of Solvent (figure 3-33)
The Solvent Add and Solvent Flush valves remain on and the Gutter valve is now also
switched on. This condition lasts for 20 seconds (35 seconds for the 4 metre printhead
conduit) during which time the vacuum has a dual effect. First, it continues to act on the
nozzle, drawing the remaining solvent back along the feed line via the Feed valve (off),
Solvent Flush valve (on) and Solvent Add valve (on), to the ink tank. Secondly, it acts on
the purge line, drawing solvent from the purge line through the Purge valve (off) and the
Gutter valve (on) back to the ink tank.

Stage 9: Final Gutter Clearing (figure 3-34)

Finally, the Gutter, Solvent Add and Solvent Flush valves are switched off and a delay of
30 seconds occurs (40 seconds for the 4 metre printhead conduit) during which time the
vacuum continues to be applied to the gutter. The pump is then stopped, reducing the
pressure to zero.

Amdt 02
Aug 98 3 — 42 4800 Service Manual
 The following Flush Shutdown summary table is provided for quick reference.

48018
FLUSH SHUTDOWN
Action Description Micro Midi Macro 70 µm 2m 4m
Pressure Normal Start (P2) 255 255 160 200
Wait Pressure Response 5s 5s 5s 5s
Valve FPGTL
Pressure Clear Gutt/Nozz (P6) 255 255 255 255
Wait Gutter/Stop Jet ➨ ➨ ➨ ➨ 1s 1.5 s
Valve FPGTL
Wait TopUp/Flush 1 ➨ ➨ ➨ ➨ 30 45
Valve FPGTL
Wait TopUp/Flush 2 ➨ ➨ ➨ ➨ 20 s 30 s
Valve FPGTL
Wait Gutter/Flush ➨ ➨ ➨ ➨ 6s 15 s
Valve F P G T L (all off)
Pressure Flush Startup (P5) 150 150 80 150
Wait Pressure Response 5s 5s 5s 5s
Valve FPGTL
Wait Solvent Jet ➨ ➨ ➨ ➨ 7s 13 s
Valve FPGTL
Pressure Clear Gutt/Nozz (P6) 255 255 255 255
Wait Gutter/Stop Jet ➨ ➨ ➨ ➨ 1s 1.5 s
Valve F P G T L (all off)
Wait Absolute 5s 5s 5s 5s
Valve FPGTL
Wait TopUp/Flush 3 ➨ ➨ ➨ ➨ 40 s 70 s
Valve FPGTL
Wait TopUp/Flush 4 ➨ ➨ ➨ ➨ 20 s 35 s
Valve F P G T L (all off)
Wait End/Shutdown ➨ ➨ ➨ ➨ 30 s 40 s
Pressure Zero 0 0 0 0

Figure 3-25. Flush Shutdown summary table

Amdt 01
4800 Service Manual 3 — 43 Feb 98
Feb 98
Amdt 01

Nozzle
Chamber

Purge Line Gutter

Restrictor
Printhead
Gutter Restrictor not used
In-Line on macro printheads
Feed
Pressure Filter
18µ Union 48019
Transducer Fitting
Pressure
connections Transducer
1 = Red/Green T-
2 = Black/Grey 0V
3 = White/Black T+
4 = Red/White +5V
OFF OFF ON OFF OFF
3 — 44

Venturi Feed Purge Gutter Solvent Solvent

Add Flush

Solvent
Pick-Up
Filter
Main Ink Damper 10µ
Filter
5µ/10µ

Vent Vent

Pump
Pre-Pump
Filter
4800 Service Manual

40µ

INK SOLVENT

Figure 3-26. Flush Shutdown Stage 1: Clearing the Nozzle of Ink

4800 Service Manual

Nozzle
Chamber

Purge Line Gutter

Restrictor
Printhead
Gutter Restrictor not used
In-Line on macro printheads
Feed
Pressure Filter
18µ Union 48020
Transducer Fitting
Pressure
connections Transducer
1 = Red/Green T-
2 = Black/Grey 0V
3 = White/Black T+
4 = Red/White +5V
OFF OFF OFF ON ON
3 — 45

Venturi Feed Purge Gutter Solvent Solvent

Add Flush

Solvent
Pick-Up
Filter
Main Ink Damper 10µ
Filter
5µ/10µ

Vent Vent

Pump
Pre-Pump
Filter
40µ

INK SOLVENT
Amdt 01
Feb 98

Figure 3-27. Flush Shutdown Stage 2: Clearing the Gutter and Feed Lines of Ink
Feb 98
Amdt 01

Nozzle
Chamber

Purge Line Gutter

Restrictor
Printhead
Gutter Restrictor not used
In-Line on macro printheads
Feed
Pressure Filter
18µ Union 48021
Transducer Fitting
Pressure
connections Transducer
1 = Red/Green T-
2 = Black/Grey 0V
3 = White/Black T+
4 = Red/White +5V
OFF OFF ON ON ON
3 — 46

Venturi Feed Purge Gutter Solvent Solvent

Add Flush

Solvent
Pick-Up
Filter
Main Ink Damper 10µ
Filter
5µ/10µ

Vent Vent

Pump
Pre-Pump
Filter
4800 Service Manual

40µ

INK SOLVENT

Figure 3-28. Flush Shutdown Stage 3: Clearing the Purge Line of Ink
4800 Service Manual

Nozzle
Chamber

Purge Line Gutter

Restrictor
Printhead
Gutter Restrictor not used
In-Line on macro printheads
Feed
Pressure Filter
18µ Union 48022
Transducer Fitting
Pressure
connections Transducer
1 = Red/Green T-
2 = Black/Grey 0V
3 = White/Black T+
4 = Red/White +5V
OFF OFF ON OFF ON
3 — 47

Venturi Feed Purge Gutter Solvent Solvent

Add Flush

Solvent
Pick-Up
Filter
Main Ink Damper 10µ
Filter
5µ/10µ

Vent Vent

Pump
Pre-Pump
Filter
40µ

INK SOLVENT
Amdt 01
Feb 98

Figure 3-29. Flush Shutdown Stage 4: Priming the Nozzle with Solvent
Feb 98
Amdt 01

Nozzle
Chamber

Purge Line Gutter

Restrictor
Printhead
Gutter Restrictor not used
In-Line on macro printheads
Feed
Pressure Filter
18µ Union 40823
Transducer Fitting
Pressure
connections Transducer
1 = Red/Green T-
2 = Black/Grey 0V
3 = White/Black T+
4 = Red/White +5V
ON OFF OFF OFF OFF
3 — 48

Venturi Feed Purge Gutter Solvent Solvent

Add Flush

Solvent
Pick-Up
Filter
Main Ink Damper 10µ
Filter
5µ/10µ

Vent Vent

Pump
Pre-Pump
Filter
4800 Service Manual

40µ

INK SOLVENT

Figure 3-30. Flush Shutdown Stage 5: Flushing the Nozzle and Gutter
4800 Service Manual

Nozzle
Chamber

Purge Line Gutter

Restrictor
Printhead
Gutter Restrictor not used
In-Line on macro printheads
Feed
Pressure Filter
18µ Union 48024
Transducer Fitting
Pressure
connections Transducer
1 = Red/Green T-
2 = Black/Grey 0V
3 = White/Black T+

Linx Printing Technologies plc

4 = Red/White +5V
OFF OFF ON OFF OFF
3 — 49

Venturi Feed Purge Gutter Solvent Solvent

Add Flush

Solvent
Pick-Up
Filter
Main Ink Damper 10µ
Filter
5µ/10µ

Vent Vent

Pump
Pre-Pump
Filter
40µ

INK SOLVENT
Amdt 02
Aug 98

Figure 3-31. Flush Shutdown Stage 6: Clearing the Nozzle of Solvent

Aug 98
Amdt 02

Nozzle
Chamber

Purge Line Gutter

Restrictor
Printhead
Gutter Restrictor not used
In-Line on macro printheads
Feed
Pressure Filter
18µ Union 48025
Transducer Fitting
Pressure
connections Transducer
1 = Red/Green T-
2 = Black/Grey 0V
3 = White/Black T+

Linx Printing Technologies plc

4 = Red/White +5V
OFF OFF OFF ON ON
3 — 50

Venturi Feed Purge Gutter Solvent Solvent

Add Flush

Solvent
Pick-Up
Filter
Main Ink Damper 10µ
Filter
5µ/10µ

Vent Vent

Pump
Pre-Pump
Filter
4800 Service Manual

40µ

INK SOLVENT

Figure 3-32. Flush Shutdown Stage 7: Clearing the Gutter and Feed Lines of Solvent
4800 Service Manual

Nozzle
Chamber

Purge Line Gutter

Restrictor
Printhead
Gutter Restrictor not used
In-Line on macro printheads
Feed
Pressure Filter
18µ Union 48026
Transducer Fitting
Pressure
connections Transducer
1 = Red/Green T-
2 = Black/Grey 0V
3 = White/Black T+
4 = Red/White +5V
OFF OFF ON ON ON
3 — 51

Venturi Feed Purge Gutter Solvent Solvent

Add Flush

Solvent
Pick-Up
Filter
Main Ink Damper 10µ
Filter
5µ/10µ

Vent Vent

Pump
Pre-Pump
Filter
40µ

INK SOLVENT
Amdt 01
Feb 98

Figure 3-33. Flush Shutdown Stage 8: Clearing the Purge and Feed Lines of Solvent
Feb 98
Amdt 01

Nozzle
Chamber

Purge Line Gutter

Restrictor
Printhead
Gutter Restrictor not used
In-Line on macro printheads
Feed
Pressure Filter
18µ Union
Transducer 48027
Fitting
Pressure
connections Transducer
1 = Red/Green T-
2 = Black/Grey 0V
3 = White/Black T+
4 = Red/White +5V
OFF OFF OFF OFF OFF
3 — 52

Venturi Feed Purge Gutter Solvent Solvent

Add Flush

Solvent
Pick-Up
Filter
Main Ink Damper 10µ
Filter
5µ/10µ

Vent Vent

Pump
Pre-Pump
Filter
4800 Service Manual

40µ

INK SOLVENT

Figure 3-34. Flush Shutdown Stage 9: Final Gutter Clearing

 Non-Flush Shutdown Sequence
Initially the Feed valve 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.

Stage 1: Clearing the Nozzle of Ink (figure 3-36)

The system sets the pressure to the Normal Startup value P2 and 5 seconds is allowed to
elapse to allow the pressure to stabilize. The Feed valve is then switched off, the Gutter
valve is switched on for 1 second (1.5 seconds for the 4 metre printhead conduit), and the
pressure is set to the Clear Gutter/Nozzle value P6. This stops the jet and briefly applies
the venturi vacuum to the purge line, through the Gutter valve (on) and Purge valve (off),
drawing the ink back from the nozzle.

Stage 2: Clearing the Gutter Line of Ink (figure 3-37)

The Gutter valve is switched off after 1 second as stated in Stage 1 above. All the valves
now remain in the off state for the “Gutter Off” time of 30 seconds (60 seconds for the 4
metre printhead conduit). The vacuum, now acting on the gutter, draws ink from the
gutter line through the Gutter valve and back to the ink tank.

Stage 3: Clearing the Purge Line of Ink (figure 3-38)

The Gutter valve is switched on again for 2 seconds, which further clears the purge line,
and then switched off.

Stage 4: Final Gutter Clearing (figure 3-39)

All the valves are now in the off state and remain so for an additional period of 30 seconds
which reapplies the vacuum to the gutter, further clearing the gutter line. The pump is
then stopped, reducing the pressure to zero.
The following Non-Flush Shutdown summary table is provided for quick reference.
48028
NON-FLUSH SHUTDOWN
Action Description Micro Midi Macro 70 µm 2m 4m
Pressure Normal Start (P2) 255 255 160 200
Wait Pressure Response 5s 5s 5s 5s
Valve FPGTL
Pressure Clear Gutt/Nozz (P6) 255 255 255 255
Wait Absolute 1s 1s 1s 1s
Valve F P G T L (all off)
Wait Gutter Off ➨ ➨ ➨ ➨ 30 s 60 s
Valve FPGTL
Wait Absolute 2s 2s 2s 2s
Valve F P G T L (all off)
Wait End/Shutdown 30 s 30 s 30 s 30 s
Pressure Zero 0 0 0 0

Figure 3-35. Non-Flush Shutdown summary table

Amdt 01
4800 Service Manual 3 — 53 Feb 98
Feb 98
Amdt 01

Nozzle
Chamber

Purge Line Gutter

Restrictor
Printhead
Gutter Restrictor not used
In-Line on macro printheads
Feed
Pressure Filter
18µ Union 48029
Transducer Fitting
Pressure
connections Transducer
1 = Red/Green T-
2 = Black/Grey 0V
3 = White/Black T+
4 = Red/White +5V
OFF OFF ON OFF OFF
3 — 54

Venturi Feed Purge Gutter Solvent Solvent

Add Flush

Solvent
Pick-Up
Filter
Main Ink Damper 10µ
Filter
5µ/10µ

Vent Vent

Pump
Pre-Pump
Filter
4800 Service Manual

40µ

INK SOLVENT

Figure 3-36. Non-Flush Shutdown Stage 1: Clearing the Nozzle of Ink

4800 Service Manual

Nozzle
Chamber

Purge Line Gutter

Restrictor
Printhead
Gutter Restrictor not used
In-Line on macro printheads
Feed
Pressure Filter
18µ Union 48030
Transducer Fitting
Pressure
connections Transducer
1 = Red/Green T-
2 = Black/Grey 0V
3 = White/Black T+

Linx Printing Technologies plc

4 = Red/White +5V
OFF OFF OFF OFF OFF
3 — 55

Venturi Feed Purge Gutter Solvent Solvent

Add Flush

Solvent
Pick-Up
Filter
Main Ink Damper 10µ
Filter
5µ/10µ

Vent Vent

Pump
Pre-Pump
Filter
40µ

INK SOLVENT
Amdt 02
Aug 98

Figure 3-37. Non-Flush Shutdown Stage 2: Clearing the Gutter Line of Ink
Aug 98
Amdt 02

Nozzle
Chamber

Purge Line Gutter

Restrictor
Printhead
Gutter Restrictor not used
In-Line on macro printheads
Feed
Pressure Filter
18µ Union 48031
Transducer Fitting
Pressure
connections Transducer
1 = Red/Green T-
2 = Black/Grey 0V
3 = White/Black T+

Linx Printing Technologies plc

4 = Red/White +5V
OFF OFF ON OFF OFF
3 — 56

Venturi Feed Purge Gutter Solvent Solvent

Add Flush

Solvent
Pick-Up
Filter
Main Ink Damper 10µ
Filter
5µ/10µ

Vent Vent

Pump
Pre-Pump
Filter
4800 Service Manual

40µ

INK SOLVENT

Figure 3-38. Non-Flush Shutdown Stage 3: Clearing the Purge Line of Ink
4800 Service Manual

Nozzle
Chamber

Purge Line Gutter

Restrictor
Printhead
Gutter Restrictor not used
In-Line on macro printheads
Feed
Pressure Filter
18µ Union
Transducer 48032
Fitting
Pressure
connections Transducer
1 = Red/Green T-
2 = Black/Grey 0V
3 = White/Black T+

Linx Printing Technologies plc

4 = Red/White +5V
OFF OFF OFF OFF OFF
3 — 57

Venturi Feed Purge Gutter Solvent Solvent

Add Flush

Solvent
Pick-Up
Filter
Main Ink Damper 10µ
Filter
5µ/10µ

Vent Vent

Pump
Pre-Pump
Filter
40µ

INK SOLVENT
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Aug 98

Figure 3-39. Non-Flush Shutdown Stage 4: Final Gutter Clearing

 Linx Printing Technologies plc

Fault Shutdown Sequence

Initially the Feed valve will be switched on and the jet will be running, i.e. ink flow in both
the primary and secondary circuits. On detection of a fault the Feed valve is switched off
which stops the jet.

Stage 1: Clearing the Nozzle of Ink (as figure 3-36)

The system sets the pressure to the Normal Startup value P2. After 5 seconds to allow the
pressure to stabilize the Gutter valve is switched on for 1 second and then switched off
again. This briefly allows the vacuum in the venturi to act through the Gutter valve and
Purge valve (off), drawing ink from the nozzle chamber back along the purge line, thereby
removing any residual pressure in the line.

Stage 2: Clearing the Gutter Line of Ink (as figure 3-37)

With all the valves in the off state the pressure is then set to the Clear Gutter/Nozzle value
P6 for 60 seconds. The vacuum, now acting on the gutter, draws ink from the gutter line
through the Gutter valve and back to the ink tank. Finally the pump is stopped, reducing
the pressure to zero.
The following Fault Shutdown summary table is provided for quick reference:
48033
FAULT SHUTDOWN
Action Description Micro Midi Macro 70 µm 2m 4m
Valve F P G T L (all off)
Pressure Normal Start (P2) 255 255 160 200
Wait Pressure Response 5s 5s 5s 5s
Valve FPGTL
Wait Absolute 1s 1s 1s 1s
Valve F P G T L (all off)
Pressure Clear Gutt/Nozz (P6) 255 255 255 255
Wait End/Shutdown 60 s 60 s 60 s 60 s
Pressure Absolute 0 0 0 0

Figure 3-40. Fault Shutdown summary table

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Quick Stop Sequence

The Quick Stop facility is initiated by pressing the STOP key while pressing and holding
the CTRL key. The printer will immediately abort any other jet sequence and perform this
one. This is the quickest method of stopping the jet and should only be used for fault
finding purposes.
Initially the Feed valve will be switched on and the jet will be running, i.e. ink flow in both
the primary and secondary circuits.

Stage 1: Clearing the Nozzle of Ink (as figure 3-36)

The system sets the pressure to the Normal Startup value P2. After 5 seconds to allow the
pressure to stabilize, the Feed valve is switched off and the Gutter valve is switched on for
1 second and then switched off again. This briefly allows the vacuum in the venturi to act
through the Gutter valve and Purge valve (off), drawing ink from the nozzle chamber back
along the purge line, thereby removing any residual pressure in the line.

Stage 2: Clearing the Gutter Line of Ink (as figure 3-37)

With all the valves in the off state the vacuum, now acting on the gutter, draws ink from
the gutter line through the Gutter valve and back to the ink tank. This action lasts for 20
seconds and then the pump is stopped, reducing the pressure to zero.
The following Quick Stop summary table is provided for quick reference:
48034
QUICK STOP
Action Description Micro Midi Macro 70 µm 2m 4m
Pressure Normal Start (P2) 255 255 160 200
Wait Pressure Response 5s 5s 5s 5s
Valve FPGTL
Wait Absolute 1s 1s 1s 1s
Valve F P G T L (all off)
Wait End/Shutdown 20 s 20 s 20 s 20 s
Pressure Absolute 0 0 0 0

Figure 3-41. Quick Stop summary table

3.7.9 Clear Nozzle (Diagnostics Menu) (as figure 3-36)

This procedure can be carried out when there is a suspected blocked or obstructed nozzle.
The Clear Nozzle sequence is initiated from the Diagnostics sub-menu, but the jet must be
stopped before the option can be selected.
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 Clear Gutter/Nozzle value P6 and, after a 5 second
delay for the pressure to stabilize, the Gutter valve is switched on for 15 seconds. This
transfers the 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 to the tank.
This action attempts to clear the blocked nozzle by also sucking air in through the nozzle
aperture. Finally the Gutter valve is switched off and the pump is stopped, reducing the
pressure to zero.
NOTE: The Clear Nozzle sequence should be performed a minimum of three times
followed by an attempt to start the jet. This routine should then be repeated a
maximum of 10 times in an attempt to clear the nozzle (i.e. a total of 30 Clear
Nozzle sequences). Refer to “The Diagnostics Menu” in Section 5:
“Maintenance” for more information.

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3.7.10 Nozzle Flush (Diagnostics Menu)

Like the Clear Nozzle option, this option can also be used when there is a suspected
blocked or obstructed nozzle. 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.
The Nozzle Flush sequence is initiated from the Diagnostics sub-menu, but the jet must be
stopped before the option can be selected.
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 following Nozzle Flush
summary table is provided for quick reference:

48196
NOZZLE FLUSH
Action Description Micro Midi Macro 70 µm 2m 4m
Pressure Normal Start (P2) 255 255 160 200
Valve FPGTL
Wait Pressure Response ➨ ➨ ➨ ➨ 12 s 24 s
Valve F P G T L (all off)
Pressure Flush Start (P5) 150 150 80 150
Wait Pressure Response 5s 5s 5s 5s
Valve FPGTL
Wait Pressure Response ➨ ➨ ➨ ➨ 5s 10 s
Valve F P G T L (all off)
Wait Press. Response x 2 10 s 10 s 10 s 10 s
Valve FPGTL
Wait Absolute ➨ ➨ ➨ ➨ 3s 6s
Valve F P G T L (all off)
Pressure Clear Gutt/Nozz (P6) 255 255 255 255
Wait Pressure Response 5s 5s 5s 5s
Valve FPGTL
Wait Absolute ➨ ➨ ➨ ➨ 45 s 90 s
Valve FPGTL
Wait Absolute ➨ ➨ ➨ ➨ 20 s 40 s
Valve F P G T L (all off)
Wait End/Shutdown 30 s 30 s 30 s 30 s
Pressure Absolute 0 0 0 0

Figure 3-42. Nozzle Flush summary table

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INK TYPE DEPENDENT PARAMETERS

4800 Series — Versions 1.0 and 1.1 Software
48035

Ink Type

P/head MEK Pigment Ethanol 3XXX

Normal running Solvent Add Time (sec) Micro 12 12 6 12
Midi 62 & 70 µm 9 9 5 9
Macro 15 15 8 15
Max. no. of consecutive Solvent Adds — 8 8 25 25
1st Solvent Add if Set Pressure > 3 points Micro 12 12 35 0
above normal Solvent Add Pressure (sec) Midi 62 & 70 µm 9 9 35 0
(1) Macro 15 15 35 0
1st Solvent Add if Set Pressure > 7 points Micro 12 12 47 12
above normal Solvent Add Pressure (sec) Midi 62 & 70 µm 9 9 47 9
(2) Macro 15 15 47 15
1st Solvent Add if Set Pressure > 11 points Micro 12 12 59 12
above normal Solvent Add Pressure (sec) Midi 62 & 70 µm 9 9 59 9
(3) Macro 15 15 59 15
Purge after 1st Solvent Add — No No Yes Yes
Warm-up time (min) — 45 45 60 45
Default Flush Shutdown mode — Auto Auto Auto Auto
Delay after Nozzle Clear on startup (sec) — 0 60 0 0
TOF control range — ± 0.5% ± 0.5% ± 0.5% ± 0.5%
Consecutive TOFs for pressure — 2 2 2 2
adjustments (startup)
Consecutive TOFs for pressure — 5 5 5 5
adjustments (normal running)

Figure 3-43. Ink Type Dependent Parameters table

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3.8 Electronics and Software

The main electronics system in the 4800 printer is contained on one printed circuit board
(PCB), known as the Integrated Processor Module (IPM) PCB, which is mounted
horizontally in the front of the cabinet base unit. The Keyboard and Display Assembly in
the printer cabinet top cover contains a PCB, and there is also a Photocell PCB mounted on
the inside of the rear wall of the base unit on the left-hand side.
The functions of the circuit boards are briefly described as follows:
IPM PCB: Contains the main Z80 Central Processing Unit which
controls printer operation. Also contains the GALs and
amplifiers for processing the CPU controls.
Display PCB: Processes the input from the keyboard, and provides
control of the liquid crystal display (LCD) screen.
Photocell PCB Selects the types and modes of operation of the various
photocells and shaft encoders that can be used It also
drives the external alarm output, and provides RS–232
and RS–485 connections.

3.8.1 Circuit Diagrams

Circuit diagrams of the 4800 electronic and electrical functions are provided at the end of
this section. Engineers involved in fault diagnosis at PCB level should ensure that they use
the appropriate issue of circuit diagrams for the configuration of the machine.

3.8.2 IPM PCB

Test Points and Links
Test points and links are provided to aid fault diagnosis. Links are also used to enable or
disable various printer functions and certain of the links must be fitted in order for the
printer to operate correctly.
Lists of the IPM PCB test points and links follow with details of their functions.
To make the test points and links easier to find on the IPM PCB, the board edge is marked
out with a grid. Against each of the test points and links in the following lists is a grid
reference which can be used to locate it on the IPM PCB.

Test Points
TP1 (A7) MOD. Modulation amplifier output. A sine wave should be observed
with a frequency dependent on the type of printhead fitted: 26.6 kHz
(Macro), 80 kHz (Midi 62 µm), 60 kHz (Midi 70 µm) or 120 kHz (Micro).
The signal should be a.c. coupled with the peaks of the sine wave going
positive and negative with respect to 0 V.
TP2 (D10) EHT DRIVE. In the region of 0 volts to 10 volts, depending on the print
height setting. To measure this voltage make sure that the printhead cover
is fitted (or LK6 Cover Override is fitted) and that the machine is printing.
TP3 (B1) PHASE A. Amplified signal from the phase detector. There should be less
than 1 V peak-to-peak noise during quiescent (non-printing) conditions.
The signal produced by the series of phase drops should exceed 4 V with
respect to 0 V. When printing, this signal will look erratic as the amplifier
is driven firmly into saturation.

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TP4 (B1) PHASE D. Digital representation of the phase signal. The quiescent (non-
printing) state for the signal is +11 V. When the phase signal is detected
(voltage at TP3 exceeds 4 V) the signal switches to –15 V. When phasing,
two negative going pulses separated by a few milliseconds should be
observed.
TP5 (D10) RD PRESS. Read Pressure value. This is the amplified output of the
pressure transducer and is a voltage representation of the pressure in the
ink manifold. During normal operation, with link LK1 fitted, the voltages
measured at TP5 and TP6 should be identical within a few millivolts.
However, the Read Pressure and Set Pressure values observed in the
MONITOR JET screen of the Diagnostics menu are approximate values
and are almost never the same due to cumulative errors in the system.
TP6 (C10) SET PRESS. This is the set pressure value and has a range of 0 – 10 V d.c.
It represents the pressure set by the electronics to maintain the required
ink flow. During normal operation, with LK1 fitted, the voltages
measured at TP5 and TP6 should be identical within a few millivolts.
TP7 (D7) 5VREF. The voltage at this test point should be +5 V ±25 mV. Indirectly,
this also tests the 10 V master reference.
TP9 (A6) CHG. Charge amplifier output which is applied to the charge electrode.
The typical output range is 0 V to 255 V and can be observed on an
oscilloscope. Useful for observing the pattern being printed and phasing
pulses.
TP10 (C6) CHARGE CLOCK. The frequency of this clock is dependent on the type of
printhead fitted, and is very useful for checking the presence of the clock
and whether it corresponds to the actual printhead fitted:
Macro 26.6 kHz;
Midi 80 kHz;
Micro 120 kHz.
TP13 (E10) 0VL. Zero volts (Logic).
TP15 (D6) 0VL. Zero volts (Logic).
TP17 (A8) 300V. This is the regulated supply for the modulation and charge
amplifiers and has a tolerance of ±15 V. The supply can be isolated from
the amplifiers by removing links LK1 and LK2 respectively. This can be
useful in determining which amplifier or cable assembly is at fault when a
“2.04 300V Power Supply” fault is reported.
TP21 (A5) 0VL. Zero volts (Logic).
TP28 (D2) NEXT OBJ. Next object input. This is the primary photocell signal after it
has been through the edge-selection and opto-isolating circuits. It is a 0 V
to 5 V digital CMOS signal, with the falling or rising edge indicating the
presence of the object, depending on the position of link LK11.
TP32 (B3) SHFT ENC. Single ended shaft encoder input. This is the shaft encoder
signal after it has been through the edge-selection and opto-isolating
circuits, and is a 0 V to 5 V digital CMOS signal.
TP35 (B1) 0VL. Zero volts (Logic).
TP40 (A9) +5V. A convenient point to test for the presence of the supply on the +5
volt rail.
TP44 (A9) 0VL. Zero volts (Logic).
TP49 (D5) AUX IN. Auxiliary photocell input. This is the opto-isolated auxiliary
photocell signal, and is a 0 V to 5 V digital CMOS signal.

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Links
LK1 (D10) 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. Due to the non-linearities in the control loop, the
scaling factors for the Set Pressure commands in Diagnostics do not apply
when the link is removed. The Read Pressure command is unaffected.
This link should normally be fitted.
LK2 (B3) BAT. This link connects the NiCad battery to the message store so that
data is retained when the printer is switched off. Removing this link will
delete all messages and datasets from the message store. In addition
various other parameters will be reset to their default values, for example:
Printhead Code, Ref Modulation, Conduit Length, Ink Type, Head Height,
etc. These will all need to be re-entered.
LK3 (C2) RESET. Fitting this link will cause the microprocessor to reset.
LK4 (E5) SAFETY OVERRIDE. This link overrides the EHT sense, temperature
sense and printhead cover sense safety circuits. It may be fitted with
caution to aid fault diagnosis. See also error message “3.11 Safety
Override Detected”.
WARNING: TO ENSURE SAFE OPERATION LK4 MUST NOT BE
FITTED PERMANENTLY AND THE PRINTER MUST NOT BE LEFT
UNATTENDED WHILE THE LINK IS FITTED.
LK5 (A5) 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.
LK6 (A3) CVR OVERRIDE. This link simulates the printhead cover being fitted.
When fitted, it allows the EHT to remain on while the printhead cover is
removed (i.e. it is not automatically disabled) for fault diagnosis purposes.
See also error message “3.07 Print Head Cover Off”.
WARNING: TO ENSURE SAFE OPERATION LK6 MUST NOT BE
FITTED PERMANENTLY AND THE PRINTER MUST NOT BE LEFT
UNATTENDED WHILE THE LINK IS FITTED.
LK7 (A4) Links LK7D and LK7E are software links and as such should not be moved
or interfered with.
LK8 (A8) 300VM. Connects the 300 volts stabilized supply to the modulation
amplifier.
LK9 (B6) 300VC. Connects the 300 volts 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 (C1) Links LK10A, LK10B and LK10C are software links and as such should not
be moved or interfered with.
LK11 (D2) EDGE SELECT. The position of this link determines which edge of the
primary photocell signal (the falling or rising edge) will indicate the
presence of the object to be printed on.

Replacement and Calibration

If the IPM PCB is replaced, or if the software is exchanged or upgraded, the electronics
system will require recalibrating. Also, the NVR will have been reinitialized causing the
printer configuration settings to be reset to the default values. Therefore, the original
settings will need to be re-entered.
If recalibration is required, refer to the “IPM PCB Calibration” Maintenance Instruction in
Section: 5 “Maintenance”.

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3.8.3 Display PCB

The user interface consists of a full “qwerty” membrane keypad (see figure 3-7), a back lit
LCD display and a Display PCB.
The Display PCB is fitted to the rear of the LCD display and the combined assembly is
fitted inside the printer top cover.

Test Points
There are two test points on the Display PCB:
TP1 0 V.
TP2 5 V.

3.8.4 Photocell PCB

Test Points
TP1 PCELL. This is the opto-isolated digital signal from the primary photocell.
It is a 0 V to 5 V CMOS signal, with the falling or rising edge indicating the
presence of the object, depending on the position of link LK11 on the IPM
PCB.
TP2 SHFT ENC. This is the opto-isolated digital signal from the single ended
shaft encoder, and is a 0 V to 5 V CMOS signal.
TP3 0VL. Zero volts (Logic).
TP7 AUX. This is the opto-isolated digital signal from the auxiliary photocell,
and is a 0 V to 5 V CMOS signal. There will only be a signal at this test
point if an auxiliary photocell interface is fitted as a special option.

Links
LK1 RELAY. This is the alarm relay output mode selector. The relay contacts
can be selected for normally open (NO) or normally closed (NC) operation.
The standard factory setting is (NC).
LK2 PRINT READY. This signal is asserted by the CPU; 5 V signifies that the
printer is ready to print, and 0 V disables printing—perhaps due to a fault
condition. If link LK2 is fitted then the print ready opto signal can be used
to disable the photocell input. This is particularly useful if several printers
are connected together to print on the same production line. If any one of
the printers fails, then all the printers will be disabled.
LK3 NPN/PNP PCELL. This link is used to select the circuitry to accept either
a NPN or PNP type of primary photocell.
LK4 DELAY PCELL. When this link is fitted, 30 ms of debounce is available
which filters out multiple primary photocell edges to give one genuine
pulse. This is of particular use if a relay contact is used as a trigger source.
LK5 5V/24V S/E. This link is used to select the appropriate line driver for the
shaft encoder, either 5 V (pins 1 and 2) or 24 V (pins 2 and 3). For an open
collector device the position of link LK5 is irrelevant.
LK6 NPN/PNP AUX. This link is used to select the circuitry to accept either a
NPN or PNP type of auxiliary photocell.
LK7 DELAY AUX. When this link is fitted, 30 ms of debounce is available
which filters out multiple auxiliary photocell edges to give one genuine
pulse. This is of particular use if a relay contact is used as a trigger source.

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3.8.5 Software
The following information identifies and details the current Standard Software Sets and
Configuration Software Sets for v1.1 of the 4800 printer.

Standard Software Sets

Standard Software Sets are language dependent, therefore, there is a set for each language
available. All sets contain English menu strings plus one other language.
All Standard Sets can be fitted to any issue of the 4800 IPM PCB.

PART NO. DESCRIPTION DATE OF ISSUE

S-4-8-001-02 “German Std Set v1.1” 01/06/98

A-4-8-000-02 “Program – German v1.1 IC31 256K” 01/06/98

S-4-8-002-02 “French Std Set v1.1” 01/06/98

A-4-8-001-02 “Program – French v1.1 IC31 256K” 01/06/98

S-4-8-003-02 “Spanish Std Set v1.1” 01/06/98

A-4-8-002-02 “Program – Spanish v1.1 IC31 256K” 01/06/98

S-4-8-004-02 “Dutch Std Set v1.1” 01/06/98

A-4-8-003-02 “Program – Dutch v1.1 IC31 256K” 01/06/98

S-4-8-005-02 “Italian Std Set v1.1” 01/06/98

A-4-8-004-02 “Program – Italian v1.1 IC31 256K” 01/06/98

S-4-8-006-02 “Japanese Std Set v1.1” 01/06/98

A-4-8-005-02 “Program – Japanese v1.1 IC31 256K” 01/06/98

S-4-8-007-02 “Portuguese Std Set v1.1” 01/06/98

A-4-8-006-02 “Program – Portuguese v1.1 IC31 256K” 01/06/98

S-4-8-008-02 “Norwegian Std Set v1.1” 01/06/98

A-4-8-007-02 “Program – Norwegian v1.1 IC31 256K” 01/06/98

S-4-8-009-02 “Polish Std Set v1.1” 01/06/98

A-4-8-008-02 “Program – Polish v1.1 IC31 256K” 01/06/98

S-4-8-010-02 “Indonesian Std Set v1.1” 01/06/98

A-4-8-009-02 “Program – Indonesian v1.1 IC31 256K” 01/06/98

S-4-8-011-02 “US Std Set v1.1” 01/06/98

A-4-8-010-02 “Program – US v1.1 IC31 256K” 01/06/98

S-4-8-012-00 “Hungarian Std Set v1.1” 01/06/98

A-4-8-011-00 “Program – Hungarian v1.1 IC31 256K” 01/06/98

S-4-8-013-00 “Swedish Std Set v1.1” 01/06/98

A-4-8-012-00 “Program – Swedish v1.1 IC31 256K” 01/06/98

S-4-8-014-00 “Croatian Std Set v1.1” 01/06/98

A-4-8-013-00 “Program – Croatian v1.1 IC31 256K” 01/06/98

S-4-8-015-00 “Greek Std Set v1.1” 01/06/98

A-4-8-014-00 “Program – Greek v1.1 IC31 256K” 01/06/98

S-4-8-016-00 “Danish Std Set v1.1” 01/06/98

A-4-8-015-00 “Program – Danish v1.1 IC31 256K” 01/06/98

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Configuration Software Sets

Configuration Sets determine the raster configurations for each printhead type. The
Standard Configuration GAL (IC88) is supplied with each set to enable the correct rasters.
If a software option is required, the Standard Configuration GAL should be replaced with
the correct GAL that enables the option, but also enables the same rasters as the Standard
device (see “Software Options”).
NOTE: The XT Configuration Set contains only the Configuration GAL. The raster
devices are soldered to the IPM PCB and are part of the 4800 XT Decode Set.

PART NO. DESCRIPTION DATE OF ISSUE

S-4-8-040-01 “OP Micro Std Set v2.0” 01/06/98

A-4-8-160-01 “Cfg OP v2.0 IC88 16V8” 01/06/98
A-4-8-060-00 “OP Micro Charge v1.0 IC94 8K” 01/09/97
A-4-8-061-00 “OP Micro PDrop v1.0 IC111 22V10” 01/09/97
A-4-8-062-00 “OP Micro TDrop v1.0 IC108 22V10” 01/09/97

S-4-8-041-01 “OP Midi 62µ Std Set v2.0” 01/06/98

A-4-8-160-01 “Cfg OP v2.0 IC88 16V8” 01/06/98
A-4-8-063-00 “OP Midi 62µ Charge v1.0 IC94 8K” 01/09/97
A-4-8-065-00 “OP Midi PDrop v1.0 IC111 22V10” 01/09/97
A-4-8-066-00 “OP Midi TDrop v1.0 IC108 22V10” 01/09/97

S-4-8-042-01 “OP Midi 70µ Std Set v2.0” 01/06/98

A-4-8-160-01 “Cfg OP v2.0 IC88 16V8” 01/06/98
A-4-8-064-00 “OP Midi 70µ Charge v1.0 IC94 8K” 01/09/97
A-4-8-065-00 “OP Midi PDrop v1.0 IC111 22V10” 01/09/97
A-4-8-066-00 “OP Midi TDrop v1.0 IC108 22V10” 01/09/97

S-4-8-043-01 “OP Macro Std Set v2.0” 01/06/98

A-4-8-160-01 “Cfg OP v2.0 IC88 16V8” 01/06/98
A-4-8-067-00 “OP Macro Charge v1.0 IC94 8K” 01/09/97
A-4-8-068-00 “OP Macro PDrop v1.0 IC111 22V10” 01/09/97
A-4-8-069-00 “OP Macro TDrop v1.0 IC108 22V10” 01/09/97

S-4-8-044-01 “OP (Jap) Midi 62µ Std Set v2.0” 01/06/98

A-4-8-163-01 “Cfg OP (Jap) v2.0 IC88 16V8” 01/06/98
A-4-8-070-00 “OP (Jap) Midi 62µ Charge v1.0 IC94 8K” 01/09/97
A-4-8-073-00 “OP (Jap) Midi PDrop v1.0 IC111 22V10” 01/09/97
A-4-8-074-00 “OP (Jap) Midi TDrop v1.0 IC108 22V10” 01/09/97

S-4-8-045-01 “OP (Jap) Midi 70µ Std Set v2.0” 01/06/98

A-4-8-163-01 “Cfg OP (Jap) v2.0 IC88 16V8” 01/06/98
A-4-8-072-00 “OP (Jap) Midi 70µ Charge v1.0 IC94 8K” 01/09/97
A-4-8-073-00 “OP (Jap) Midi PDrop v1.0 IC111 22V10” 01/09/97
A-4-8-074-00 “OP (Jap) Midi TDrop v1.0 IC108 22V10” 01/09/97

S-4-8-046-01 “HS Midi 62µ Std Set v2.0” 01/06/98

A-4-8-166-01 “Cfg HS v2.0 IC88 16V8” 01/06/98
A-4-8-075-00 “HS Midi 62µ Charge v1.0 IC94 8K” 01/09/97
A-4-8-077-00 “HS Midi PDrop v1.0 IC111 22V10” 01/09/97
A-4-8-078-00 “HS Midi TDrop v1.0 IC108 22V10” 01/09/97

S-4-8-047-01 “HS Midi 70µ Std Set v2.0” 01/06/98

A-4-8-166-01 “Cfg HS v2.0 IC88 16V8” 01/06/98
A-4-8-076-00 “HS Midi 70µ Charge v1.0 IC94 8K” 01/09/97
A-4-8-077-00 “HS Midi PDrop v1.0 IC111 22V10” 01/09/97
A-4-8-078-00 “HS Midi TDrop v1.0 IC108 22V10” 01/09/97

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S-4-8-050-00 “SH Midi 62µ Std Set v2.0” 01/06/98

A-4-8-175-00 “Cfg SH v2.0 IC88 16V8” 01/06/98
A-4-8-087-00 “SH Midi 62µ Charge v2.0 IC94 8K” 01/06/98
A-4-8-089-00 “SH Midi PDrop v2.0 IC111 22V10” 01/06/98
A-4-8-090-00 “SH Midi TDrop v2.0 IC108 22V10” 01/06/98

S-4-8-051-00 “SH Midi 70µ Std Set v2.0” 01/06/98

A-4-8-175-00 “Cfg SH v2.0 IC88 16V8” 01/06/98
A-4-8-088-00 “SH Midi 70µ Charge v2.0 IC94 8K” 01/06/98
A-4-8-089-00 “SH Midi PDrop v2.0 IC111 22V10” 01/06/98
A-4-8-090-00 “SH Midi TDrop v2.0 IC108 22V10” 01/06/98

S-4-8-052-00 “XT Midi Std Set v1.0” 01/06/98

A-4-8-172-00 “Cfg XT v2.0 IC88 16V8” 01/06/98

Software Options
To enable a particular Raster Configuration and Software Option (or options) the
appropriate Configuration Gal should be fitted.
The abbreviations used in the descriptions of the Software Options below are explained in
the following key. Each 4800 printer model has two paired rasters and these are also
shown in the key:
Cfg = Configuration
OP = Optima (7 GEN STD and 16 GEN STD)
OP (Jap) = Optima (Japanese) (7 HI QUALITY or 7 GEN STD, and 16 GEN STD)
HS = High Speed (7 HI SPEED and 16 N HI SPEED)
SH = Super High Speed (7 HI SPEED and 16 S HI SPEED)
XT = Xtra (5 S HI SPEED and 7 HI SPEED)
D1 = DDE 1
D2 = DDE 2
NOTE: All configurations enable RS–232, RS–485 and the 5 message store.

PART NO. DESCRIPTION/OPTIONS ENABLED DATE OF ISSUE

A-4-8-160-01 “Cfg OP v2.0 IC88 16V8” 01/06/98

“Cfg OP v2.0 IC88 16V8” 01/06/98
“GAL16V8A-15LNC”

A-4-8-161-01 “Cfg OP D1 v2.0 IC88 16V8” 01/06/98

“Cfg OP D1 v2.0 IC88 16V8” 01/06/98
“GAL16V8A-15LNC”

A-4-8-162-01 “Cfg OP D2 v2.0 IC88 16V8” 01/06/98

“Cfg OP D2 v2.0 IC88 16V8” 01/06/98
“GAL16V8A-15LNC”

A-4-8-163-01 “Cfg OP (Jap) v2.0 IC88 16V8” 01/06/98

“Cfg OP (Jap) v2.0 IC88 16V8” 01/06/98
“GAL16V8A-15LNC”

A-4-8-164-01 “Cfg OP (Jap) D1 v2.0 IC88 16V8” 01/06/98

“Cfg OP (Jap) D1 v2.0 IC88 16V8” 01/06/98
“GAL16V8A-15LNC”

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A-4-8-165-01 “Cfg OP (Jap) D2 v2.0 IC88 16V8” 01/06/98

“Cfg OP (Jap) D2 v2.0 IC88 16V8” 01/06/98
“GAL16V8A-15LNC”

A-4-8-166-01 “Cfg HS v2.0 IC88 16V8” 01/06/98

“Cfg HS v2.0 IC88 16V8” 01/06/98
“GAL16V8A-15LNC”

A-4-8-167-01 “Cfg HS D1 v2.0 IC88 16V8” 01/06/98

“Cfg HS D1 v2.0 IC88 16V8” 01/06/98
“GAL16V8A-15LNC”

A-4-8-168-01 “Cfg HS D2 v2.0 IC88 16V8” 01/06/98

“Cfg HS D2 v2.0 IC88 16V8” 01/06/98
“GAL16V8A-15LNC”

A-4-8-172-00 “Cfg XT v2.0 IC88 16V8” 01/06/98

“Cfg XT v2.0 IC88 16V8” 01/06/98
“GAL16V8A-15LNC”

A-4-8-173-00 “Cfg XT D1 v2.0 IC88 16V8” 01/06/98

“Cfg XT D1 v2.0 IC88 16V8” 01/06/98
“GAL16V8A-15LNC”

A-4-8-174-00 “Cfg XT D2 v2.0 IC88 16V8” 01/06/98

“Cfg XT D2 v2.0 IC88 16V8” 01/06/98
“GAL16V8A-15LNC”

A-4-8-175-00 “Cfg SH v2.0 IC88 16V8” 01/06/98

“Cfg SH v2.0 IC88 16V8” 01/06/98
“GAL16V8A-15LNC”

A-4-8-176-00 “Cfg SH D1 v2.0 IC88 16V8” 01/06/98

“Cfg SH D1 v2.0 IC88 16V8” 01/06/98
“GAL16V8A-15LNC”

A-4-8-177-00 “Cfg SH D2 v2.0 IC88 16V8” 01/06/98

“Cfg SH D2 v2.0 IC88 16V8” 01/06/98
“GAL16V8A-15LNC”

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3.9 External Signals

The following external signal information contains descriptions of Primary Photocells,
Auxiliary Photocells, Shaft Encoders, the Alarm Output, the Print Ready Signal, and the
RS–232 and RS–485 Interfaces.

3.9.1 Primary Photocell

The primary photocell is connected to either PL2 or PL3 on the Photocell PCB – these two
connectors being located on the printer rear panel. The two connectors are wired in
parallel so either may be used for a primary photocell. The photocell is used to detect the
presence of the product on the production line, as it approaches the printhead, and supply
a “next object” signal to the printer firmware. This initiates a print delay, after which a
message will be printed. Hence, by correctly positioning the photocell and programming a
suitable delay, the position of the message on the product (print registration) can be
controlled.
The photocell itself should be an open collector device, of either NPN or PNP type, capable
of using a 24 volt supply. The choice of photocell type is determined by fitting link LK3, on
the Photocell PCB, in one of two positions (NPN or PNP).
If “next object” triggers are being generated on the wrong edge of the photocell input
signal this can be altered by changing the position of link LK11 on the IPM PCB.
By fitting link LK4 on the Photocell PCB, up to 50 ms of debounce is available which filters
out multiple primary photocell edges to give one genuine pulse.
Typical configurations for NPN and PNP primary photocells are shown in the following
two figures:

48152
PRINTER PHOTOCELL PCB PL2/PL3
NPN PHOTOCELL
24VF 1

R3
330R 2
R1/R2 1 3 6 NEXT OBJ
TR1
2 x 2k4 LK3

R4/R5/R6/R7
4 x 510R
INTERNAL
IC3
SIGNAL
2V7
0VF 2

Figure 3-44. Primary Photocell – NPN Configuration

48153
PRINTER PHOTOCELL PCB PL2/PL3
PNP PHOTOCELL
24VF 1

R3
330R 2
R1/R2 1 3 6 NEXT OBJ
TR1
2 x 2k4 LK3

R4/R5/R6/R7
4 x 510R
INTERNAL
IC3
SIGNAL
2V7
0VF 2

Figure 3-45. Primary Photocell – PNP Configuration

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3.9.2 Auxiliary Photocell

The auxiliary photocell may be used in future software releases to increment or reset
sequential numbers or messages, or to change from printing one message to another. It is
connected to either PL2 or PL3 on the Photocell PCB – these two connectors being located
on the printer rear panel. The two connectors are wired in parallel so either may be used
for an auxiliary photocell. The hardware input circuit is separate from, but identical to,
that of the primary photocell.
For the auxiliary photocell, the choice of photocell type is determined by fitting link LK6,
on the Photocell PCB, in one of two positions (NPN or PNP).
By fitting link LK7 on the Photocell PCB, up to 50 ms of debounce is available which filters
out multiple auxiliary photocell edges to give one genuine pulse.
Typical configurations for NPN and PNP auxiliary photocells are shown in the following
two figures:

48154
PRINTER PHOTOCELL PCB PL2/PL3
NPN AUXILIARY PHOTOCELL
24VF 1

R29
330R 2
R27/R28 1 3 4 AUX IN
TR4
2 x 2k4 LK6

R23/R24/R25/R26
4 x 510R
INTERNAL
IC4
SIGNAL
2V7
0VF 2

Figure 3-46. Auxiliary Photocell – NPN Configuration

48155
PRINTER PHOTOCELL PCB PL2/PL3
PNP AUXILIARY PHOTOCELL
24VF 1

R29
330R 2
R27/R28 1 3 4 AUX IN
TR4
2 x 2k4 LK6

R23/R24/R25/R26
4 x 510R
INTERNAL
IC4
SIGNAL
2V7
0VF 2

Figure 3-47. Auxiliary Photocell – PNP Configuration

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3.9.3 Shaft Encoders

Either a 5 V or a 24 V single ended shaft encoder can be used. The input circuit of the
single ended shaft encoder has a frequency response of 60 kHz.
The shaft encoder is connected to either PL2 or PL3 on the Photocell PCB – these two
connectors being located on the printer rear panel. The two connectors are IP67 rated, D-
type and are wired in parallel so either may be used for a shaft encoder. The shaft encoder
line driver selection is determined by fitting link LK5, on the Photocell PCB, in one of two
positions. Pins 1 and 2 are linked for a 5 V shaft encoder and pins 2 and 3 are linked for a
24 V shaft encoder. The position of link LK5 is irrelevant when using an open collector
type of shaft encoder.
Regardless of the power setting, the shaft encoder must be capable of sinking 15 mA.
The following figure shows typical input connections for both a 5 V and a 24 V single
ended shaft encoder:

48156
PRINTER PHOTOCELL PCB PL2/PL3
5V OR 24V SINGLE ENDED
5VF 3 SHAFT ENCODER

24VF 1

R15 R17/R18/R19/R20
330R 4 x 510R 8 SE INPUT

2
LK5
1 3

NOTE:
INTERNAL WIRING AND LINK
IC1
SIGNAL SHOWN FOR A 5 V
SHAFT ENCODER
0VF 2

Figure 3-48. 5 V and 24 V Single Ended Shaft Encoder Inputs

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3.9.4 Alarm Output

WARNING. LETHAL VOLTAGE. IF A MAINS POWERED EXTERNAL ALARM IS

CONNECTED TO THE PRINTER THERE MAY BE MAINS VOLTAGE 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 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 output is taken from connector PL5 on the printer rear panel and is
protected by a 1 A, glass, slow-blow fuse. The relay contacts can be either volt-free for
control of a mains operated external alarm or used to control an internally generated 24
volts for a 24 volt external alarm. Mains alarm operation is the configuration that the
printer is shipped in, however, a 24 volt external alarm is available as an option.
The alarm output mode can be selected for either “normally open” (NO) or “normally
closed” (NC) relay contact operation. This is determined by fitting link LK1, on the
Photocell PCB, in one of two positions. Pins 1 and 2 are linked for NC operation and pins 2
and 3 are linked for NO operation. The normal (factory set) operation is for NC contacts.
In the NC condition, when power is applied to the printer the relay is energized causing
the relay contacts to open and therefore the external alarm is not activated. When a printer
warning or failure is detected the alarm relay is de-energized and the relay contacts close
causing the external alarm to activate.
With the NO relay contacts condition the operation is in the opposite sense. When power
is applied to the printer the relay is energized causing the relay contacts to close but the
external alarm is not activated. When a printer warning or failure is detected the alarm
relay is de-energized and the relay contacts open causing the external alarm to activate.

3.9.5 Print Ready Signal

The “print ready” signal is both an input and an output. When used as an input to the
printer it can be externally pulled low to prevent a signal from the primary photocell from
generating an internal “next object” signal. When used as an output from the printer, the
printer itself can force this line low when it is not ready to print for any reason, e.g. the jet
is not running, no message is selected, a fault condition exists.
It is intended to be used where more than one printer is being used on the same line. The
print ready signals are connected together so that printing is effectively disabled until all
the printers are ready. Alternatively, any external controller can suspend printing by
pulling this line low. Note that the print ready signal cannot be used to monitor the ready
state, since its level when active cannot be guaranteed.
Removing LK2 on the Photocell PCB will prevent the printer itself from pulling the line
low, but will still allow an external controller to disable next object signals.
NOTE: “Print in continuous mode” printing will continue even if the print ready
signal is pulled low, because continuous printing does not rely on photocell
triggers to initiate a print.

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3.9.6 RS–232 and RS–485 Interfaces

The 4800 printer has a Remote Interface which is a means of controlling all the printer
functions from a serial port rather than using the local keyboard and display. The printer
is a ‘slave’ that receives commands from a remote host and sends back status information
and data as requested.
The protocol used for the serial communications is defined by Linx and is available in both
RS–232 and RS–485 variants. Printers are able to use RS–232 as standard which gives point
to point communications. RS–485 is available as an option and allows networks of up to
248 printers to be driven from one host serial port.

References
The Remote Setup Menu for the RS–232 and RS–485 interfaces is described in Section 4:
“The Setup Menu”. Further information about RS–232 and RS–485 data set formats and
protocols is available in the Remote Interface Specification.

Cable Connections
Connection for the RS–232 and RS–485 interfaces is via PL4 on the printer rear panel, and is
a 9-way, D-type connector with numeric pin-out designations. Pin connections for the RS–
232 interface cable are specified in the following illustration:

COMPUTER 48202 PRINTER

PL4

TxD TxD 3
3
RxD RxD 2
2
RTS RTS 7
7
DCD DCD 1
1
DSR DSR 6
6
DTR DTR 4
4
CTS CTS 8
8
Gnd Gnd 5
5
9 9 (not connected)

NOTE: The D-type connectors are to be marked 'COMPUTER' and 'PRINTER'

to ensure correct fitting orientation of the cable assembly.

Figure 3-49. RS–232 Interface Cable Pin Connections

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3.9.7 D-type Connector Assembly

Correct assembly of the D-type connector, used for Photocell, Shaft Encoder, RS–232 and
RS–485 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 RS–232 and RS–485 cables Item 9 is a female connector.

2. Test all cable connections for continuity and short circuits before use.

Figure 3-50. Correct Assembly of the ‘Wet’ D-type Connector

3.10 Drawing List

DRAWING TITLE DRAWING NO. SHEET NO.
4800 SYSTEM DIAGRAM CD13005/1 Sheet 1 of 1
4800 IPM CIRCUIT SCHEMATIC: ROOT SHEET AS13333/1 Sheet 1 of 4
4800 IPM CIRCUIT SCHEMATIC: CPU AS13333/1 Sheet 2 of 4
4800 IPM CIRCUIT SCHEMATIC: DROP 2 AS13333/1 Sheet 3 of 4
4800 IPM CIRCUIT SCHEMATIC: DROP 1 AS13333/1 Sheet 4 of 4
4800 PHOTOCELL PCB AS13336/4 Sheet 1 of 1
4800 DISPLAY PCB AS13337/2 Sheet 1 of 1
4800 RS–485 PCB AS16031/1 Sheet 1 of 1

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SECTION 4: THE SETUP MENU

4.1 Introduction
This section explains the options that are available on the Linx 4800 printer’s SETUP menu.
The detailed information given in this chapter refers to printers fitted with Version 1.1
software unless otherwise stated.
Refer to the 4800 Ink Jet Printer User Manual for details of message editing and other
functions available from the 4800 message display.

4.2 The Current Message Screen

This 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 will be shown in the message area of the display:

48037

CURRENT MESSAGE : MESSAGE 1

F1 : Change Message F2 : Check Status

F3 : New Message F4 : Change Setup

Figure 4-1. Current Message screen

Pressing the function key [F4] will select the SETUP menu, provided that the Password
option in the SETUP menu has previously been set to Off (see below).

4.3 Password Access

The PASSWORD screen is displayed after the CURRENT MESSAGE screen and before the
SETUP menu, if the Password option in the SETUP menu has been set to On. This is to
ensure that only personnel who know the current password are able to enter the SETUP
menu, and thereby switch the Password option off, 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.

48040

PASSWORD
Enter Password > _

Figure 4-2. Password screen

Three levels of password are used: User Level 1, User Level 2 and Service Level. The
relevant 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.

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The last page of this section contains the passwords. The page can be removed and filed in
a safe place or the passwords can be written in below:
User Level 1 “- - - - - - - -”
User Level 2 “- - - - - - - -”
Service Level “- - - - - - - -”
To enter the SETUP menu press [F4], type in the password and press [enter]. Note that
passwords are not sensitive to upper or lower case letters, so entering “ABC”, “abc” or
“Abc” will have the same effect.

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:

48041

SETUP
> Password : Off
Print Height : Normal
Normalise Height
Print Width : 0

Print Delay : 16
Print Count : 9
Reverse Message : Off
Bold Ratio : 2
Set Time : 10:16
Set Date : 16:07:97
Julian Date Format : European
Photocell : Triggered
Shaft Encoder : Off
Conduit Length : 2m
Head Height : 0.5m
Print Head Code : 11850010001962
Ref Modulation : 150
Ink Selection : MEK
Calibrate Print Head
Alarm
Change Password
Change Language
Remote Setup Menu
Diagnostic Menu
Solv Add Time : 0

Figure 4-3. Setup screen

The full list of SETUP options is shown here which is available with User Level 2 and
Service Level passwords.
Refer to the Password option paragraph in this section for the passwords/user levels
required to gain access to the Diagnostics options. Also refer to Section 5: “Maintenance”
for more detailed information about the availability of the various Diagnostics options.

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4.5 Option Availability

The printer has three main states: Jet Off, Jet Running and Printing. 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 Print Head Code option will only be 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
Printing states, the Print Head Code option will be displayed, but cannot be selected and
changed.
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.

48205

USER LEVEL 1 USER LEVEL 2 SERVICE LEVEL

PASSWORD PASSWORD PASSWORD

Setup Menu Options Jet Jet Print Jet Jet Print Jet Jet Print
Off Run Off Run Off Run

Password ● ● ● ● ● ● ● ● ●

Print Height ● ● ● ● ● ● ● ● ●

Normalise Height – – – – – – ● ● ●

Print Width ● ● ● ● ● ● ● ● ●

Print Delay ● ● ● ● ● ● ● ● ●

Print Count ● ● ● ● ● ● ● ● ●

Reverse Message ● ● ¢ ● ● ¢ ● ● ¢

Bold Ratio ● ● ¢ ● ● ¢ ● ● ¢

Set Time ● ● ¢ ● ● ¢ ● ● ¢

Set Date ● ● ¢ ● ● ¢ ● ● ¢

Julian Date Format ¢ ¢ ¢ ● ● ¢ ● ● ¢

Photocell ● ● ¢ ● ● ¢ ● ● ¢

Shaft Encoder ● ● ¢ ● ● ¢ ● ● ¢

Conduit Length – – – ● ¢ ¢ ● ¢ ¢

Head Height – – – ● ¢ ¢ ● ¢ ¢

Print Head Code – – – ● ¢ ¢ ● ¢ ¢

Ref Modulation – – – ● ● ● ● ● ●

Ink Selection – – – ● ¢ ¢ ● ¢ ¢

Calibrate Print Head – – – ¢ ● ● ¢ ● ●

Alarm – – – ● ¢ ¢ ● ¢ ¢

Change Password – – – ● ● ● ● ● ●

Change Language – – – ● ● ¢ ● ● ¢

Remote Setup Menu – – – ● ● ● ● ● ●

Diagnostic Menu (Refer – – – ● ● ● ● ● ●

to Diagnostics section)
Solv Add Time – – – ¢ ¢ ¢ ¢ ¢ ¢

Figure 4-4. Setup menu option availability table

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4.6 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 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 which can be stepped through using the left and right
arrow keys (e.g. the range of Print Height values; or Password : On/Off). Other options
allow a value to be typed in (e.g. 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 turn the Password option on or off: scroll to Password, select the On or Off setting by
pressing [enter], change the setting to On or Off by pressing the left or right arrow keys,
then press [enter] again.
The ability to access the DIAGNOSTICS menu from the SETUP menu is dependent on the
password entered. If the User Level 1 password is entered, only a limited list of options is
displayed on 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, whereas the Service Level password allows access 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 machine will remain 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 will then be able to access the User Level 2 functions, but NO users
(including service personnel) will be able to access the additional “service only”
Diagnostics options. To gain access to these service diagnostics options, it will be necessary
to switch the Password function back on, exit from the SETUP menu, and re-enter using
the Service Level password.

4.7.2 Print Height

This option is used to increase or decrease the height of all the stored messages by up to
plus or minus 30%. The height can be adjusted from –30%, through Normal, to +30%, in
5% steps.

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 4.7.3 Normalise Height
Used in conjunction with Print Height, this option can be used to ‘normalise’ the selected
height, i.e. to store the Print Height setting as the Normal height. This enables a greater
print height range and can be used to eliminate deflector plate/gutter clipping at
maximum and minimum drop deflection.
The print height setting operates in a small part of the actual print range available from the
printhead. By using the Normalise Height 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 (see figure 4-5).

6180
Maximum height range determined by drops
clipping the deflector plate and the gutter

+30% N −30%

Nominal
Print Height
setting range
(default)
Maximum Minimum
(deflector (gutter
plate clipping)
clipping)
+30% N −30%

By using Normalise Height at a

Print Height setting of −30%, the
print size has been reduced and
the normal position is now equal
to nominal −30%, which allows
print height to be further
reduced to −30%, again.

Figure 4-5. Normalise Height adjustment

This example shows the Normalise Height option being used to increase the print range
which allows smaller print. For very small print this option may be used a number of
times. To obtain larger print Normalise Height may be used when a positive (+) height
setting is selected.
NOTES: (1) In some instances print quality may be adversely affected if very large
changes are made away from the default nominal character height.
(2) The larger the raster used, the smaller the character height range
available.
The maximum and minimum limits of the print range are when the print clips the deflector
plate or the gutter (not all rasters will clip the deflector plate at maximum deflection). Both
conditions will give poor print quality which will usually deteriorate as ink builds up on
the deflector plate or gutter. To avoid this condition it must be ensured that the
combination of Normalise Height and the maximum or minimum Print Height setting will
not allow clipping to occur. Therefore, a test should be carried out by selecting +30% or –
30%, depending on whether the print height is being increased or decreased, to determine
if clipping will occur.
When using the Normalise Height option, if the setting exceeds the upper and lower limits
the following standard warning will be displayed in the status line:
“Normalised Height Limit”

4800 Service Manual 4—5 Oct 97

 If clipping occurs, then first the percentage at which it starts to happen must be identified.
A tolerance of 10% must then be allowed to ensure trouble free operation. This is achieved
by adjusting the Print Height setting and then normalising the height such that when the
maximum and minimum print height settings are selected the print will not clip the
deflector plate or the gutter, with the 10% tolerance taken into account. An example of this
is shown in figure 4-6:
48086

Gutter

Nozzle
Deflector Plate

−10% +10%

With Normalise Height adjusted, clipping starts at +20%

+30% +25% +20% +15% +10% +5% N −5% −10% −15% −20% −25% −30%

Clipping at
+20%

Maximum Print Height

setting with 10% tolerance

+30% +25% +20% +15% +10% +5% N

Print Height setting adjusted to −20% and normalised.

This now gives trouble free operation at maximum
print height range of +30%

Figure 4-6. Normalise Height adjustment to avoid clipping

NOTE: The Normalise Height option is only available with the Service Level
password.

4.7.4 Print Width

This 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 the printer can
print.
Print width is a timing delay of drops between rasters and is measured by counting the
drops into the gutter. A Print Width setting of 0 means one complete raster plus one drop
into the gutter; a Print Width setting of 500 means one complete raster plus 501 drops into
the gutter.
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.
NOTE: Altering the message width can affect the Print Delay setting (see Print Delay).

Oct 97 4—6 4800 Service Manual

 4.7.5 Print Delay
This option is used to control the delay between the photocell trigger signal and the start of
printing (if the Photocell option is set to Triggered), or the delay between prints (if the
Photocell option is set to Off or Enable). The delay is controlled by setting a number in the
range 0 to 65535 (the higher the number, the longer the delay).
Print delay is counted in rasters and is the total number of drops in a raster plus any width
setting. For example, in a 16 High-Standard Speed raster there are 16 printed drops and 36
guard drops, and with perhaps a width setting of 10 giving an extra 11 drops, there would
be 63 drops counted for a Print Delay setting of 1.
NOTE: The size of the delay will increase or decrease if the shaft encoder setting is
anything other than ideal pitch.
Too small a delay may result in a System Warning “3.02 Over Speed (Print Go)” error
message being reported.
There are minimum delay settings for each raster 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
as the ink viscosity may move out of range. The minimum delay for each raster and
printhead combination is shown in the following table, and these are the values that the
printer will default to if no other value is entered.
48042
PRINTHEAD TYPE / MINIMUM DELAY

RASTER MICRO MIDI 62 µm MIDI 70 µm MACRO

5 HI SPEED – 105 75 –
7 GEN STD 33 42 30 34
7 HI SPEED 82 79 57 55
7 HIGH QUALITY – 32 23 –
16 GEN STD 13 12 9 14
16 N HI SPEED – 15 11 –
16 S HI SPEED – 26 18 –

Figure 4-7. Table of raster/printhead type minimum delay default values

The minimum delay values in the above table assume a Print Width setting of 0 and that
the next photocell trigger will occur after the last message has completed printing. They do
not take account of photocell 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 to:
1. Adjust the Print Delay setting first to get the message on the product.
2. Adjust the Print Width for the required message width.
3. Finally make a further adjustment to the Print Delay setting to achieve the
precise print registration.
Entering a Print Delay value less than the recommended minimum will result in the
standard warning 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

This 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] key (Check Status)
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.

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 4.7.7 Reverse Message
This 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
will have the printhead cover 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 will be printed from left to right (as displayed in the
CURRENT MESSAGE screen).

On
With the option set to On the message will be printed from right to left (in reverse).

4.7.8 Bold Ratio

The Bold Ratio option is used to adjust the density of the characters to be printed. To alter
the bold ratio of an existing message printing must be stopped, the ratio figure entered (in
the range 1 to 9), and the message edited.
A bold ratio of 1 is equivalent to standard print, i.e. 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 will produce a repeat print of each raster x
the bold ratio. For example, using a bold ratio of 2 with a 7 high character will make the
character the same height but twice as wide (see figure 4-8).

4006

BOLD RATIO BOLD RATIO

x1 x2

Figure 4-8. Bold Ratio setting

NOTE: For very porous substrates a bold ratio of 5 or more may be used, and over
printing each raster by typically 40% or 50% using a fast print rate and a slow
product line speed.

4.7.9 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 (e.g. 10:16).

4.7.10 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 (e.g. 16:07:97).
NOTE: The turn of the century will have no adverse effect on the printer’s internal
date setting. The printer will continue to display the correct date and will
operate normally.

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 4.7.11 Julian Date Format
This option gives the user the choice of two conventions (European or American) for the
day number in the year, as shown in figure 4-9:
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 = Day365 31 Dec = Day365
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 = Day365 31 Dec = Day366

Figure 4-9. Julian Date format

4.7.12 Photocell
The printer can be set-up to print on receipt of an external print trigger signal. The
Photocell option provides four modes: Triggered, Enable, Remote and Off.

Triggered
The photocell signal is used to trigger the printing of each message. A single message is
printed for each photocell trigger signal. The Print Delay option specifies the number of
blank rasters between the signal and the actual start of printing.

Enable
The photocell signal is used to start printing. The printer then prints continuously as long
as the photocell signal is present (HIGH). The Print Delay option specifies the number of
blank rasters between individual messages; the larger the delay, the longer the blank space
between messages. Printing is stopped when the end of the substrate is detected by the
photocell signal going LOW, and restarts at the next HIGH signal.
If a print was already started when the signal goes LOW, the message will be finished and
not restarted until the signal goes HIGH again.

Remote
The printer will print on receipt of a signal from a remote computer, via the RS232 link.

Off
The photocell input to the printer is turned off and the printer will print continuously 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.
NOTES: (1) The setting of the Photocell option is retained when the printer is off.
(2) If the Shaft Encoder option is enabled (set to On), then pulses must be
present for printing to occur.

4800 Service Manual 4—9 Oct 97

 4.7.13 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.
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)

This 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 set-up. 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

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 Linx Printing Technologies plc

* The Ideal Pitch between rasters is dependent on the raster and printhead type, as shown
in the following table:

48043
PRINTHEAD TYPE / IDEAL PITCH (mm)

RASTER MICRO MIDI 62 µm MIDI 70 µm MACRO

5 HI SPEED – 0.550 0.623 –

7 GEN STD 0.211 0.353 0.400 0.627
7 HI SPEED – 0.500 0.600 –
7 HI QUALITY – 0.353 0.400 –
16 GEN STD 0.211 0.353 0.400 0.627
16 N HI SPEED – 0.400 0.400 –
16 S HI SPEED – 0.700 0.700 –

Figure 4-10. Table of raster/printhead type ideal pitch values

Example Calculation
To illustrate this calculation the following information is assumed:
Printhead: Midi 70 µm.
Raster: 16 GEN STD.
Line speed: Variable speed up to 0.4 m/s (which is less than
the maximum speed that this raster will operate at
with ideal pitch).
Ideal Pitch (PI): 0.4 mm for a Midi 70 µm printhead (16 GEN STD
raster—from table above).
The following information on 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).
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 should be 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

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 Linx Printing Technologies plc

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 would be
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 (MP65632) 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.

4.7.14 Conduit Length

This identifies which of the two standard lengths of printhead conduit is fitted to the
printer, which ensures that the correct startup and shutdown routine timings are used. The
printhead conduit lengths available are 2 and 4 metres (the Macro printhead is only
available in 2 metre lengths), therefore this option has only two settings of 2m and 4m. The
jet must be stopped to set this option.

4.7.15 Head Height

Pressure varies by 2.5 pressure points, rounded up (positive) to the nearest whole number,
for every half metre the printhead is above or below the printer. The setting of this option
may be altered between –9.5 metres and +9.5 metres, however, printhead conduits are
currently a maximum of 4 metres in length so the maximum setting will be “4.0m”.
The setting is entered in terms of half or whole metres for the distance above or below the
printer that the printhead is mounted. In reality, the distance is from the printer pressure
transducer to the printhead nozzle assembly. For practical purposes, the measurement
should be made from the keyboard space bar to the printhead nozzle.
If the printhead is mounted below the printer, the value is entered in the format “–X.Xm”.
If the printhead is mounted above the printer it is not necessary to place a “+” in front of
the value. The value is entered simply as “X.Xm”.
The setting will automatically change the printhead pressure reference from which the
solvent add pressure value is calculated. Therefore, the MONITOR JET screen of the
DIAGNOSTICS sub-menu will display different Solvent Add pressures depending on the
Head Height setting.
NOTE: Care must be exercised with this option, otherwise poor printer performance
will result if incorrectly set.

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4.7.16 Print Head Code

A 14 digit code number is printed on all printhead conduit labels. This code contains
important calibration information which must be entered, using this option, whenever a
new printhead is fitted, or when the software or IPM PCB are replaced. These calibration
parameters are used by the printer to optimize performance. The 14 digits are encoded as
follows:
Digit 1 (H) is the printhead type:
0 = Micro.
1 = Midi 62 µm and 70 µm
2 = Macro.
Digits 2 to 6 (TTTTT) specify the Time Of Flight reference value.
Digits 7 to 10 (GGGG) specify the Charge DAC Gain in the range 0950 to 1050 but
this would normally be 1000.
Digits 11 to 13 (PPP) specify the Pressure Reference, in the range 0 to 255.
Digit 14 (C) is the modulo 10 checksum digit to ensure that the printhead code is
entered correctly. It is calculated by adding all the previous 13 digits of the code,
then dividing by 10 and using the remainder.

6170
Time Of Flight Reference Pressure Reference
(TOF) 0 through 255

H T T T T T GGGGP P P C

Head Type Check Digit

0 = Micro Charge DAC Gain Modulo 10 checksum
1 = Midi to ensure code is
2 = Macro Normally 1000 entered correctly

Figure 4-11. Printhead Code composition

If the checksum digit does not correspond with the sum of the other digits, or if, for
example, the printhead type code or the TOF reference are entered incorrectly, the
following message is displayed:
“Value Not Set : Invalid Data”
The relevant part of the code should be re-entered correctly, ensuring that every digit is
exactly as specified on the printhead conduit label.
The printhead code can only be entered when the printer is in the Jet Off state. When a
correct code has been entered it is stored in the printer memory until a new code is entered.

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 Linx Printing Technologies plc

4.7.17 Ref Modulation

This option is used for entering the reference value of the modulation voltage. The value is
entered using the reference modulation figure shown against “MOD” on the printhead
conduit label and is stored in NVR. It is also displayed on the MONITOR JET screen of the
DIAGNOSTICS sub-menu. If new software or a new IPM PCB are installed, the reference
value must be re-entered, as it will have been erased from the NVR.

4.7.18 Ink Selection

The ink type being used in the printer is selected with this option. A choice of four ink type
settings is available: MEK, Ethanol, Pigmented, or 3XXX. Unless directed otherwise, the
option should be set depending on the ink type used, as shown in the following Ink Type
Settings table:

INK TYPE SETTINGS

48044
INK TYPE SELECTION

Linx Marque Ink Name Part MEK Ethanol Pigmented 3XXX

Number

Black Pigmented 1009 ✔

Black General Purpose 1010 ✔
Black Plastic-Adherent 1014 ✔
Red General Purpose 1018 ✔
Blue General Purpose 1023 ✔
Green General Purpose 1024 ✔
Black Water Removable 1035 ✔
Yellow Pigmented 1039 ✔
Black Wet Process 1055 ✔
Black Dry Glass 1065 ✔
Black Reodourized Alkali Removable 1070 ✔
Red Reodourized Alkali Removable 1071 ✔
Clear UV-Readable 1121 ✔
Black Fast Drying General Purpose 1240 ✔
Thermochromic Blood Red to Brick Red 1270 ✔
Thermochromic Purple to Pink 1280 ✔
Thermochromic Black to Blue 1290 ✔
Black Ethanol General Purpose 2030 ✔
Black Mixed Base (Midi/Macro) 3103 ✔
Black Mixed Base (Micro) 3104 ✔
Red Food Grade 6100 ✔
Blue Food Grade 6120 ✔

Figure 4-12. Ink Type Settings Table

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 Linx Printing Technologies plc

4.7.19 Calibrate Print Head

This option may be used when a new printhead is fitted. The option can only be selected
and the printhead can only be calibrated when the jet is running. Printing will be
suspended while the printhead is being calibrated by the software and will be resumed
when calibration is complete.
On execution of the calibration a modulation voltage is automatically selected to give
optimum drop break-off position. However, the more normal action on fitting a new
printhead is to enter the calibrated modulation voltage figure shown against “MOD” on
the printhead conduit label.
Printhead calibration should only be used after the printer has been running for a
minimum of one hour and the diagnostic readings are all correct, otherwise an incorrect
calibration could result.
When the Calibrate Print Head option is selected, the following screen will be displayed:

48045

CALIBRATE PRINT HEAD

Printing Will Be Suspended. Continue?
F1 : Yes F2 : No

Figure 4-13. Calibrate Print Head screen

If the [F1] (Yes) key is pressed, the calibration will begin and the following status line
message will be displayed:
“Cal Print Head : Please Wait”
When the calibration has been completed (approximately 30 seconds), the screen will
revert to the SETUP menu and either of the following status line messages will be
displayed:
“Print Head Calibration Successful”
“Print Head Calibration Failed”
If the [F2] (No) key is pressed, the screen will revert to the SETUP menu and the following
status line message will be displayed:
“Print Head Calibration Not Done”

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 Linx Printing Technologies plc

4.7.20 Alarm
When a printer warning or failure occurs, the system activates an internal alarm tone
(beeper) and an LED on the front panel. In a warning condition the alarm tone is pulsed
twice, whereas in a failure condition the alarm tone sounds continuously.
The 4800 printer also has the facility of an output to an external alarm. The output is taken
from a 2 pin socket (PL5) located on the rear panel of the printer and this could be used to
operate a beacon, or a production line interlock, or some other similar safety device. The
alarm is a relay, which has a rating of 1 amp at 240 volts and a standard configuration of
Normally Closed (NC) contacts. However, this can be changed to Normally Open (NO) by
moving link LK1 on the Photocell PCB.
The Alarm option allows different combinations of events to be selected to trigger the
alarm relay. Selecting the Alarm option will display the following screen:

48046

ALARM
> Mode : Pulsed
Failure : Yes
Warning : Yes
Print Disabled : No

Ink and Solvent : No

Figure 4-14. Alarm screen

The options in the above screen are shown with their default settings. Any combination of
the event options may 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 error conditions. When all errors have been cleared the
alarm output will automatically be deactivated. The Mode option can be set to either
Pulsed or Continuous:

Pulsed
In the Pulsed mode the external alarm operates as normal, i.e. if a System Warning error
occurs the alarm relay will be switched to pulse the external alarm on and off twice
simultaneously with the internal alarm tone. (If a System Failure or Print Failure occurs
the alarm will still be continuous).

Continuous
In the Continuous mode the alarm relay will be switched to activate the external alarm
continuously while a System Warning error is present.

Failure
The alarm relay will be switched to activate the external alarm continuously only when a
Print Failure occurs, not in a System Warning error condition.

Warning
The alarm relay will be switched to pulse the external alarm on and off twice each time a
System Warning error occurs, or switched to activate the external alarm continuously while
a System Warning error is present, depending on the Mode setting.

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 Print Disabled
The alarm relay will be switched to activate the external alarm continuously while the
printer cannot print for whatever reason, e.g. when the printhead cover has been removed.
As soon as the printer is ready to print or is printing the alarm relay will be deactivated.

Ink and Solvent

The alarm relay will be switched to activate the external alarm only when the “3.03 Ink
Low” or “3.04 Solvent Low” System Warning errors are present. The alarm will be either
pulsed on and off twice or continuous depending on the Mode setting.
NOTE: Selecting the options Warning and Ink and Solvent has the same effect as
selecting just Warning.

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 will
appear first and a password will be required to gain access to the Change Password
function. If the User Level 1 password is entered here, only the current User Level 1
password will be displayed in the CHANGE PASSWORD screen. If the User Level 2 or the
Service Level passwords are entered, both the User Level 1 and User Level 2 passwords
will be displayed:
48047

CHANGE PASSWORD
> Level 1 : LINX1
Level 2 : LINX2

Figure 4-15. Change Password screen

Any new password entered must be between 4 and 10 characters in length, and is not
sensitive to upper or lower case letters (e.g. 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 with the
User Level 1 password.

4.7.22 Change Language

The language and associated parameters used by the printer can be set up using this
option. Selecting this option will display the CHANGE LANGUAGE menu, and selecting
a language will change the language in which menus are displayed (English is always
present). The menu will only ever display a choice between English and one other
language, e.g. German.
48048

CHANGE LANGUAGE
> English
Deutsch

Figure 4-16. Change Language screen

4800 Service Manual 4 — 17 Oct 97

 4.7.23 Remote Setup Menu (RS–232)
The RS–232 interface provides the facility for a remote computer to be used to control a
majority of printer functions of a LINX printer. 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 are described in the Remote Computer Interface
Specification. The full list of ASCII Control Characters is given in the RS–232
Communications Protocol Specification. Both of these documents are contained in the RS–232
Interface User Manual.
The following describes the Remote Setup Menu structure and explains how to use the
menus to set up the printer for remote operation.
Selecting the Remote Setup Menu option will display the following screen which allows
access to a further six sub-menus:
48049

REMOTE SETUP MENU

> Transfer Parameters
Serial Parameters
Flow Control
Message Delimiters

Print Control
Print Mode

Figure 4-17. Remote Setup Menu screen (RS–232)

NOTE: All the following Remote Setup sub-menus are shown with their default
settings.

Transfer Parameters
The Transfer Parameters option defines the general parameters for the RS–232 link.
48050

TRANSFER PARAMETERS
> Mode : RS 232
Escape Char : ESC (27)
Checksum Disabled : No
Buffer Threshold : 128

Figure 4-18. Transfer Parameters screen

Mode
The Mode option allows the user to select the communications protocol.

Escape Char
Escape Char defines the character that is used by the RS–232 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 may be set. It is also used to identify other “special”
data characters. This is described in further detail in the RS–232 Communications Protocol
Specification.
NOTE: Special characters are used for various tasks in the interface and, as with the
escape character, may be set to any value between 01 and 31 (ASCII control
characters SOH to US). No two special characters may have the same value. If
an attempt is made to set two special characters to the same value, a warning is
given and displayed in the status line.

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 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 will also
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 will disable 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 may be set to any value between 1 and 244.

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 for successful transmission and reception to take
place.
48051

SERIAL PARAMETERS
> Baud Rate : 9600
Stop Bits : 1
Parity : None
Data Bits : 8

Figure 4-19. Serial Parameters screen

Baud Rate
This option determines the speed of the transferred data and may 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. It may be set to None, Odd or Even.

Data Bits
This shows the number of data bits used. It is for display purposes only and cannot be
changed.

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 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 loose characters, flow control is implemented at regular intervals to stop
reception of characters.
48052

FLOW CONTROL
> Flow Control : Cts/Dtr (H/w)
Xon Char : DC1 (17)
Xoff Char : DC3 (19)

Figure 4-20. Flow Control screen

Flow Control
Flow control may be implemented by either using hardware lines (Cts and Dtr) in the RS–
232 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 may be set to any value between 01 and 31 (ASCII control characters
SOH to US).

Xoff Char
The Xoff Char option may 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 may be
specified in this sub-menu. All the characters are identified in the data stream by the
escape character preceding them.

48053

MESSAGE DELIMITERS
> Start Char : STX (02)
Alternate Start Char : SOH (01)
End Char : ETX (03)
Ack Char : ACK (06)

Nak Char : NAK (21)

Figure 4-21. Message Delimiters screen

All the options in the MESSAGE DELIMITERS menu may be set to any value between 01
and 31 (ASCII control characters SOH to US).

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 Print Control
Under most circumstances the remote computer initiates communications, and the printer
will only reply 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.

48054

PRINT CONTROL
> Print Trigger State : Off
Print Delay State : Off
Print Go State : Off
Print End State : Off

Print Trigger Char : ENQ (05)

Print Delay Char : BS (08)
Print Go Char : SI (15)
Print End Char : EM (25)

Figure 4-22. Print Control screen

These control characters indicate the following:
• the printer has started the print delay (BS 08);
• the printer has started to generate rasters (SI 15);
• the printer has completed a print sequence (EM 25);
• the computer is triggering a “print go” (ENQ 05).
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 may 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 in the HARDWARE SETUP menu 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 will not be
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, i.e. when a stop print
command is issued or the message print count reaches 0 with no other message pending.

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 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 using the PRINT MODE
sub-menu, to receive data during printing.

48055

PRINT MODE
> Mode : Continuous
Print Go / No Data : Warn/Ignore PG
Print Go / Pixel Ram : Warn/Ignore PG
Clear Remote Buffers : Yes

Number Of Buffers : 2

Figure 4-23. Print Mode screen

Using the Print Mode option it is possible to control the following:
• circumstances under which printing will take place;
• field data download during printing;
• failure conditions;
• issuing of print control characters;
• size and amount of data received.

Mode
The Mode option may be set to either Continuous or Single print:

Continuous
In Continuous print mode, printing will always take place regardless of whether or
not any remote data has been received. Therefore, if one set of remote data is
received, this will be continuously printed until more remote data is received.

Single
In Single print mode, printing will take place once for each set of remote data
received. If no more data is received, any print triggers that occur will be dealt
with according to how the failure condition has been set up.
For normal printing where no remote data is expected, this option should always be set to
Continuous mode. 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 Remote Computer
Interface Specification.

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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 may be set to carry out one of the following three actions:
1. Do nothing and ignore the “print go” (Ignore Prn Go).
2. Report the error and ignore the “print go” (Warn/Ignore PG).
3. Report the error and stop printing but not stop the jet (Fail/Stop Prn).
If the print mode has been set to Continuous print, then the Print Go/No Data error will
not occur. This is regardless of whether any remote data has been received or not. In
Continuous print mode printing will 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 may be set to carry out one of three actions as for Print Go/
No Data above.

Clear Remote Buffers

The remote print buffer is used to store any remote data which has been downloaded to the
printer using commands 28 and 29.
The Clear Remote Buffers option is available to clear the buffer when printing stops.
If it is set to Yes, once printing stops the buffer will be cleared. This will 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 will remain there.
Therefore, if printing is restarted, it will continue with the data already in the buffer.

Number Of Buffers
The remote buffer is 1024 bytes long and may 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 was divided into 8
blocks, each block would be 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.

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4.7.24 Remote Setup Menu (RS–485)

The RS–485 interface provides the facility for a remote computer to be used to control a
majority of printer functions of one or more Linx printers.
NOTE: RS–485 is only available if the Photocell PCB is fitted and the RS–485
configuration is enabled.
Selecting the Remote Setup Menu option will display the following screen which allows
access to a further three sub-menus only:

48203

REMOTE SETUP MENU

> Transfer Parameters
Serial Parameters
Print Mode

Figure 4-24. Remote Setup Menu screen (RS–485)

All options are the same as the RS–232 Remote Setup Menu described earlier in this
section, with the exception of the Serial Parameters “Baud Rate” option which has an extra
setting of 38400, and the Transfer Parameters options.

Transfer Parameters
48204

TRANSFER PARAMETERS
> Mode : RS 485
Printer Address : 0

Figure 4-25. Transfer Parameters screen (RS–485)

In this screen only the Mode can be changed (back to RS–232) and the Printer Address set.

Printer Address
The Printer Address option is used to identify a particular printer in a network of up to 248
printers. With the address set to 0, the printer will not respond to any communication; it
must be set to a value between 1 and 248 for communication to take place. Care must be
taken to ensure that no two printers on the network have the same address.

4.7.25 Diagnostics
For full details of the diagnostic options refer to “The Diagnostics Menu” in Section 5:
“Maintenance”

4.7.26 Solv Add Time

This option indicates the total time (in tenths of 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 table in the “Ink System” part of Section 3:
“Technical Description”.

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4.8 Passwords
User Level 1: “LINX1”

User Level 2: “LINX2”

Service Level: “SVC2”

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SECTION 5: MAINTENANCE

5.1 The Diagnostics Menu

5.1.1 Password Access
Access to the SETUP menu is by password as described in Section 4: “The Setup Menu”;
three levels of password are used. The first two levels are intended for users and have
limited or no access to the DIAGNOSTICS menu; the third 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 Section 4: “The 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 3 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 Diagnostics option, then pressing [enter].
Alternatively, immediate access can be made by pressing the letter [D] key. The first five
diagnostic options are now displayed and the up and down arrow keys can be used to
scroll through the full menu.

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5.1.2 Total Menu Options

The DIAGNOSTICS menu of options shown below covers the full range that is available
with the Service Level password. The menu below is shown irrespective of jet state and is
for illustration purposes only as all options will not be available all of the time.

48057

DIAGNOSTICS
> Start Jet
Stop Jet
Quick Start Jet
Start Print

Stop Print
Test Print
Clear Nozzle : 1
Nozzle Flush
Flush Shutdown : Auto
Monitor Jet
System Times
System Config
Phase : 0
Phase Offset : 0
Set Pressure : 0
Ref Pressures
Filter Purge : Off
Clear Message Area
Phase Fault : On
Phase Period : 30
Auto Phase : On
TOF Correction : On
TOF Warm Up : On
DAC Cal Mode : Off
DAC Cal Value : 1000
Save Cal Value
Alarm Test : Off
Generate Test Pattern :
System Flush
Valve Test

Figure 5-1. Diagnostics screen

5.1.3 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 Printing. The DIAGNOSTICS
menu changes to reflect these states, which may affect the availability of some options and
also the ability to select or change their 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, e.g. the option Start Jet would not be displayed when the printer is in the Jet
Running state. This keeps the menu list to a minimum at all times.
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.

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The table in figure 5-2 lists all of the options available with Versions 1.0 and 1.1 software.
48058
USER LEVEL 2 PASSWORD SERVICE LEVEL PASSWORD

Diagnostic Options Jet Off Jet Printing Jet Off Jet Printing
Running Running

Start Jet ● – – ● – –

Stop Jet – ● – – ● –

Quick Start Jet ● – – ● – –

Start Print – ● – – ● –

Stop Print – – ● – – ●

Test Print – – ● – – ●

Clear Nozzle ● – – ● – –

Nozzle Flush – – – ● – –

Flush Shutdown ● ● ● ● ● ●

Monitor Jet ● ● ● ● ● ●

System Times ● ● ● ● ● ●

System Config ● ● – ● ● –

Phase ¢ ¢ ¢ ● ● ●

Phase Offset ¢ ¢ ¢ ● ● ●

Set Pressure ¢ ¢ ¢ ● ● ●

Ref Pressures ● ● ● ● ● ●

Filter Purge ● – – ● – –

Clear Message Area – – – ● ● –

Phase Fault – – – ● ● ¢
Phase Period – – – ● ● ¢
Auto Phase – – – ● ● ¢
TOF Correction – – – ● ● ¢
TOF Warm UP – – – – ● ¢
DAC Cal Mode * – – – ● – –

DAC Cal Value * – – – ● – –

Save Cal Value * – – – ● – –

Alarm Test – – – ● – –

Generate Test Pattern – – – ● ● –

System Flush – – – ● – –

Valve Test – – – ● ● ●
* Only available on the 4800 Issue 1 IPM PCB (not available on the 4800 Issue 2 IPM PCB)

Figure 5-2. Diagnostics menu option availability table

5.1.4 Option Description

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 will be displayed:
“Starting Jet : Please Wait”
Before the jet starts all the normal static checks will be made, bor example, pressure/filter
check, ink and solvent levels, and Service and Filter times. As the jet is starting the
dynamic functional checks and adjustments are carried out: pressure check, phasing and
TOF. 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 then the printer will
attempt a further three starts (four in total). If an invalid condition still exists then the
printer will provide an audible and on-screen warning, or will fail with an fault code.

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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.
See also: Start Print; Quick Start Jet; Phase Fault.
Section 3: “Technical Description” > Ink System > Startup and Shutdown Routines.
Section 6: “Error and Fault Messages”.

Stop Jet
This option stops the jet. While the jet is stopping the following status line message will be
displayed:
“Stopping Jet : Please Wait”
When the jet has stopped the following status line message will be displayed:
“Jet Stopped : You May Now Switch Off”

Quick Stop
Pressing the [stop] key while holding the [ctrl] key will provide a quick stop. This will stop
the jet, clear the nozzle for 1 second and clear the gutter for 20 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.

Quick Start Jet

This option starts the jet using a different method from a normal start, to assist with fault
diagnosis. These important differences are described below.
Firstly, there is a change to the sequence of operations on startup. Normally the sequence
is as follows:
1. Pressure checks.
2. Establish jet.
3. Set pressure to Pressure Reference.
4. Phase jet.
5. Measure Time Of Flight.
6. Adjust pressure if Time Of Flight is out of range.
7. Repeat 4 to 6 until Time Of Flight is in range.
8. Printer state Jet Running or Printing.
When the Quick Start Jet option is used, the sequence is rearranged as follows:
1. Pressure checks.
2. Establish jet.
3. Set pressure to Pressure Reference.
4. Printer state Jet Running.
5. Phase 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.

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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 and Phase : “!”.
A second important difference is that the Phase Fault error detection function is
automatically 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).
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; Monitor Jet; Start Jet; TOF Correction.
Section 3: “Technical Description” > Ink System > Startup and Shutdown
Routines.

Start Print
This option changes the printer state from Jet Running to Printing. This will only happen if
a message is currently displayed in the CURRENT MESSAGE screen. Refer to “Selecting
and Editing Messages” in the 4800 Ink Jet Printer User Manual.
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.
The [start] and [F1] keys can also be used to start printing but these will re-enable the
Phase Fault option.
NOTE: The Start Print command has a lower level function than the main [start]
button which sets, for example, Phase Fault to On when pressed. Start Print
will leave Phase Fault in its current state.
See also: Stop Print; Start Jet; Quick Start Jet; Phase Fault; Test Print.

Stop Print
This option changes the printer state from Printing to Jet Running, i.e. it disables printing
but maintains the jet. This will allow 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 will also change
the printer state from Printing to Jet Running.
See also: Start Print; Start Jet; Quick Start Jet.

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 photocell trigger signal, and will print the message displayed
in the CURRENT MESSAGE screen. The Print Delay and Print Width settings selected in
the SETUP menu apply as with a normal photocell trigger. The Test Print facility has the
same effect as the photocell trigger in updating software options, sequential numbers and
print counters.

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This function will only operate if the Photocell option in the SETUP menu is set to
Triggered and the printhead cover is fitted. If either of these conditions are incorrect one of
the following status line messages will be displayed:
“Test Print : Invalid Photocell Mode”
“Test Print : Cover Off”
If the Shaft Encoder option in the SETUP menu is set to Direct then printing will only
commence 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 the
printer will then print 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 off
and overspeed are made, and any associated error messages are displayed. When Test
Print is selected one of the following status line messages will be displayed:
“Test Print : Print Started”
“Test Print : Already Printing”
See also: Section 4: “The Setup Menu” > Photocell and Shaft Encoder options.

Clear Nozzle

WARNING: SAFETY GLASSES AND PROTECTIVE GLOVES MUST BE WORN

THROUGHOUT THE CLEAR NOZZLE OPERATION.
This option enables a nozzle clear sequence to clear an obstruction or blockage by applying
the 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.
A single Clear Nozzle sequence lasts for 20 seconds. The pump is run at the Clear Gutter/
Nozzle pressure of 255 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, after
which time the gutter valve is closed and the pump is stopped.
It is recommended that a minimum of three Clear Nozzle sequences are carried out in an
attempt to clear an obstruction or blockage. This can be performed as a continuous routine
by entering “3” in the Clear Nozzle option and pressing [enter]. If two or more Clear
Nozzle sequences are run as a routine the pump will continue to run between individual
sequences. This routine of three Clear Nozzle sequences should be repeated a maximum of
10 times (i.e. a total of 30 Clear Nozzle sequences), with an attempt to start the jet carried
out after each routine. If after this procedure the nozzle is still blocked the printhead
should be replaced.
While the Clear Nozzle sequence is being performed the following status line message will
be displayed:
“Clearing Nozzle : Please Wait”
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.
See also: Set Pressure.
Section 2: “Safety”.
Section 3: “Technical Description” > Ink System > Clear Nozzle (Diagnostics
Menu).

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Nozzle Flush

WARNING: SAFETY GLASSES AND PROTECTIVE GLOVES MUST BE WORN

THROUGHOUT THE NOZZLE FLUSH OPERATION.
Like the Clear Nozzle option, this option can also be used when there is a suspected
blocked or obstructed nozzle. 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.
The current 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.
WARNING: SOLVENT JET HAZARD. THE USE OF THE NOZZLE FLUSH OPTION
MUST NOT BE CONFUSED WITH THE CLEAR NOZZLE OPTION. 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 Nozzle Flush sequence is initiated from the Diagnostics sub-menu, but the jet must be
stopped before the option can be selected. The duration of the sequence is 135 seconds for
a 2 metre printhead conduit and 220 seconds for a 4 metre conduit.

Flush Shutdown
The Flush Shutdown routine introduces solvent into the printhead and nozzle, during jet shutdown,
to remove any ink in preparation for a period of non-use. Refer to the “Ink System” part of Section
3: “Technical Description” for a more detailed description of operation.
This option has three settings: Off, On and Auto, the default setting being Auto, i.e. the settings Off
and On will not be remembered by the printer when it is switched off. It is convenient during
certain maintenance procedures to set the Flush Shutdown option to On or Off.

Off
This is the disabled setting. When set to Off the printer will not carry out the flush part of
the flush shutdown routine when the jet is stopped.

On
This is the enabled setting. When set to On the printer will carry out the flush part of the
flush shutdown routine when the jet is stopped.

Auto
This is the default setting for normal operation. In this mode the decision as to whether a
flush shutdown is performed or not is dependent on the time since the previous flush
shutdown, as follows:
• for ethanol inks, if the time since the previous flush shutdown is less than 40
minutes (80 minutes for a 4 metre printhead conduit), a non-flush shutdown
will be performed;
• for all other inks, if the time since the previous flush shutdown is less than 15
minutes (30 minutes for a 4 metre printhead conduit), a non-flush shutdown
will be performed.
NOTE: For a successful overnight shutdown the printer should be run for greater than
the times specified above.

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It is recommended that the option is set to Off if extended fault diagnosis is intended. This
will prevent the possibility of excessive amounts of solvent being added to the ink tank at
shutdown, which could cause a low ink viscosity condition.
If a printer is to be stored for a short time it is recommended that the option is set to On
prior to shutdown before storage, as this will ensure a solvent flush is completed.
As with any shutdown routine it is most important that the printer is allowed to complete
the full routine and is not switched off before the following status line message is
displayed:
“Jet Stopped : You May Now Switch Off”
See also: Section 3: “Technical Description” > Ink System > Startup and Shutdown
Routines.

Monitor Jet
The Monitor Jet screen displays the printer’s current operational parameters; the example
shown below is for a Midi printhead with the jet running:
48060

MONITOR JET
Press : 198 Solv Add : 200
TOF : 18553 Ref TOF : 18500
Modln : 150 Ref Modln : 150
Phase : 6 Read Press : 194

Figure 5-3. Monitor Jet screen

This option groups together the key jet control parameters in a single screen. The values
shown here are typical of the readings that would normally be seen. The parameters are
for display only; they cannot be changed by the user.
This screen can also be called up from the DIAGNOSTICS menu by simply pressing the
[M] key regardless of the current position of the menu cursor (>).
The following paragraphs describe each of the parameters in the Monitor Jet screen:

Press (Pressure)
When the printer is in jet state, i.e. Jet Running or Printing, this pressure value is adjusted
by the microprocessor to maintain the Time Of Flight (TOF) within the control parameters.
Otherwise, the value reflects the different pressures required for other routines, e.g. Start
Up and Shutdown.
See also: Read Pressure (Monitor Jet screen); Ref Pressures; Set Pressure.

TOF
This displays the current average of the TOF. Measurements of TOF are obtained by
monitoring specially low charged drops as they pass two datum points—the phase and
TOF detectors on the printhead. As the drops pass the first datum point (phase detector) a
counter is started and as the drops pass the second datum point (TOF detector) the counter
is stopped. The value displayed represents an average count; the higher the reading, the
slower the jet; the lower the reading, the faster the jet. The microprocessor compares the
average against the reference to maintain the correct TOF.
The printer tries to maintain the TOF at the reference value with a small tolerance of ±0.5%
and the pressure is increased or decreased to provide this control.
The counter readings are accumulated over six measurement cycles to obtain the displayed
TOF value. Occasionally the phase or the TOF detector output will not be sensed, so a
spurious reading will be obtained. These spurious readings are rejected by the TOF control
software, but the averaged reading will still be displayed in the Monitor Jet screen.

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 Linx Printing Technologies plc

A symbol may be displayed after the TOF value and a key to the validity of these symbols
is given below. If no symbol is displayed after the TOF value this indicates that the value is
valid and will be used to maintain the jet control.

TOF SYMBOL KEY

Symbol Description
“+” “Over Range”. Indicates that at least one of the TOF values
obtained is greater than the TOF Ref plus 40%.
“–” “Under Range”. Indicates that at least one of the TOF values
obtained is less than the TOF Ref minus 40%.
If either of the following symbols are displayed then the TOF value is invalid and will not
be used to maintain jet control:
Symbol Description
“++” “No Reading Max”. Indicates that at least one of the TOF values
obtained was 65,535, the maximum count from the TOF counter.
“––” “No Reading Min”. Indicates that at least one of the TOF values
obtained was 0, the minimum count from the TOF counter.
The printer will obtain a further six TOF counts if any of the displayed TOF readings are
invalid. The standard warning message “No TOF Readings” will be displayed in the
screen status line when a valid TOF has not been obtained for 15 minutes. The message
will be redisplayed every 15 minutes while no TOF readings are obtained.
To avoid confusion between a “No TOF Readings” standard warning message and a
printer fault, the warning message is removed from the screen once a valid TOF has been
received. The warning message will also be removed if a key is pressed or another
warning/failure occurs.

Modln (Modulation)
This displays the current modulation voltage being used by the printer and is the same as
the Ref Modulation value in the SETUP menu. Alternatively, it may have been set
automatically by the use of the option Calibrate Print Head which is also in the SETUP
menu.
See also: Section 4: “The Setup Menu” > Ref Modulation and Calibrate Print Head
options.

Phase
This displays the current phase position the printer is using to charge the drops for printing
and is the same as the value displayed separately against Phase in the DIAGNOSTICS
screen. A symbol may be displayed after the Phase value in the MONITOR JET screen and
a key to the validity of these symbols is given below. If no symbol is displayed after the
phase value this indicates that the printer has found a valid Phase position and should give
correct charge/drop break-off timing.

PHASE SYMBOL KEY

Symbol Description
“!” “Phasing”. Indicates that the printer is currently phasing the jet to
establish the correct phase position.
“!!” “No Phase”. Indicates that the printer is not trying to phase the
jet; this would typically be seen during the pressure check and as
the jet is being established when the printer is starting the jet.
See also: Phase.

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 Linx Printing Technologies plc

Solv Add
This is the solvent add pressure reference and is the same as the Solvent Add value in the
REF PRESSURES screen. When the pressure exceeds this value the printer will allow a
solvent addition if all of the solvent add criteria have been met (refer to “Solvent Addition”
in the “Ink System” part of Section 3: “Technical Description”).
When the option Head Height (SETUP menu) is used to compensate for differences
between the printer and printhead heights the printhead pressure reference is
automatically adjusted. The Solvent Add value is calculated from the printhead pressure
reference and therefore is also adjusted.
See also: Ref Pressures > Solvent Add.
Section 4: “The Setup Menu” > Head Height.
Section 3: “Technical Description” > Ink System > Ink and Solvent Flows >
Solvent Addition.

Ref TOF
This displays the TOF reference value which should be the same value as that given as part
of the printhead code located on the printhead conduit label. The code is also displayed
against the Print Head Code option in the SETUP menu. If the Print Head Code is
different it should be re-entered. The Ref TOF is used to provide the jet velocity reference.
See also: Section 4: “The Setup Menu” > Print Head Code.

Ref Modln (Modulation)

This displays the current reference modulation being used by the printer and is the same as
Modulation described earlier within Monitor Jet. It should be the same value as that
printed on the printhead conduit label and displayed in the SETUP menu. Alternatively it
may have been set automatically by the use of the Calibrate Print Head option in the
SETUP menu.
See also: Section 4: “The Setup Menu” > Ref Modulation and Calibrate Print Head
options.

Read Press (Pressure)

This value displays the actual pressure measured by the ink system pressure transducer.
The value would normally reflect the Pressure value with only a small difference of
typically 4 or 5 points. If the Read Pressure should exceed ±14 points of the requested
Pressure value of 235 during the pressure check of the jet start sequence, then a System
Warning “3.12 Low Pressure” error message will be displayed.
See also: Pressure (MONITOR JET screen); Set Pressure.

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 System Times
This option displays the operating times of the printer, in four categories:
48062

SYSTEM TIMES
> Power On : 75
Jet Running : 50
Filter Change : 1350
Service : 1350

Figure 5-4. System Times screen

For User Diagnostics the System Times parameters are for display only and cannot be
altered; for Service Diagnostics new values may be entered. The values for the Power On
and Jet Running times can only be reset to zero. The Filter Change and Service times can be
altered to any value from zero to a maximum of 1400.
It is important that a note is made of these four values when carrying out maintenance on
the printer which involves changing the software or removing the battery link LK2. These
actions will initialize the Non-Volatile RAM (NVR) and reset all the values. The Power On
and Jet Running times will be reset to zero, and the Filter Change and Service times will be
reset to 1400.

Power On
This displays the total cumulative time in hours that the machine has been switched on.
The value can only be reset to zero.

Jet Running
This displays the total cumulative time in hours that the jet has been running in Jet
Running or Printing states. The value can only be reset to zero.

Filter Change
This displays the hours remaining until the main ink filter and pre-pump filter replacement
is required. The time decrements (only when the jet is running) from a normally set 1400
hours maximum. In certain operating environments with very dusty conditions, the filters
may require replacing more frequently than every 1400 hours. In these circumstances the
Filter Change value can be set to less than 1400.
When the displayed time reaches zero the printer filters should be replaced. However, if
this is not carried out, the time will continue to decrement and will be displayed as a
negative value, indicating how long ago the filters should have been replaced.
NOTE: Initiating the Filter Purge option will reset the Filter Change time to 1400.

Service
This displays the hours remaining until scheduled maintenance of the printer is required.
The time decrements (only when the jet is running) from a normally set 1400 hours
maximum.
When the Service time reaches zero, the System Warning error message “3.06 Service
Time” will be displayed every time the printer is switched on. This warning message will
continue to be displayed until the 1400 hour scheduled maintenance has been carried out
and the Service time has been reset by the engineer. If the warning is ignored the time will
continue to decrement and will be displayed as a negative value, indicating how long ago
the printer scheduled maintenance should have been carried out.
If a time value is altered in error, and before the [enter] key is pressed, the [esc] key can be
used to exit the System Times screen without the time setting being effected.
Refer to Maintenance Instructions > 1400 Hour Scheduled Maintenance in this section.

4800 Service Manual 5 — 11 Oct 97

 System Config
The SYSTEM CONFIGURATION screen provides a full list of the printer’s hardware and
software configuration. It details the type of printhead fitted, the versions of software and
data blocks installed, and the raster types available. These details may be required by
LINX or a LINX distributor if additional logo or software features are required.
The information shown is for display purposes only and cannot be altered.

48064

SYSTEM CONFIGURATION
> Head Type : Midi
Raster Type
SW Links : A
SW Version : 50 v1.0 01/09/97

PCB Issue : 1
Data
Enabled Options

Figure 5-5. System Configuration screen

Head Type
Shows the type of printhead fitted to the printer, i.e. Micro, Midi, Midi (70µ), or Macro.

Raster Type
Selecting this option will display the RASTER TYPE screen which shows the types of raster
available in the printer. Several raster types exist, suitable for different applications. The
following screen shows the two rasters available with the Optima model:

48149

RASTER TYPE
> 7 GEN STD
16 GEN STD

Figure 5-6. Raster Type screen

SW Links
This option will only be displayed in the menu if a software link has been fitted, in which
case it will list all of the software links that are currently fitted. These links would not
normally be fitted for customer purposes.

SW Version
Shows the software version number and release date of the software installed in the
printer.

PCB Issue
Shows the issue number of the IPM PCB.

Oct 97 5 — 12 4800 Service Manual

 Data
Selecting this option will display the DATA screen which shows the version numbers and
release dates of the data PROM blocks installed in the printer:

48150

DATA
> R 30 48 Raster v1.0
D 50 v1.0 01/09/97
D 50 v1.0 01/09/97
C 23 v2.3 48E 05/97

C 23 v2.3 48E 05/97

F 30 v3.0 01/09/97
L 22 v1.0 01–08–97

Figure 5-7. Data screen

Enabled Options
When selected, the ENABLED OPTIONS screen is displayed showing which options are
active on the printer, e.g. RS-232 Comms; 5 Message Store:

48065

ENABLED OPTIONS
> RS–232 Comms
5 Message Store

Figure 5-8. Enabled Options screen

Phase
This option shows the current phase position, in the range 0 to 15, which the printer is
using to charge the drops for printing or jet control. The actual value displayed is not
important, but the value should be stable and should not change by more than ±1 digit in
normal operation.
The printer checks the phase position at regular intervals during jet starting, jet running or
printing; the period between checks changes depending on the jet state.
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 option Phase Offset (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 4800 printers should have the Phase Offset set to 0.
Under normal operating conditions the printer should not be “hunting” for a good phase
position. If the figure displayed is unstable, the possible cause is ink on the phase sensor,
giving the following symptoms:
• modulation problems;
• ink viscosity far out of range;
• electrical printhead fault (e.g. sensor line continuity problems);
• fluctuating pump pressure.
See also: Phase Offset; Auto Phase.

4800 Service Manual 5 — 13 Oct 97

 Phase Offset
This option adds an offset to the actual phase position, up to a complete phase cycle, which
will change the charging of the drops in relation to the drop break-off. The number shown
indicates the current setting of the phase offset in the range 0 to 15.
The 4800 printers have a normal phase offset value of 0 (zero); currently this is the only
value that should be used. This should only be altered as an aid to fault diagnosis, or as
directed in Product Bulletins which give information on future ink releases which may
require the phase offset to be altered.
See also: Phase; Auto Phase.

Set Pressure
This option displays the current pressure and also allows the pressure in the printer to be
altered. Set Pressure must be looked at in two ways:
Firstly, when the jet is running this option will display the pressure the printer requires to
obtain the correct TOF. During a startup or shutdown sequence the display will reflect the
different pressure values being used during the sequence. The Monitor Jet option can also
be used to follow the startup and shutdown pressure changes.
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 as 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 will allow values in the range 0 to 255 to be set. The maximum
pressure in the system is 65 lb/in2. This makes one pressure point equal to 0.255 lb/in2,
therefore, a set pressure of 200 would give a pressure of 51 lb/in2 (200 x 0.255).
NOTE: 65 lb/in2 = 4.57 kg/cm2 = 4.48 bar.
Typical diagnostic uses for setting a specific pressure are as follows:
• fault diagnosis of pressure loss problems;
• cleaning out the printhead;
• purging the filter without resetting the Filter Change time (e.g. if changing ink
only);
• varying the pressure when using the 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: Read Pressure (MONITOR JET screen); Monitor Jet; Quick Start Jet.

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 screen shown below
is for a Midi printhead:

48166

VALVE TEST
Feed : On
Purge : Off
Gutter : Off
> Solvent Top-Up : On

Figure 5-9. Pressure Refs screen

The values shown are for display purposes only and cannot be altered.

Oct 97 5 — 14 4800 Service Manual

 Print Head Ref
This is the pressure reference value as specified in the printhead code found on the
printhead conduit. The complete printhead code must be programmed into the printer
using the option Print Head Code in the SETUP menu.
NOTE: The printhead pressure reference value is automatically adjusted when the
option Head Height is changed in the SETUP menu.
See also: Section 4: “The Setup Menu” > Print Head Code and Head Height options.

Solvent Add
The Solvent Add pressure is a reference pressure which 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 offsets for each printhead type are:
Micro 5
Midi 62 µm 4
Midi 70 µm 4
Macro 3
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 Selection option in the SETUP menu.

Solvent Add Conditions (Normal Running)

• Read Pressure > Solvent Add Reference Pressure;
• TOF within ±0.5% of TOF Reference;
• warm-up period expired;
• solvent level OK;
• no “Low Pressure” System Warning.
Solvent addition will take place at startup if increased pressure is required to obtain the
correct TOF, perhaps caused by extremes of temperature.

Solvent Add Conditions (Startup)

• Read Pressure > First Solvent Add Pressure;
• TOF within ±0.5% of TOF Reference;
• solvent level OK;
• no “Low Pressure” System Warning.
See also: Section 3: “Technical Description” > Printhead Principles of Operation >
Viscosity Control.
Section 3: “Technical Description” > Ink System > Ink and Solvent Flows >
Solvent Addition.
Section 3: “Technical Description” > Ink System > Startup and Shutdown
Routines > Printhead Dependent Parameters table.
Section 3: “Technical Description” > Ink System > Ink Type Dependent
Parameters table.
Section 4: “The Setup Menu” > Ink Selection option.

4800 Service Manual 5 — 15 Oct 97

 Maximum Run
This is the maximum pressure the printer will use to establish the jet and maintain the TOF.
For the different printhead types the maximum pressures are as follows:
Micro 255
Midi 62 µm 255
Midi 70 µm 200
Macro 150
NOTE: These maximum pressures can be adjusted (using the Head Height option) to
compensate for the distance the printhead is mounted above or below the
printer.
See also: Section 4: “The Setup Menu” > Head Height.
Section 3: “Technical Description” > Ink System > Startup and Shutdown
Routines > Printhead Dependent Parameters table.

Filter Purge
When a new main ink filter is fitted this option is used to pump ink slowly through the
filter to purge it. The two settings are simply On and Off:

On
Sets a fixed pressure of 120 (30 lb/in2) to purge the new filter.

Off
Sets the pressure back to zero and resets the Filter Change time in the System Times option
to 1400 hours. Check that this has happened and if it has not reset the time manually.
To run the Filter Purge routine: select On, allow the pump to run for 5 minutes, then select
Off.

Clear Message Area

Selecting the Clear Message Area option will display the following screen:

48067

CLEAR MESSAGE AREA

Are You Sure?
F1 : Yes F2 : No

Figure 5-10. Clear Message Area screen

If the [F1] (Yes) key is pressed, all messages are cleared from the 5 Message Store and a
destructive RAM test is performed on the message storage area.
When all messages have been cleared, the following status line message will be displayed:
“Message Area Cleared”
If there is a hardware problem and the software cannot access the RAM where the message
is stored, the following status line message will be displayed:
“Failed To Clear Message Area”

Oct 97 5 — 16 4800 Service Manual

 If the [F2] (No) key is pressed the display will revert to the DIAGNOSTICS menu without
clearing the message area and the following status line message will be displayed:
“Message Area Not Cleared”
If there are no messages stored, printing cannot be started and the following System
Warning error message will be displayed:
“Error 3.18 No Message Stored In Memory”

Phase Fault
The printer monitors the operation of the jet for phase and TOF and will report any errors
that are detected. These errors, in most instances, will cause a print failure and the jet will
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.
The normal default setting is On; the software does not remember the Off setting when the
printer switched off. Therefore, 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 will automatically reset the Phase Fault option to On when the
printer state is changed to Printing by the use of the [start] or [F1] keys.
NOTE: If the Quick Start Jet option is used, the Phase Fault function is automatically
switched off, however, it will be switched back 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 table in the “Ink
System” part of Section 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; Monitor Jet.

Phase Period
Under normal idle running conditions the printer will alternately carry 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 will be
updated more frequently.
NOTE: If the Phase Period is altered it should be reset to the default value of 30 before
leaving diagnostics. However, the printer will automatically reset the Phase
Period option to 30 when the printer state is changed to Printing by the use of
the [start] or [F1] keys.

Auto Phase
Auto Phase is normally set to On. This causes the printer to automatically perform TOF
measurements and to adjust the phase position to give optimum drop charging conditions.
The Off setting is not normally used.
See also: Phase; Phase Offset.

4800 Service Manual 5 — 17 Oct 97

 TOF Correction
The TOF Correction option is normally set to On. Under normal operating conditions 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 then 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.
NOTE: The software does not remember the TOF Correction Off setting when the
printer is switched off. TOF Correction is automatically set to On when the
printer is started.

TOF Warm Up
The TOF Warm Up period is normally set to On. In this condition the printer will use only
pressure adjustments to control the TOF during the initial, predetermined (ink type
dependent), period of operation when the printer may be cold and the ink thick. Solvent
addition will usually only occur after this warm-up period has elapsed.
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 selected 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 is a high viscosity.
See also: Ref Pressures.
Section 3: “Technical Description” > Printhead Principles of Operation >
Viscosity Control.
Section 3: “Technical Description” > Ink System > Ink and Solvent Flows >
Solvent Addition.
Section 3: “Technical Description” > Ink System > Ink Type Dependent
Parameters table.

DAC Cal Mode

This option sets the charge DAC control system to calibration mode so that the charge
voltage can be calibrated.
When the DAC Cal Mode option is set to On a constant d.c. voltage is generated by the
charge DAC, allowing the voltage to be adjusted as required.

WARNING: WHEN THE DAC CAL MODE OPTION IS SET TO ON, UP TO 300 V
D.C. IS APPLIED TO THE PRINTHEAD CHARGE ELECTRODE. ENSURE THAT THE
PRINTHEAD COVER IS FITTED AND THE SECURING SCREW IS FIRMLY
TIGHTENED WHEN CARRYING OUT THIS CALIBRATION.
Setting the DAC Cal Mode to Off resets the charge DAC to normal mode for printing.
NOTE: The jet must be off for this option to be used.

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 Linx Printing Technologies plc

DAC Cal Value

This option is used to alter the DAC calibration charge value.
The jet must be off and the DAC Cal Mode option set to On for this function to operate.
Entering a value in the range 800 to 1200 will adjust the charge DAC gain to give a voltage
output from the charge amplifier circuit of 255 volts. When this pre-defined voltage has
been obtained, the Save Cal Value option is used to store the value in Non-Volatile RAM
(NVR).

Save Cal Value

When the pre-defined voltage has been obtained from the charge DAC by setting the DAC
Cal Value option, the value can be saved in NVR. Three gain values can be saved, in the
range 800 to 1200, one for each printhead type:

48068

SAVE CAL VALUE

> Micro : 968
Midi : 968
Macro : 968

Figure 5-11. Save Cal Value screen

Enter the DAC Cal Value for the printhead type in the relevant field.

Alarm Test
This option is used to switch the alarm relay On and Off for test purposes, and can be used
to test any device fitted to the alarm relay.
See also: Section 4: “The Setup Menu” > Alarm Relay.

Generate Test Pattern

A standard test pattern is available for each of the standard and high speed rasters. These
test patterns should be used when taking a print sample after completion of a repair or
when diagnosing print quality problems. The rasters used would be 7 or 16 High
depending on the configuration of the particular model of printer.
When selecting the test pattern up to 14 characters can be appended to the end, which for
reference purposes would normally be the printer and printhead serial numbers (for
example, “LP12345LH12345”). The Generate Test Pattern option is initiated by pressing
[enter], then typing in the serial numbers against the option and then pressing [enter]
again. The default Print Delay and Print Width settings will be used.
The test pattern can then be selected from the CURRENT MESSAGE screen by scrolling
through the five message locations using the up and down arrow keys.

48037

CURRENT MESSAGE : MESSAGE 1

F1 : Change Message F2 : Check Status

F3 : New Message F4 : Change Setup

Figure 5-12. Test pattern in the Current Message screen

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 Linx Printing Technologies plc

Test message editing is achieved by pressing the [F1] Change Message key. Scrolling with
the right arrow key will reveal the part of the test message containing the previously
entered serial numbers.

48072

EDIT MESSAGE : MESSAGE 1

LP12345LH12345

F1 : Size 7 High Full F2 : Bold On

F3 : Field Type

Figure 5-13. Editing the test pattern in the Edit Message screen
NOTE: The Generate Test Pattern option will not be displayed in the SETUP menu if
all of the five message store locations are occupied. Space must be made
available for the test pattern by deleting a message before the option will
appear in the SETUP menu.

System Flush (prior to v1.1 software)

This 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;
• when removing contaminated ink;
• when converting a used printer to a new ink in preparation for calibration;
• when converting a new unused printer to a new ink in preparation for
calibration.
Selecting the System Flush option will display the following screen:

48069

SYSTEM FLUSH
F1 : Empty Tank
F2 : Start Short Cycle – 0
F3 : Start Flush Cycle – 0

Figure 5-14. System Flush screen (prior to v1.1)

Prior to the system being flushed with solvent, all ink must be removed from the ink tank
and this is achieved by pressing the [F1] key to select the Empty Tank option from the
SYSTEM FLUSH menu. This initiates a procedure which is described in more detail in a
maintenance instruction contained in the “Maintenance Instructions” part of this section.
The System Flush menu also displays Short Cycle and Flush Cycle usage counts which will
increment each time the particular cycle is used. The count will be reset to zero when the
power is switched off. If the cycle is aborted before completion the count will not
increment.
See also: Section 5: “Maintenance” > Maintenance Instructions.

System Flush (v1.1 software)

The System Flush option has been updated in Version 1.1 software. As with the previous
System Flush option it can only be selected when the jet is off and is used to completely
flush the ink system in the same circumstances.

Amdt 02
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 Linx Printing Technologies plc

The new 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 will display the following screen:

48206

SYSTEM FLUSH
> Flush Cycle / Tank Empty
Valve Dry

Figure 5-15. System Flush screen (v1.1)

The System Flush procedure is self-explanatory and provides prompts, displayed in the
status line, at each stage to guide the operator through the procedure.
NOTE: The Valve Dry option is for use only by the Linx production department
during manufacture and is NOT to be used by service personnel.

Valve Test
This option allows the valves to be operated by manual selection from the keyboard to aid
fault diagnosis.
48069

SYSTEM FLUSH
F1 : Empty Tank
F2 : Start Short Cycle – 0
F3 : Start Flush Cycle – 0

Figure 5-16. Valve Test screen

The cursor keys are used to select the valve to be tested, and by pressing the [enter] key the
valve will open for 1 second and then close. If the [enter] key is held down the valve will
remain open until the key is released.
The valve options will only be selectable to operate the valves when the jet is off. When the
printer is in the Jet Running or Printing states the VALVE TEST screen only shows the
current state of the valves and they cannot be selected.
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 will also activate the Feed
valve, therefore, if the pump is running (i.e. a Set Pressure has been selected)
the jet will be started.
See also: Set Pressure.
Section 3: “Technical Description” > Ink System > Startup and Shutdown
Routines.

Amdt 02
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 Linx Printing Technologies plc

5.2 Maintenance Instructions

5.2.1 Introduction
The following Maintenance Instructions are provided for the use of Service Engineers
when carrying out certain maintenance tasks on the LINX 4800 Ink Jet Printer. The
primary instruction is the 1400 Hour Scheduled Maintenance procedure which is used for
carrying out maintenance at the recommended intervals of 1400 jet running hours. The
purpose of the scheduled maintenance is to eliminate possible future causes of failure.
The remaining instructions detail various individual aspects of maintaining the printer.
For example, draining, flushing and replenishing the ink system; replacing filters; 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 1400 Hour
Scheduled Maintenance instruction and are carried out as part of that maintenance task.

5.2.2 Maintenance Terminology

Certain maintenance operations detailed in this chapter have specific meanings and these
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 leaking of fluids.
Operate Ensure an item or system functions correctly, as far as can be
ascertained without the use of test equipment or reference to
measurements.
Replenish Refill tank, bottle or other container to a predetermined level,
pressure or quantity, and where necessary:
• remove caps or covers from filler orifices and/or drains;
• clear orifices;
• fill container as directed in item operation;
• ensure drains are free from obstruction;
• ensure gaskets and caps or covers are free from damage;
• refit caps or covers;
• fit locking devices as necessary.

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Fit Correctly attach one item to another.

Refit Fit an item which has previously been removed.
Replace Remove an item and fit a new or serviced item.
Disconnect Uncouple or detach cables, pipelines or controls.
Reconnect Reverse of Disconnect.

5.2.3 Antistatic Precautions

The PCBs in LINX printers carry some static-sensitive components, which can be severely
damaged if subjected to static discharge. Static, which is generated in the human body
through friction and movement, will be discharged through the first contacted route to
earth. Static damage is not always immediately apparent and can cause component failure
up to a year after the static discharge has occurred. Therefore, it is very important that
service engineers use the following antistatic precautions when handling PCBs:
• An industry approved antistatic wrist strap should be worn which
incorporates a resistive component (greater than 2 MΩ) in the lead, and should
be connected to an effective earth point. The continuity of the wrist strap and
the earth point should 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
electronic software components. All LINX PCBs are shipped in special
antistatic boxes and these should be reused for any further transportation.
To facilitate the use of antistatic precautions, an earth stud is fitted to the 4800 printer. This
earth stud provides a convenient and effective earth point to which an antistatic wrist strap
can be connected during maintenance and fault diagnosis.
CAUTION: In order for this stud to provide an effective earth, the printer must be
connected to an earthed mains power supply, but the power should NOT be switched
on.
The earth stud is located on the front face of the ink system enclosure, to the left of the ink
pump. It is a standard size, 10 mm male connector which fits most antistatic wrist straps.

5.2.4 Ink System Cableform Assembly—Solvent Damage

CAUTION: In the event of a major ink leak within the ink system, which requires the
ink system to be washed down with solvent, the ink system cableform assembly could
become damaged by solvent if not protected.
Precautions must be taken to ensure that the solvent does not come into contact with the
ink system cableform assembly. Prior to washing the ink system with solvent the
cableform should be either protected by a covering (plastic bag) or temporarily removed
from the ink system.
Failure to comply with this caution could result in solvent damage to, and electrical
breakdown of, the cableform insulation, which could result in the failure of the ink
system.

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5.2.5 Good Practice

After switching off the printer it is good practice to wait at least 10 seconds before
switching on again. This allows the capacitors to discharge adequately before being
powered-up again.

5.2.6 4800 CE Approval Checklist

CE approval for the LINX 4800 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 the CE approval
and general safety are maintained.

Cabinet
• All three top cover security-headed screws must be fitted.
• EMC gaskets on the top cover and the chassis must be intact and correctly
fitted.
• The earth bonding lead between the top cover and the chassis must be
connected.
• Nothing must impede the ventilation of the printer.

Printhead
• The earth lead from the printhead to the chassis must be connected.
• The cover tube must be correctly fitted and the securing thumb screw firmly
tightened.

Ink System
• Gland fittings from the printhead to the ink system enclosure, and from the ink
system enclosure to the electronics compartment must be fitted and secure.
• The valve gaskets must be correctly fitted and the valves must be firmly
secured.

Electronics
• Links LK4 and LK6 must NOT be left fitted on the IPM PCB.
• The PCBs must have all of their securing screws fitted.

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5.2.7 1400 Hour Scheduled Maintenance Checklist

The Scheduled Maintenance Checklist summarizes the “1400 Hour Scheduled
Maintenance” instruction and provides useful information about a printer’s history. An
example of the form is given at the end of the 1400 Hour 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 recommend that it is reproduced as a two page
duplicate document. The top copy being the Customer Copy and the duplicate being the
Service Copy (printer history).

5.2.8 Maintenance Instruction Documents

Maintenance Instructions detailing the correct procedures for carrying out various
maintenance tasks on the 4800 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.

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4800 Maintenance Instruction

1400 Hour Scheduled Maintenance

Parts Required
FA65027 4200CE/4800 Scheduled Maintenance Kit
comprising:
FA13004 Ink Dip Tube Assembly
FA72050 Feed Damper Assembly
FA73044 Main Ink Filter 10 µm

FA65026 4200CE/4800 Basic Scheduled Maintenance Kit

comprising:
FA13004 Ink Dip Tube Assembly
FA73044 Main Ink Filter 10 µm

Additional Parts Required

FA13005 Solvent Dip Tube Assembly
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
MP10319 Air Filter

Equipment Required
FA65016 Scheduled Maintenance Tool Kit
comprising:
FA65007 Blanking Set 1/8 in. Union Fitting
FA65022 Fluid Connector 3-Way—Service Accessories
FA65023 Pre-Pump Swage Tool
FA69012 Lubricant Small—Main Ink Filter
FA74005 Damper Drain Tube
MP65337 4800/6800 Dip Tube Removal Tool
BP100001 Tube PTFE 1/8 in. OD x 1/16 in. ID, Natural, 1 metre
BP100002 Tube PTFE 1/8 in. OD x 1/16 in. ID, Blue, 1 metre
BP100003 Tube PTFE 1/8 in. OD x 1/16 in. ID, Red, 1 metre
BP100006 Tube PTFE 6 mm OD x 4 mm ID, Natural, 1 metre
BP100009 Tube PTFE 3/16 in. OD x 1/8 in. ID, Natural, 1 metre
BP900003 Solvent Cleaning Bottle
BP900005 Beaker 0.25 Litre
BP940003 Eyeglass x9 Magnification
BP940021 Syringe Polypropylene 50 ml

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4800 Maintenance Instruction

1400 Hour Scheduled Maintenance

BP940029 Cleaning Brush Solvent Resistant

BP940067 Double-Ended Trim Tool
BP999045 Gloves Latex Medical (large)
BP999076 Safety Spectacles Blue

Additional Equipment Required

FA74046 Nozzle Cleaning Service Accessory
MP65339 Mandrel Extraction Tool
BP940052 Tube Cutting Tool 4 mm–14 mm Diameter
BP940060 4800 Security Key
BP999046 Gloves Latex Medical (medium) ) as required
BP999047 Gloves Latex Medical (small) ) as required
BP999066 Gloves Latex Powder-Free (small) ) were recommended
BP999067 Gloves Latex Powder-Free (medium) ) were recommended
BP999068 Gloves Latex Powder-Free (large) ) were recommended
Antistatic Wrist Strap and Lead
DVM (Digital Voltmeter)
Tweezers
Waste ink container (at least 5 litre capacity)
Beaker, stainless steel or glass
Absorbent, lint-free paper towel

Recording
Raise and complete a 1400 Hour Scheduled Maintenance Checklist (not applicable to Linx
Service Engineers). An example of the document is provided at the end of this 1400 Hour
Scheduled Maintenance instruction.

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4800 Maintenance Instruction

1400 Hour Scheduled Maintenance

Procedure

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.
1 Speak to the operators and enquire if there are any problems with the printer
performance.
2 Record the printer and printhead details, and the printhead code and Reference
Modulation taken from the printhead conduit label and the Setup Menu.
3 Shut down the printer and switch off the main power switch at the rear of the
cabinet.
4 Examine the printhead conduit for damage and ensure that it is secured correctly at
the terminating bushes. Examine the mains supply cable for damage and ensure that
the connector is in good condition and correctly connected. Replace as necessary.
5 Remove the printhead from its cover tube. Examine the printhead and
components for damage or obvious misalignment.
6 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 the
Maintenance Instruction “Printhead Cleaning for Pigmented Inks”.
7 Switch the printer on and start the jet. Record all of the required data from the
Monitor Jet and System Times screens. Observe and record any error or fault
warning messages.
8 Stop the jet and switch off the printer.
9 Drain the ink from the ink system. Refer to Maintenance Instruction “Draining the
Ink System”.
10 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.
11 Examine the inside of the ink reservoir and filler tube for any debris (e.g. foil from
an ink bottle cap) and remove if found.

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4800 Maintenance Instruction

1400 Hour Scheduled Maintenance

12a If the printer is fitted with a pre-pump filter and the old style ink dip tube, remove
these two parts and replace them with the new design ink dip tube and integral
filter. Refer to Maintenance Instruction “Ink Tank Dip Tube Replacement”.
12b If the printer already has the new design ink dip tube fitted, simply replace it with
a new part. Refer to Maintenance Instruction “Ink Tank Dip Tube Replacement”.
This action should be carried out at every Scheduled Maintenance.
13 If the printer is fitted with a stainless steel, solvent pick-up filter and the old style
solvent dip tube, remove these two parts and replace them with the new design
solvent dip tube and integral filter. Refer to Maintenance Instruction “Solvent
Tank Dip Tube Replacement”.
NOTE: The new design solvent pick-up filter is not required to be replaced
during a Scheduled Maintenance.
14 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.
15 Examine the ink system tubing for trapping and kinks. Replace any damaged
tubing.
16 Replace the filter in the 3-way fluid connector (pigmented ink printers only).
Refer to Maintenance Instruction “3-Way Fluid Connector Filter Replacement”.
17 Refill the ink system using two 0.5 litre bottles of new ink. Ensure the ink is the
correct type for the printer.
18 Replace the main ink filter. Refer to Maintenance Instruction “Main Ink Filter
Replacement”.
19 Examine the wiring and connectors within the electronics compartment and to the
keyboard for trapping and signs of abrasion. Replace any damaged cables.
20 Remove the air filter as shown in figure 1. Clean the filter using compressed air
blown through in the reverse direction to the normal air flow. Examine the filter
for damage and replace as necessary. Ensure the new filter is fitted with the metal
side facing down.

48142

Pull the filter to the right,

out of the housing, using
the tab attached to the filter

Figure 1. Removing the Air Filter

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4800 Maintenance Instruction

1400 Hour Scheduled Maintenance

21 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 band 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.
22 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.

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. THERE IS A
DANGER OF DEATH OR INJURY FROM ELECTRIC SHOCK IF THE CORRECT
ELECTRICAL SAFETY PRECAUTIONS ARE NOT TAKEN.
23 Calibrate the IPM PCB. Refer to Maintenance Instruction “IPM PCB Calibration”.
24 Perform ink system valve tests. Refer to Maintenance Instructions: “Feed Valve
Test”; “Purge and Gutter Valves Test”; “Solvent Top-up Valve Test”; and
“Solvent Flush Valve Test”.
25 Ensure that the jet is correctly aligned. Refer to Maintenance Instruction “Jet
Alignment and Nozzle Cleaning”.
26 Start the printer and record the parameters displayed on the Monitor Jet screen.
27 While observing the printhead, stop 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 readings and times taken. Both
shutdown and startup should be clean. If any startup takes longer than nominally
2 minutes, check for any associated error messages and investigate the cause of the
problem.
28 Take print samples using the standard test pattern and record the calculated Ref
Modulation on the “1400 Hour Scheduled Maintenance Checklist”. Refer to
Maintenance Instruction “Modulation Range Checks”.
29 Remove the printhead from its cover and reconfirm correct jet alignment. Refer to
Maintenance Instruction “Jet Alignment and Nozzle Cleaning”.
30 Ensure that the printhead cover tube is refitted.

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4800 Maintenance Instruction

1400 Hour Scheduled Maintenance

31 In the System Times diagnostic option, reset the Service time to 1400 hours. In
certain environments, such as dairies or very dusty applications, it may be
necessary to enter a shorter service period of 1200 or even 1000 hours. Discuss this
with the customer before making this decision.
32 Run the printer for ½ hour, taking print samples every 10 minutes using the
standard test pattern. Record the calculated Reference Modulation on the “1400
Hour Scheduled Maintenance Checklist”. Refer to Maintenance Instruction
“Modulation Range Checks”.
33 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 on the Service Report any advice given.
34 Ensure all screws are refitted and secured.
35 Clean the printer top cover and cabinet.
36 On completion of the scheduled maintenance, ensure that the Service Report is
signed by the customer.
37 Ensure that all print samples are retained with the Service Report.
38 The “1400 Hour Scheduled Maintenance” is now completed.

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4800 Maintenance Instruction

1400 Hour Scheduled Maintenance

SCHEDULED MAINTENANCE CHECKLIST

CUSTOMER DATE CALL NUMBER

PRINTER MODEL PRINTER SERIAL No.

PRINTHEAD TYPE PRINTHEAD SERIAL No.

PRINTHEAD CODE (CONDUIT) REF MOD PRINTHEAD 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 & solvent tanks (pigmented inks only) • Stop/start checks
• Examine ink/solvent filler tubes for debris • Perform Mod range checks with print samples
• Replace pre-pump filter (6800 not applicable) • Record calculated Ref Mod value ➼
• Replace ink dip tube (6200 not applicable) • Reconfirm jet alignment
• Replace damper • Reset Service/Maintenance time interval
• Replace solvent pick-up filter (6800 not applicable) • 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

CUSTOMER’S SIGNATURE
NAME
SIGNATURE

Issue 4 Nov 99

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4800 Maintenance Instruction

1400 Hour Scheduled Maintenance

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4800 Maintenance Instruction

Printhead Cleaning for Pigmented Inks

Equipment Required
FA81505/5L General Purpose MEK 1505
BP900003 Solvent Cleaning Bottle
BP900005 Beaker 0.25 Litre
BP940029 Cleaning Brush Solvent Resistant
BP999066 Gloves Latex Powder-Free (small) )
BP999067 Gloves Latex Powder-Free (medium) ) as required
BP999068 Gloves Latex Powder-Free (large) )
BP999076 Safety Spectacles Blue
Absorbent, lint-free paper towel

Introduction
This maintenance instruction details the procedure for cleaning printheads fitted to
printers which use pigmented inks 1009 and 1039. Linx recommend that the printhead
should be checked daily for ink build-up and cleaned if necessary. It should also be
cleaned at intervals of one working week using a non-abrasive, solvent resistant brush
(BP940029).

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.
CAUTION: Contamination of the printhead nozzle assembly. It is recommended that
powder-free latex gloves are 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.

Procedure
1 Stop the jet and wait for the status line message:
“Jet Stopped : You May Now Switch Off”
or wait until the Auto Power Down facility switches the printer off.
2 Switch off the printer and disconnect it from the mains electrical supply.
3 Remove the printhead from the cover tube.

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4800 Maintenance Instruction

Printhead Cleaning for Pigmented Inks

4 Hold the printhead over a beaker, as shown in figure 1, and wash the area (shown
circled) from the charge electrode downwards with solvent.
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.

6361

MIDI

WASH THIS
AREA ONLY

Figure 1. Correct Area of the Printhead to Wash with Solvent

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4800 Maintenance Instruction

Printhead Cleaning for Pigmented Inks

5 Use the brush to gently remove any ink deposits which will not wash off from the
circled area shown in figure 2, paying particular attention to the deflector plates
(figure 2). Do not use the brush to clean the nozzle.

6362

MIDI

CLEAN ONLY
THIS AREA WITH
THE BRUSH

Figure 2. Correct Area of the Printhead to Clean with the Brush

NOTES:
1. 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, phase and TOF sensors,
and between the deflector plates. If these areas are not thoroughly
cleaned the residual carbon can cause short circuits which may damage
the printhead.
2. Over a period of time a thin film of ink pigment builds up on the top
surfaces of the phase and TOF sensors. This deposit must be removed as
it can reduce the ability of the sensors to detect the signal from the
charged ink drops. The recommended method of removing the pigment
deposits is to gently rub the top surfaces of the sensors with a piece of
folded cardboard, such as a business card, until all the deposits have
been removed.

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4800 Maintenance Instruction

Printhead Cleaning for Pigmented Inks

6 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.
7 Allow the printhead to dry.
8 Wash the inside of the printhead cover tube with solvent until all ink has been
removed. Use the brush, where possible, to remove ink deposits which will not
wash off. Finish the cleaning with a wash and allow the cover to dry.
9 Refit the printhead in the cover and securely tighten the knurled screw.
10 The “Printhead Cleaning for Pigmented Inks” maintenance instruction is now
completed.

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4800 Maintenance Instruction

Draining the Ink System

Equipment Required
FA74005 Damper Drain Tube
BP940060 4800 Security Key
BP999045 Gloves Latex Medical (large) )
BP999046 Gloves Latex Medical (medium) ) as required
BP999047 Gloves Latex Medical (small) )
BP999076 Safety Spectacles Blue
Waste ink container (at least 5 litre capacity)
Absorbent, lint-free paper towel

Procedure

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.
1 Switch off the printer and disconnect it from the mains electrical supply.
2 Remove the ink and solvent filler caps.
3 Remove the three security screws from the rear of the top cover using the Security
Key and remove the cover. 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 Carefully lift the feed damper clear of the ink system enclosure.
6 Hold the feed damper in the vertical position with the drain cap uppermost.
Remove the drain cap and connect the Damper Drain Tube Luer fitting (included
in the Damper Drain Tube kit) to the damper drain.

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4800 Maintenance Instruction

Draining the Ink System

7 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 (see figure 1).

68050

Drain Tube

Figure 1. Feed Damper with Drain Tube Connected

8 Switch the printer on and select the System Flush option from the DIAGNOSTICS
menu, which will display the following screen:

48069

SYSTEM FLUSH
F1 : Empty Tank
F2 : Start Short Cycle – 0
F3 : Start Flush Cycle – 0

Figure 2. System Flush Screen (Empty Tank option)

9 Press [F1] to select the Empty Tank option. The SYSTEM FLUSH screen content
will change to the following:
48157

SYSTEM FLUSH
Connect Bleed Line
F1 : Start Pump

Figure 3. System Flush Screen (Start Pump)

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4800 Maintenance Instruction

Draining the Ink System

10 Press [F1] to start the pump. The pump will run at maximum pressure for 1
minute or until [F1] is pressed to stop the pump (this option appears on the screen
while the pump is running). See figure 4:
48158

SYSTEM FLUSH
Tank Empty – Running
F1 : Stop Pump

Figure 4. System Flush Screen (Stop Pump)

CAUTION: Pump damage. Do not allow the ink system pump to run dry. Initiate the
Empty Tank cycle only the number of times required to empty the system of ink. The
pump should not be run for longer than 30 seconds after it becomes noisy through ink
starvation (cavitation). Damage to the pump will result if it is allowed to run
continuously in a dry condition.
11 If the tank is not empty after 1 minute, press [F1] (Start Pump) again to repeat the
operation.
12 Ensure the “3.03 Ink Low” error message is displayed.
13 When the audible pitch of the pump changes press [F1] to stop the pump.
14 Switch the printer off.
15 Disconnect the drain tube from the damper and refit the drain cap.
16 Remove the ink and solvent filler caps.
17 Refit the top cover and the three security screws.
18 Refit the ink and solvent filler caps.
19 The “Draining the Ink System” instruction is now completed.

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4800 Maintenance Instruction

Draining the Ink System

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4800 Maintenance Instruction

Ink Tank Dip Tube Replacement

Parts Required
FA13004 4800 Ink Dip Tube Assembly
BP100006 Tube PTFE 6 mm OD x 4 mm ID, Natural, 1 metre

Equipment Required
MP65337 4800/6800 Dip Tube Removal Tool
BP940052 Tube Cutting Tool 4 mm–14 mm Diameter
BP940060 4800 Security Key
BP999045 Gloves Latex Medical (large) )
BP999046 Gloves Latex Medical (medium) ) as required
BP999047 Gloves Latex Medical (small) )
BP999076 Safety Spectacles Blue
Absorbent, lint-free paper towel

Introduction
The ink tank dip tube used in the 4800 printer has been replaced by a new design of
moulded dip tube and filter assembly. The new unit has an integral 40 µm, stainless steel,
in-line filter fitted inside the dip tube, which makes the pre-pump filter redundant and it
has therefore been removed. This change was implemented on new printers from serial
number LP82608.
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. 4800 Ink Dip Tube and Filter Assembly

This maintenance instruction details the procedure for replacing the older type of ink dip
tube and the pre-pump filter, with the new dip tube and filter assembly. The instruction
also includes the procedure for any subsequent replacement of the new dip tube and filter
assembly which should be carried out at every Scheduled Maintenance.

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4800 Maintenance Instruction

Ink Tank Dip Tube Replacement

Procedure

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.

Printers Fitted with the Older Ink Dip Tube and Pre-pump Filter (prior to
printer serial number LP82608)
1 Switch off the printer and disconnect it from the mains electrical supply.
2 Remove the ink and solvent filler caps.
3 Remove the three security screws from the rear of the top cover using the Security
Key and remove the cover. 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 under the pre-pump filter and around the
area of the ink dip tube to contain any ink which may be spilt.
6 Identify the pre-pump filter outlet pipe and disconnect it from the pump/motor
assembly inlet by unscrewing the compression fitting. Retain the compression
fitting.
7 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. Discard the dip tube, pre-pump
filter and pipe.
8 Cut a new length (300 mm) of pipe (PTFE 6 mm OD x 4 mm ID, Natural) and insert
one end into the new dip tube outlet. Slide the new compression fitting onto the
other end of the pipe and down to the dip tube connection. Screw the compression
fitting firmly onto the connection.
9 Lubricate the two O-rings fitted to the neck of the new dip tube assembly by
applying a small quantity of solvent. Fit the dip tube to the ink tank by pushing it
firmly into place.
10 Slide the compression fitting, retained at Item 6, onto the other end of the pipe.
Insert the pipe into the pump/motor assembly inlet and screw the compression
fitting firmly onto the connection.

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4800 Maintenance Instruction

Ink Tank Dip Tube Replacement

WARNING: LETHAL VOLTAGE. DANGEROUS VOLTAGES ARE PRESENT IN

THIS EQUIPMENT WHEN ELECTRICAL POWER IS APPLIED. EXTREME CARE
MUST BE TAKEN WHEN WORKING INSIDE THE PRINTER WHILE POWER IS
APPLIED TO IT AND THE 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
SAFETY PRECAUTIONS ARE NOT TAKEN.
11 Reconnect the printer to the mains supply and switch the printer on.
12 Start the jet and examine the dip tube and pump/motor compression fittings for
leaks.
13 Shut down and switch off the printer.
14 Remove any absorbent material from the ink system.
15 Remove the ink and solvent filler caps.
16 Refit the top cover and the three security screws.
17 Refit the ink and solvent filler caps.
18 The “Ink Tank Dip Tube Replacement“ is now completed.

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4800 Maintenance Instruction

Ink Tank Dip Tube Replacement

Printers Fitted with the New Design Ink Dip Tube Assembly (from printer
serial number LP82608)
1 Switch off the printer and disconnect it from the mains electrical supply.
2 Remove the ink and solvent filler caps.
3 Remove the three security screws from the rear of the top cover using the Security
Key and remove the cover. 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 which may be spilt.
6 Unscrew the ink dip tube compression fitting and disconnect the ink pick-up pipe.
Discard the compression fitting.
7 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. Discard the dip tube.
8 Prepare the end of the ink pick-up pipe by cutting off the small portion
(approximately 5 mm) previously compressed by the compression fitting. Use the
Tube Cutting Tool to ensure the pipe is cut straight.
9 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. Screw the compression fitting firmly onto the connection.
10 Lubricate the two O-rings fitted to the neck of the new dip tube assembly by
applying a small quantity of solvent. Fit the dip tube to the ink tank by pushing it
firmly into place.

WARNING: LETHAL VOLTAGE. DANGEROUS VOLTAGES ARE PRESENT IN

THIS EQUIPMENT WHEN ELECTRICAL POWER IS APPLIED. EXTREME CARE
MUST BE TAKEN WHEN WORKING INSIDE THE PRINTER WHILE POWER IS
APPLIED TO IT AND THE 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
SAFETY PRECAUTIONS ARE NOT TAKEN.
11 Reconnect the printer to the mains supply and switch the printer on.
12 Start the jet and examine the dip tube compression fitting for leaks.
13 Shut down and switch off the printer.
14 Remove any absorbent material from the ink system.
15 Remove the ink and solvent filler caps.
16 Refit the top cover and the three security screws.
17 Refit the ink and solvent filler caps.
18 The “Ink Tank Dip Tube Replacement“ is now completed.

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4800 Maintenance Instruction

Solvent Tank Dip Tube Replacement

Parts Required
FA13005 4800 Solvent Dip Tube Assembly
FA73006 Miniature Barb Y-Connector 1/16 in.—Pack
BP100001 Tube PTFE 1/8 in. OD x 1/16 in. ID, Natural, 1 metre

Equipment Required
MP65337 4800/6800 Dip Tube Removal Tool
BP940052 Tube Cutting Tool 4 mm–14 mm Diameter
BP940060 4800 Security Key
BP999045 Gloves Latex Medical (large) )
BP999046 Gloves Latex Medical (medium) ) as required
BP999047 Gloves Latex Medical (small) )
BP999076 Safety Spectacles Blue
Absorbent, lint-free paper towel

Introduction
The solvent tank dip tube used in the 4800 printer has been replaced by a new design of
moulded dip tube and filter assembly. The new unit has an integral 20 µm, stainless steel,
in-line filter fitted inside the dip tube, which makes the original solvent pick-up filter
redundant and it has therefore been removed. This change was implemented on new
printers from serial number LP82608.
The dip tube and filter, together with relevant O-rings, come ready assembled in the spare
part pack. A compression fitting is also included.
48217

Figure 1. 4800 Solvent Dip Tube and Filter Assembly

This maintenance instruction details the procedure for replacing the older type of solvent
dip tube and the stainless steel, solvent pick-up filter with the new dip tube and filter
assembly. The instruction also includes the procedure for any subsequent replacement of
the new solvent dip tube and filter assembly.

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4800 Maintenance Instruction

Solvent Tank Dip Tube Replacement

Procedure

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.

Printers Fitted with the Older Solvent Dip Tube and Stainless Steel Solvent
Pick-up Filter (prior to printer serial number LP82608)
1 Switch off the printer and disconnect it from the mains electrical supply.
2 Remove the ink and solvent filler caps.
3 Remove the three security screws from the rear of the top cover using the Security
Key and remove the cover. 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 under the solvent pick-up filter and around
the area of the solvent dip tube to contain any solvent which may be spilt.
6 Identify the solvent pick-up filter outlet pipe and cut it off immediately behind the
A1 barb of the Y-piece connector (approximately 5 mm) using the Tube Cutting
Tool.
7 Remove the dip tube from the solvent tank using the Dip Tube Removal Tool.
Note that the dip tube is not threaded but is a push fit. Discard the dip tube,
solvent pick-up filter and pipe.
8 Cut a new length (250 mm) of pipe (PTFE 1/8 in. OD x 1/16 in. ID, Natural) and
insert one end into the new dip tube outlet. Slide the new compression fitting onto
the other end of the pipe and down to the dip tube connection. Screw the
compression fitting firmly onto the connection.
9 Lubricate the two O-rings fitted to the neck of the new dip tube assembly by
applying a small quantity of solvent. Fit the dip tube to the solvent tank by
pushing it firmly into place.

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4800 Maintenance Instruction

Solvent Tank Dip Tube Replacement

10 Connect the other end of the new solvent pick-up pipe to a new Y-piece connector.
Ensure that the pipe is connected to the ‘stem’ portion of the Y-piece connector (see
figure 2).

48218

SOLVENT
PICK-UP PIPE
'STEM' PORTION OF THE
Y-PIECE CONNECTOR

Figure 2. Connecting the Solvent Pick-up Pipe to the Y-piece Connector

11 Cut off the remaining two solvent pipes from the old Y-piece connector
immediately behind the A1 barbs (approximately 5 mm). Discard the Y-piece
connector.
12 Connect the two solvent pipes to the two ‘arms’ of the new Y-piece connector.

WARNING: LETHAL VOLTAGE. DANGEROUS VOLTAGES ARE PRESENT IN

THIS EQUIPMENT WHEN ELECTRICAL POWER IS APPLIED. EXTREME CARE
MUST BE TAKEN WHEN WORKING INSIDE THE PRINTER WHILE POWER IS
APPLIED TO IT AND THE 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
SAFETY PRECAUTIONS ARE NOT TAKEN.
13 Reconnect the printer to the mains supply and switch the printer on.
14 Start the jet and examine the dip tube and the Y-piece connections for leaks whilst
carrying out a solvent addition test.
15 Shut down and switch off the printer.
16 Remove any absorbent material from the ink system.
17 Remove the ink and solvent filler caps.
18 Refit the top cover and the three security screws.
19 Refit the ink and solvent filler caps.
20 The “Solvent Tank Dip Tube Replacement“ is now completed.

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4800 Maintenance Instruction

Solvent Tank Dip Tube Replacement

Printers Fitted with the New Design Solvent Dip Tube Assembly (from
printer serial number LP82608)
1 Switch off the printer and disconnect it from the mains electrical supply.
2 Remove the ink and solvent filler caps.
3 Remove the three security screws from the rear of the top cover using the Security
Key and remove the cover. 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 solvent dip tube to
contain any solvent which may be spilt.
6 Unscrew the solvent dip tube compression fitting and disconnect the solvent pick-
up pipe. Discard the compression fitting.
7 Remove the dip tube from the solvent tank using the Dip Tube Removal Tool.
Note that the dip tube is not threaded but is a push fit. Discard the dip tube.
8 Prepare the end of the solvent pick-up pipe by cutting off the small portion
(approximately 5 mm) previously compressed by the compression fitting. Use the
Tube Cutting Tool to ensure the pipe is cut straight.
9 Slide the new compression fitting onto the solvent pick-up pipe. Insert the pipe
into the new dip tube outlet and slide the compression fitting down to the dip tube
connection. Screw the compression fitting firmly onto the connection.
10 Lubricate the two O-rings fitted to the neck of the new dip tube assembly by
applying a small quantity of solvent. Fit the dip tube to the solvent tank by
pushing it firmly into place.

WARNING: LETHAL VOLTAGE. DANGEROUS VOLTAGES ARE PRESENT IN

THIS EQUIPMENT WHEN ELECTRICAL POWER IS APPLIED. EXTREME CARE
MUST BE TAKEN WHEN WORKING INSIDE THE PRINTER WHILE POWER IS
APPLIED TO IT AND THE 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
SAFETY PRECAUTIONS ARE NOT TAKEN.
11 Reconnect the printer to the mains supply and switch the printer on.
12 Start the jet and examine the dip tube compression fitting for leaks.
13 Shut down and switch off the printer.
14 Remove any absorbent material from the ink system.
15 Remove the ink and solvent filler caps.
16 Refit the top cover and the three security screws.
17 Refit the ink and solvent filler caps.
18 The “Solvent Tank Dip Tube Replacement“ is now completed.

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4800 Maintenance Instruction

3-Way Fluid Connector Filter Replacement

Parts Required
FA74163 3-Way Connector Replacement Filter

Equipment Required
BP940060 4800 Security Key
BP999066 Gloves Latex Powder-Free (small) )
BP999067 Gloves Latex Powder-Free (medium) ) as required
BP999068 Gloves Latex Powder-Free (large) )
BP999076 Safety Spectacles Blue
Tweezers
Absorbent, lint-free paper towel

Procedure

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.
1 Shut down and switch off the printer. Ensure that it is switched off at the mains
electrical supply.
2 Remove the ink and solvent filler caps.
3 Remove the three security screws from the rear of the top cover using the Security
Key and remove the cover. 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 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 which may be spilt.
7 Unscrew and remove the 3-way fluid connector assembly screw and separate the
two parts of the connector (see figure 1).

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4800 Maintenance Instruction

3-Way Fluid Connector Filter Replacement

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 halves of the
fluid connector, using the thicker, grooved end of the plastic insert/extract tool
supplied with the new filter.
CAUTION: 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 are worn. Handling of the new parts should be performed carefully using a
pair of tweezers. The procedure should 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 half 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.

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4800 Maintenance Instruction

3-Way Fluid Connector Filter Replacement

15 Refit and fully tighten the fluid connector assembly screw.

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.
18 Remove the ink and solvent filler caps.
19 Refit the top cover and the three security screws.
20 Refit the ink and solvent filler caps.
21 The “3-Way Fluid Connector Filter Replacement” procedure is now completed.

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4800 Maintenance Instruction

3-Way Fluid Connector Filter Replacement

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4800 Maintenance Instruction

Main Ink Filter Replacement

Parts Required
FA73044 Main Ink Filter 10 µm
BP100006 Tube PTFE 6 mm OD x 4 mm ID, Natural, 300 mm

Equipment Required
FA69012 Lubricant Small—Main Ink Filter
MP65339 Mandrel Extraction Tool
BP940052 Tube Cutting Tool 4 mm–14 mm Diameter
BP940060 4800 Security Key
BP999066 Gloves Latex Powder-Free (small) )
BP999067 Gloves Latex Powder-Free (medium) ) as required
BP999068 Gloves Latex Powder-Free (large) )
BP999076 Safety Spectacles Blue
Absorbent, lint-free paper towel

Procedure

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.

Main Ink Filter Replacement

1 Switch off the printer and disconnect it from the mains electrical supply.
2 Remove the ink and solvent filler caps.
3 Remove the three security screws from the rear of the top cover using the Security
Key and remove the cover. 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 Carefully lift the main ink filter clear of the ink system enclosure.
6 Place absorbent, lint-free paper towel under the filter to contain any ink which may
be spilt.
7 Unscrew the fluid connection from the inlet side of the old filter.

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4800 Maintenance Instruction

Main Ink Filter Replacement

8 Hold the disconnected end of the old filter, then pull off the glove from the hand
holding the filter so that the glove turns inside out over the filter (figure 1). Fit a
new glove on bare hand.

68051

Figure 1. Enclosing One End of the Main Ink Filter with a Rubber Glove
9 Remove the nut, olive and ferrule from the inlet tube and discard.
10 Cut the tube immediately behind where it was compressed by the olive
(approximately 5 mm) using the Tube Cutting Tool to ensure that a clean and
straight cut is made. Remove the cut portion of tube and push the stainless steel
insert back into the inlet tube until it is flush with the end. (It may help to grip the
tube if it is held in a piece of abrasive paper.)
11 Fit the new nut, olive and ferrule over the tube in the correct order (see figure 2).

6203

Ferrule Olive Nut

Figure 2. Correct Assembly of the Main Ink Filter Fluid Connections

12 Insert the end of the inlet tube into the inlet port of the new filter until it meets the
tube stop inside the elbow. Do not push the tube past the tube stop.
13 Push the ferrule, olive and nut up to the elbow and screw the nut on one turn.

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4800 Maintenance Instruction

Main Ink Filter Replacement

14 Apply two drops of thread assembly lubricant to the threads of the filter elbow
which is being connected (see figure 3).

6223

Figure 3. Applying Thread Lubricant to the Main Ink Filter Fluid Connections
15 Hold the elbow of the filter inlet in the jaws of spanner (wrench) of the correct size,
as shown in figure 4, and tighten the nut with fingers only until firm resistance is
felt. DO NOT OVERTIGHTEN. If available, use a torque wrench set to 3 Nm.
Note that if the nut reaches the end of the threaded portion of the elbow, the nut is
overtight.
6222

Figure 4. Correct Tightening of the Main Ink Filter Fluid Connections

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4800 Maintenance Instruction

Main Ink Filter Replacement

16 Unscrew the fluid connection from the outlet side of the old filter.
17 Hold the disconnected end of the old filter, then pull off the glove from the hand
holding the filter so that the glove turns inside out over the filter. The old filter
will now be enclosed from both ends in gloves (figure 5). Discard the old filter. Fit
a new glove on bare hand.

68052

Figure 5. Both Ends of the Main Ink Filter Enclosed with Rubber Gloves
18 Remove the nut, olive and ferrule from the outlet tube and discard.
19 Take a new length (190 millimetres) of tube (PTFE 6 mm OD x 4 mm ID, Natural)
and fit the steel insert from the disconnected outlet tube into one end until it is
flush with the end (it may help to grip the tube if it is held in a piece of abrasive
paper). Fit the new nut, olive and ferrule over the tube in the correct order (see
figure 2).
20 Insert the end of the tube into the outlet port of the new filter until it meets the tube
stop inside the elbow. Do not push the tube past the tube stop.
21 Push the ferrule, olive and nut up to the elbow and screw the nut on one turn.
22 Apply two drops of thread assembly lubricant to the threads of the filter elbow
which is being connected (see figure 3).
23 Hold the elbow of the filter outlet in the jaws of spanner (wrench) of the correct
size, as shown in figure 4, and tighten the nut with fingers only until firm
resistance is felt. DO NOT OVERTIGHTEN. If available, use a torque wrench set
to 3 Nm. Note that if the nut reaches the end of the threaded portion of the elbow,
the nut is overtight.

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4800 Maintenance Instruction

Main Ink Filter Replacement

Main Ink Filter Purge

After replacing the main ink filter, the new filter must be purged with ink to remove any
particles from the outlet side of the filter which may be present from the manufacturing
process.
24 Remove the ink tank filler cap and then remove the ink mandrel assembly using
the Mandrel Extraction Tool.
25 Insert the free end of the new length of tube (fitted to the filter outlet) deep into the
tank (see figure 6). Pack absorbent, lint-free paper towel around the opening of the
filler tube to contain any ink splashes.

68048

From ink
system pump

Main ink filter

outlet tube inserted
in filler neck

Figure 6. Clearing the Main Ink Filter Outlet of Debris

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4800 Maintenance Instruction

Main Ink Filter Replacement

WARNING: LETHAL VOLTAGE. DANGEROUS VOLTAGES ARE PRESENT IN

THIS EQUIPMENT WHEN ELECTRICAL POWER IS APPLIED. EXTREME CARE
MUST BE TAKEN WHEN WORKING INSIDE THE PRINTER WHILE POWER IS
APPLIED TO IT AND THE 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
SAFETY PRECAUTIONS ARE NOT TAKEN.
26 Switch the printer on and access the DIAGNOSTICS menu.
27 Scroll to the Filter Purge option and set it to On to initiate the purge sequence
(figure 7):

48089

DIAGNOSTICS
Phase Offset : 0
Set Pressure : 120
Ref Pressures
> Filter Purge : On

Figure 7. Filter Purge Option in the Diagnostics Menu

28 Hold the tube in the ink tank for the duration of the purge sequence to prevent it
slipping out. The ink will be circulated through the ink system primary circuit at a
Set Pressure of 120, which will clear any plastic debris from the outlet side of the
filter.
29 Leave the Filter Purge sequence running for 4 or 5 minutes and check for leaks at
the main ink filter and all other fluid connections. If any leaks are observed from
the filter connections, stop the pump and tighten the appropriate elbow nut by half
a turn. Remember to hold the elbow with a wrench to avoid damage to the filter,
and use only fingers to tighten the nut. Repeat the Filter Purge sequence after
tightening.
30 When satisfied that there are no leaks in the system, set the Filter Purge option to
Off.
31 If the System Warning message “3.03 Ink Low” is reported, add another 0.5 litre
bottle of ink to the tank.
32 Access the SYSTEM TIMES menu and check that the Filter Change time has
automatically reset to 1400. If it has not, manually reset the time to 1400.
33 Switch the printer off.
34 Disconnect the length of tube which was left connected to the inlet of the venturi
manifold, by unscrewing the nut from the blue Festo fitting and then pulling the
tube off the plastic fitting. Discard the tube but retain the nut.

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4800 Maintenance Instruction

Main Ink Filter Replacement

35 Remove the new filter outlet tube from the tank and wipe it clean. Remove the
absorbent packing and discard.
36 Refit the ink mandrel assembly.
37 Temporarily refit the ink filler cap.
38 Fit the nut which was removed from the venturi manifold over the end of the tube.
Push the tube onto the manifold connection (it may help to grip the tube if it is
held with a piece of abrasive paper). Screw the nut firmly onto the manifold
connection.
39 Remove any absorbent material from the ink system enclosure and position the
new main ink filter in its original location.
40 Remove the ink and solvent filler caps.
41 Refit the top cover and the three security screws.
42 Refit the ink and solvent filler caps.
43 The “Main Ink Filter Replacement” is now completed.

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4800 Maintenance Instruction

Main Ink Filter Replacement

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4800 Maintenance Instruction

IPM PCB Calibration

Equipment Required
BP940060 4800 Security Key
BP940067 Double-Ended Trim Tool
Antistatic Wrist Strap and Lead
DVM (Digital Voltmeter)

Introduction
If either the IPM PCB or the Pressure Transducer are replaced, or if the software is
exchanged or upgraded, the electronics system must be recalibrated. (Software exchange
or upgrade reinitializes the non-volatile RAM, causing the calibration values to be reset to
the default values). The following procedures detail how to calibrate the Pressure
Transducer and Charge Amplifier, both of which must be carried out under 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

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. THERE IS A
DANGER OF DEATH OR INJURY FROM ELECTRIC SHOCK IF THE CORRECT
ELECTRICAL SAFETY PRECAUTIONS ARE NOT TAKEN.

CAUTION: The PCBs contain static-sensitive devices. Antistatic precautions must be

taken when handling the PCBs. An antistatic wrist band 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.

Pressure Transducer Calibration

1 Switch off the printer and disconnect it from the mains electrical supply.
2 Remove the ink and solvent filler caps.
3 Remove the three security screws from the rear of the top cover using the Security
Key and remove the cover. Position the cover so that the IPM PCB and the
keyboard can both be accessed.
4 Temporarily refit the ink and solvent filler caps to reduce evaporation of the ink
and solvent.

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4800 Maintenance Instruction

IPM PCB Calibration

5 Disconnect the pump drive connector PL6 (marked PUMP on the PCB) from the
top right corner of the IPM PCB.
6 Switch the printer on. Using a Digital Volt Meter (DVM) set to DC Volts, connect
the negative lead to test point TP13 or TP15 (0 V) and the positive lead to TP5 (RD
PRESS) on the IPM PCB.
7 Turn VR2 on the IPM PCB anticlockwise until the DVM reading is greater than 1
volt.
8 Slowly turn VR2 clockwise until a reading of +20 millivolts is achieved, with a
tolerance of ±2 millivolts.
9 Switch off the printer and disconnect the DVM.
10 Reconnect the pump drive connector PL6.
11 The pressure transducer calibration is now completed.

Charge Amplifier Calibration

NOTE: Leave the printer switched on for at least 30 minutes before proceeding with
the following calibration.

Charge at Zero
12 Switch the printer on.
13 Connect the DVM negative lead to test point TP13 or TP15 (0 V) 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 volt. Leave the DVM connected to these test points.

Charge at Full Scale

WARNING: LETHAL VOLTAGE. WHEN THE CALIBRATE MODE IS SET TO “DAC

CAL MODE” THERE WILL BE A HIGH VOLTAGE ON THE CHARGE ELECTRODE.
THE PRINTHEAD COVER TUBE MUST BE CORRECTLY FITTED AND SECURED
WHEN CARRYING OUT THE CHARGE CALIBRATION PROCEDURE. THERE IS A
DANGER OF DEATH OR INJURY FROM ELECTRIC SHOCK IF THE PRINTHEAD
COVER TUBE IS NOT FITTED DURING THIS PROCEDURE.
15 Access the DIAGNOSTICS menu and scroll to the DAC Cal Mode option:

48161

DIAGNOSTICS
> DAC Cal Mode : Off
DAC Cal Value : 1000
Save Cal Value :
Alarm Test : Off

Figure 1. DAC Cal Mode option in the Diagnostics menu

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4800 Maintenance Instruction

IPM PCB Calibration

16 Press [enter] to select the DAC Cal Mode setting. Use the left or right arrow keys
to set the option to On, then press [enter] 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, the DAC Cal Mode can be
set to Off, the DVM can be disconnected and the top cover refitted. If the reading
is outside the specification, leave the DVM connected and continue with the
remainder of the calibration procedure.
18 Select DAC Cal Value option from the DIAGNOSTICS menu and enter a number
lower or higher than the 1000 setting to reduce or increase 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. Make a note of the DAC Cal Value which gives
the correct DVM reading.
20 Scroll back to the DAC Cal Mode option, press [enter], set the option to Off and
press [enter] again. Check that the DVM reading returns to 0 volts ±0.5 volt.
21 Scroll down to the Save Cal Value option and press [enter]; the Save Cal Value
screen will be displayed:

48068

SAVE CAL VALUE

> Micro : 968
Midi : 968
Macro : 968

Figure 2. Save Cal Value menu

22 Enter the noted DAC Cal Value against each of the printhead types: Micro, Midi
and Macro. Press [enter] after amending each of the three settings to save the new
DAC Cal Values.
23 Switch the printer off.
24 Disconnect the DVM leads.
25 Remove the ink and solvent filler caps.
26 Refit the top cover and the three security screws.
27 Refit the ink and solvent filler caps.
28 The “IPM PCB Calibration” is now completed.

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4800 Maintenance Instruction

IPM PCB Calibration

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4800 Maintenance Instruction

Feed Valve Test

Equipment Required
BP999045 Gloves Latex Medical (large) )
BP999046 Gloves Latex Medical (medium) ) as required
BP999047 Gloves Latex Medical (small) )
BP999076 Safety Spectacles Blue

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.

Testing for a Leaking Feed Valve (closed)

1 Switch the printer on and start the jet.
2 From the DIAGNOSTICS menu set the Flush Shutdown option to Off (figure 1):

48162

DIAGNOSTICS
> Flush Shutdown : Off
Monitor Jet
System Times
System Config

Figure 1. Flush Shutdown Option in the Diagnostics Menu

3 Stop the jet.
4 Scroll to the Set Pressure option and set it to 255 (figure 2):

48163

DIAGNOSTICS
System Config
Phase : 0
Phase Offset : 0
> Set Pressure : 255

Figure 2. Set Pressure Option in the Diagnostics Menu

5 Remove the printhead cover tube and observe the nozzle for 2 or 3 minutes for
signs of leakage. If leakage is observed, replace the feed valve and repeat the test.

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4800 Maintenance Instruction

Feed Valve Test

6 Switch off the printer and refit the printhead cover tube.
NOTE: Switching off the printer will automatically reset the Flush Shutdown
and Set Pressure options to their default settings of “Auto” and “0”,
respectively.
7 The “Feed Valve Test” is now completed.

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4800 Maintenance Instruction

Purge and Gutter Valves Tests

Parts Required
FA65022 Fluid Connector 3-Way—Service Accessories
FA74135 M3 x 28 CSK Poz SS Screw—Pack as required
FA74136 Gasket Fluid Connector 3-Way—Pack as required

Equipment Required
FA65007 Blanking Set 1/8 in. Union Fitting
BP900005 Beaker 0.25 Litre
BP940060 4800 Security Key
BP999045 Gloves Latex Medical (large) )
BP999046 Gloves Latex Medical (medium) ) as required
BP999047 Gloves Latex Medical (small) )
BP999076 Safety Spectacles Blue
Absorbent, lint-free paper towel

Procedures

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.

Testing for a Leaking Purge or Gutter Valve (closed)

1 Switch the printer on and start the jet using the Quick Start Jet option in the
DIAGNOSTICS menu:

48164

DIAGNOSTICS
Start Jet
> Quick Start Jet
Clear Nozzle
Nozzle Flush

Figure 1. Quick Start Jet Option in the Diagnostics Menu

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4800 Maintenance Instruction

Purge and Gutter Valves Tests

2 Access the MONITOR JET screen from the DIAGNOSTICS menu.

3 Observe the MONITOR JET screen parameters (figure 2). Wait until the TOF
reading is approximately equal to the Ref TOF reading, and the Set Pressure
(Pressure) reading has stabilized. Note the Set Pressure reading:

48060

MONITOR JET
Press : 198 Solv Add : 200
TOF : 18553 Ref TOF : 18500
Modln : 150 Ref Modln : 150
Phase : 6 Read Press : 194

Figure 2. Monitor Jet Screen

4 Shut down and switch off the printer, and disconnect it from the mains electrical
supply.
5 Remove the ink and solvent filler caps.
6 Remove the three security screws from the rear of the top cover using the Security
Key and remove the cover. Position the cover so that the keyboard can be
accessed.
7 Temporarily refit the ink and solvent filler caps to reduce evaporation of the ink
and solvent.

Printhead with Swagelok Union Fittings

8 Place absorbent, lint-free paper towel under the Swagelok union fittings, located in
the ink system enclosure, to contain any ink which may be spilt.
9 Disconnect (separate) the purge line (blue tube) Swagelok union fittings. Fit
blanking plugs and/or caps to the disconnected fittings.
10 Switch the printer on and start the printer in Diagnostics using the Quick Start Jet
option.
11 Observe the MONITOR JET screen parameters (figure 2). Wait until the TOF
reading is approximately equal to the Ref TOF reading, and the Set Pressure
reading has stabilized. Note the Set Pressure reading.
12 If the Set Pressure (Pressure) reading is less than the reading noted at Item 3,
minus 3, then the Purge or Gutter valve is leaking. To determine which valve is
leaking continue from Item 13.
Otherwise, shut down the printer, remove the blanking plugs and/or caps,
reconnect the purge line union fittings and proceed to “Testing for a Leaking or
Inoperative Gutter Valve (open)”.

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4800 Maintenance Instruction

Purge and Gutter Valves Tests

CAUTION: In the following operation, use the correct solvent type that corresponds to
the ink type being used in the printer.
13 Remove the blanking plug or cap from the purge line union fitting (Purge valve
end not the printhead end) and place the end of the 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 then the Purge
valve is leaking and must be replaced.

48176

Purge
valve
Gutter
valve Blue line tubing from
Purge valve port 11
on the manifold
1
2
3
4
5

Purge line union fitting

placed in the solvent

Figure 3. Testing for a Leaking Purge or Gutter Valve

14 After replacing either valve repeat this instruction from the beginning as both
valves may have been leaking.
15 On completion of the test, shut down the printer, remove the blanking plugs and/
or caps and reconnect the purge line union fittings.

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4800 Maintenance Instruction

Purge and Gutter Valves Tests

Printhead Fitted with a 3-Way Fluid Connector

8 Carefully lift the 3-way fluid connector clear of the ink system enclosure.
9 Place absorbent, lint-free paper towel under the 3-way fluid connector to contain
any ink which may be spilt.
10 Unscrew and remove the 3-way fluid connector assembly screw and separate the
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 4). 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.
The purpose of the Purge/Gutter Test fluid connector is to blank off the purge line.

O-ring gasket
68094

Assembly
screws

O-ring gasket
d
thea
he Prin
To t

Purge line tube

Locating
lug

Locating
m recess
kS yste
e In
m th
Fro

Figure 4. Purge/Gutter Test Fluid Connector Fitted in the 3-Way Fluid Connector
12 Switch the printer on and start the printer in Diagnostics using the Quick Start Jet
option.
13 Observe the MONITOR JET screen parameters (figure 2). Wait until the TOF
reading is approximately equal to the Ref TOF reading, and the Set Pressure
reading has stabilized. Note the Set Pressure reading.
14 If the Set Pressure (Pressure) reading is less than the reading noted at Item 3,
minus 3, then the Purge or Gutter valve is leaking. To determine which valve is
leaking continue from Item 15.
Otherwise, shut down the printer, disconnect and remove the Purge/Gutter Test
fluid connector, and reconnect the 3-way fluid connector using a new O-ring gasket
(supplied in FA65022 Fluid Connector 3-Way—Service Accessories). Ensure that
the assembly screw is tight. Proceed to “Testing for a Leaking or Inoperative
Gutter Valve (open)”.

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4800 Maintenance Instruction

Purge and Gutter Valves Tests

CAUTION: In the following operation, use the correct solvent type that corresponds to
the ink type being used in the printer.
15 Place the free end of the purge line tube in a container of clean solvent (figure 5). 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 5. Testing for a Leaking Purge or Gutter Valve (closed)

16 After replacing either valve repeat this instruction from the beginning as both
valves may have been leaking.
17 On completion of the test, shut down the printer, disconnect and remove the
Purge/Gutter Test fluid connector, and reconnect the 3-way fluid connector using
a new O-ring gasket (supplied in FA65022 Fluid Connector 3-Way—Service
Accessories). Ensure that the assembly screw is tight.

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4800 Maintenance Instruction

Purge and Gutter Valves Tests

Testing for a Leaking or Inoperative Gutter Valve (open)

1 Remove the printhead from its cover tube.
2 Scroll to the Clear Nozzle option in the DIAGNOSTICS menu. Select the option
and initiate one Clear Nozzle sequence (20 seconds) by pressing [enter].
CAUTION: In the following operation, use the correct solvent type that corresponds to
the ink type being used in the printer.
3 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.
4 Carry out the “Jet Alignment and Nozzle Cleaning” Maintenance Instruction,
checking the 3-way fluid connector for leaks at the same time.
5 Remove any absorbent material from the ink system enclosure and reposition the
Swagelok union fittings/3-way fluid connector back in the original location.
6 Remove the ink and solvent filler caps.
7 Refit the top cover and the three security screws.
8 Refit the ink and solvent filler caps.
9 The “Purge and Gutter Valves Tests” are now completed.

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4800 Maintenance Instruction

Solvent Flush Valve Tests

Equipment Required
BP940060 4800 Security Key
BP999045 Gloves Latex Medical (large) )
BP999046 Gloves Latex Medical (medium) ) as required
BP999047 Gloves Latex Medical (small) )
BP999076 Safety Spectacles Blue

Procedures

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.

Testing for an Inoperative Solvent Flush Valve

NOTE: Only carry out this test after having successfully completed the “Testing for a
Leaking or Inoperative Gutter Valve (open)” procedure in the “Purge and
Gutter Valves Tests” maintenance instruction.
1 Shut down and switch off the printer, and disconnect it from the mains electrical
supply.
2 Remove the ink and solvent filler caps.
3 Remove the three security screws from the rear of the top cover using the Security
Key and remove the cover. 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 Switch the printer on.
6 In the DIAGNOSTICS menu, note the Flush Shutdown option setting and then set
it to On if it is not already (figure 1):

48165

DIAGNOSTICS
> Flush Shutdown : On
Monitor Jet
System Times
System Config

Figure 1. Flush Shutdown Option in the Diagnostics Menu

7 Start the jet using the Start Jet option in the DIAGNOSTICS menu.

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4800 Maintenance Instruction

Solvent Flush Valve Tests

8 When the jet has successfully started press the [stop] key on the keyboard to cause
a full flush 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 then 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.
9 Test for an audible click when the Solvent Flush valve is switched on and off. This
can be determined by setting the Solvent Flush option, in the VALVE TEST menu,
from Off to On (figure 2). Reset it to Off when the test is completed:

48219

VALVE TEST
Purge : Off
Gutter : Off
Solvent Top-Up : Off
> Solvent Flush : On

Figure 2. Solvent Flush Option in the Valve Test Menu

10 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 tube filter; inefficient venturi; blocked in-line feed filter. All
possibilities should be investigated before deciding to replace the Solvent Flush
valve. After investigating and rectifying either fault repeat the test.
11 On completion of the test at Item 9, return the Flush Shutdown option setting to
that noted in Item 6.

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4800 Maintenance Instruction

Solvent Flush Valve Tests

Testing for a Leaking Solvent Flush Valve

12 In the DIAGNOSTICS menu, scroll to the Set Pressure option and set it to 255
(figure 3):

48163

DIAGNOSTICS
System Config
Phase : 0
Phase Offset : 0
> Set Pressure : 255

Figure 3. Set Pressure Option in the Diagnostics Menu

13 Scroll to the Clear Nozzle option in the DIAGNOSTICS menu. Select the option
and initiate one Clear Nozzle sequence by pressing [enter].
14 While the Clear Nozzle sequence is in operation (20 seconds), use a finger to gently
flick the pipe connecting the solvent tank to the Solvent Top-up and Solvent Flush
valves, to cause bubbles to appear. 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:

48220

Solvent Flush
valve

From solvent tank

pick-up tube

Figure 4. Creating Bubbles to Test the Solvent Flush Valve

15 Switch off the printer.
16 Remove the ink and solvent filler caps.
17 Refit the top cover and the three security screws.
18 Refit the ink and solvent filler caps.
19 The “Solvent Flush Valve Tests” are now completed.

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4800 Maintenance Instruction

Solvent Flush Valve Tests

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4800 Maintenance Instruction

Solvent Top-up Valve Tests

Equipment Required
BP940060 4800 Security Key
BP999045 Gloves Latex Medical (large) )
BP999046 Gloves Latex Medical (medium) ) as required
BP999047 Gloves Latex Medical (small) )
BP999076 Safety Spectacles Blue

Procedures

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.

Testing for a Leaking Solvent Top-up Valve

1 Shut down and switch off the printer, and disconnect it from the mains electrical
supply.
2 Remove the ink and solvent filler caps.
3 Remove the three security screws from the rear of the top cover using the Security
Key and remove the cover. 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 Switch the printer on.
6 Use a finger to gently flick the pipe connecting the solvent tank to the Solvent Top-
up and Solvent Flush valves, to cause bubbles to appear (figure 1):

48220

Solvent Flush
valve

From solvent tank

pick-up tube

Figure 1. Creating Bubbles to Test the Solvent Top-up Valve

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4800 Maintenance Instruction

Solvent Top-up Valve Tests

7 Access the DIAGNOSTICS menu, scroll to the Set Pressure option and set it to 255
(figure 2):

48163

DIAGNOSTICS
System Config
Phase : 0
Phase Offset : 0
> Set Pressure : 255

Figure 2. Set Pressure Option in the Diagnostics Menu

8 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 then the Solvent Top-up valve is leaking and must be replaced.

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4800 Maintenance Instruction

Solvent Top-up Valve Tests

Testing for an Inoperative Solvent Top-up 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.
9 Set the Set Pressure option to 50.
10 Select the Valve Test option from the DIAGNOSTICS menu.
11 In the VALVE TEST menu set the Solvent Top-up valve to On by pressing and
holding the [enter] key (figure 3). The valve will remain on as long as the enter key
is held down. Note that the Feed valve will also be automatically switched on.
Reset the Solvent Top-up valve to Off when the test is completed:

48166

VALVE TEST
Feed : On
Purge : Off
Gutter : Off
> Solvent Top-Up : On

Figure 3. Valve Test Screen in the Diagnostics Menu

12 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 valve
is not heard to operate when selected (no audible click), then the Solvent Top-up
valve is not operating. This symptom could be caused by a faulty Solvent Top-up
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 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 tube filter; inefficient
venturi. All possibilities should be investigated before deciding to replace the
Solvent Top-up valve. After investigating and rectifying either fault repeat the
test.
13 Switch off the printer.
14 Remove the ink and solvent filler caps.
15 Refit the top cover and the three security screws.
16 Refit the ink and solvent filler caps.
17 The “Solvent Top-up Valve Tests” are now completed.

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4800 Maintenance Instruction

Solvent Top-up Valve Tests

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4800 Maintenance Instruction

Blocked Gutter Clearance Procedure

Parts Required
FA65022 Fluid Connector 3-Way—Service Accessories
FA74135 M3 x 28 CSK Poz SS Screw—Pack as required
FA74136 Gasket Fluid Connector 3-Way—Pack as required

Equipment Required
BP900003 Solvent Cleaning Bottle
BP940060 4800 Security Key
BP999066 Gloves Latex Powder-Free (small) )
BP999067 Gloves Latex Powder-Free (medium) ) as required
BP999068 Gloves Latex Powder-Free (large) )
BP999076 Safety Spectacles Blue
Empty 0.5 litre ink bottle
Correct solvent for the printer as required
Absorbent, lint-free paper towel

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 will force 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

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.
WARNING: HIGH PRESSURE INK JET. DURING THE FOLLOWING PROCEDURE
INK WILL BE 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 OBSERVE THESE SAFETY PRECAUTIONS MAY RESULT IN
EYE DAMAGE OR SKIN CONTAMINATION.

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4800 Maintenance Instruction

Blocked Gutter Clearance Procedure

1 Shut down and switch off the printer, and disconnect it from the mains electrical
supply.
2 Remove the ink and solvent filler caps.
3 Remove the three security screws from the rear of the top cover using the Security
Key and remove the cover. 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 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 which may be spilt.
7 Unscrew and remove the 3-way fluid connector assembly screw and separate the
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
screws

O-ring gasket
d
thea
he Prin
To t

Ink system feed line

Locating connected to the
lug printhead gutter line

Locating
m recess
kS yste
the In
From

Figure 1. Gutter Clear Fluid Connector Fitted in the 3-Way Fluid Connector
9 Remove the printhead cover tube.
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.
11 Switch the printer on.

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4800 Maintenance Instruction

Blocked Gutter Clearance Procedure

12 Access the DIAGNOSTICS menu, scroll to the Set Pressure option and set it to 255
(figure 2):

48163

DIAGNOSTICS
System Config
Phase : 0
Phase Offset : 0
> Set Pressure : 255

Figure 2. Set Pressure Option in the Diagnostics Menu

13 Select the Valve Test option from the DIAGNOSTICS menu.
14 In the VALVE TEST menu set the Feed valve to On by pressing and holding the
[enter] key (figure 3). The valve will remain on as long as the enter key is held
down. The full force of the maximum running pressure will now be applied to the
gutter:

48221

VALVE TEST
> Feed : On
Purge : Off
Gutter : Off
Solvent Top-Up : Off

Figure 3. Valve Test Screen in the Diagnostics Menu

15 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 releasing
the [enter] key.
16 Set the Set Pressure option to 0 (zero).
17 If the gutter is still blocked after 1 minute, wait 1 minute and repeat Items 12 to 16.
If after this the gutter is still blocked then the printhead must be replaced.
18 Switch off the printer.
19 Remove the printhead and sealing material from the ink bottle.
CAUTION: In the following operation, use the correct solvent type that corresponds to
the ink type being used in the printer.
20 Thoroughly wash the printhead paying particular attention to the gutter assembly
location on the printhead.

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Blocked Gutter Clearance Procedure

21 Disconnect and remove the Gutter Clear fluid connector, and reconnect the 3-way
fluid connector using a new O-ring gasket (supplied in FA65022 Fluid Connector 3-
Way—Service Accessories). Ensure that the assembly screw is tight.
22 Carry out the “Jet Alignment and Nozzle Cleaning” maintenance instruction,
checking the 3-way fluid connector for leaks at the same time.
23 Remove any absorbent material from the ink system enclosure and reposition the
3-way fluid connector back in its original location.
24 Refit the printhead cover tube ensuring that the securing screw is fully tightened.
25 Remove the ink and solvent filler caps.
26 Refit the top cover and the three security screws.
27 Refit the ink and solvent filler caps.
28 The “Blocked Gutter Clearance Procedure” is now completed.

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4800 Maintenance Instruction

Jet Alignment and Nozzle Cleaning

Parts Required
FA73051 Screw M2x6 Lg Pan Hd Poz SS Pack
FA73052 Washer Shakeproof Int M2 SS Pack

Equipment Required
FA74046 Nozzle Cleaning Service Accessory
BP900003 Solvent Cleaning Bottle
BP900005 Beaker 0.25 Litre
BP940003 Eyeglass x9 Magnification
BP999066 Gloves Latex Powder-Free (small) )
BP999067 Gloves Latex Powder-Free (medium) ) as required
BP999068 Gloves Latex Powder-Free (large) )
BP999076 Safety Spectacles Blue
Correct solvent for the printer as required
Clean hot water (preferably de-ionized)
between 55 °C and 100 °C as required
Beaker, stainless steel or glass
Absorbent, lint-free paper towel

Procedures

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.
CAUTION: Under no circumstances should the printhead be immersed in solvent for
any period of time.

Correct Jet Alignment

1 Switch the printer on and start the jet using the Quick Start Jet option in the
DIAGNOSTICS menu.
2 Remove the printhead cover tube.
3 Examine the alignment of the jet with an eyeglass. The jet should pass exactly
through the centre of the charge electrode, exactly over the centre of the phase and
TOF sensors and enter the centre of the gutter, when viewed from the front (figure
1).

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4800 Maintenance Instruction

Jet Alignment and Nozzle Cleaning

The Micro printhead has different tolerances for the gutter entry; the left/right
alignment is 70%/30%. The Macro printhead is manufactured with a tube gutter,
which requires a different gutter entry offset to the solid gutters used on the Micro
and Midi printheads. The Macro printhead gutter left/right alignment is offset by
60%/40% (figure 1):

Micro Midi Macro 6218

Gutter Alignment Gutter Alignment Gutter Alignment
70% 30% 60% 40%
50% 50%
50% 50% 50%
50% 50% 50%

The jet must pass

exactly over the centre The clearance
of the sensors between the jet
and the sensors
must be equal

The jet must pass exactly

through the centre of
the charge electrode

Figure 1. Correct Alignment of the Jet into the Gutter

The Macro jet alignment must always be carried out in the normal printhead
orientation, i.e. as it would be when mounted on the production line. This is to
eliminate the effect of gravity on the jet due to the longer flight path and slower jet
velocity.
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 degrees

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:

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Jet Alignment and Nozzle Cleaning

Nozzle Clear Sequence

1 Shutdown the printer.
2 Invert the printhead and wrap absorbent, lint-free paper towel around the area
below the nozzle (figure 3).
3 Select the Clear Nozzle option from the DIAGNOSTICS menu. Enter “3” and
press [enter] to start a routine of three consecutive Clear Nozzle sequences.
CAUTION: In the following operation, use the correct solvent type that corresponds to
the ink type being used in the printer.
4 While the Clear Nozzle routine is in operation (60 seconds), apply small amounts
of solvent to the inverted nozzle face. Observe that the solvent is drawn in
through the nozzle (figure 3):

Take care to build up

a good coating of
solvent on the nozzle,
6080
as shown here

MIDI

Figure 3. Nozzle Clear Routine—Applying Solvent to the Nozzle

5 Attempt to start the jet in Diagnostics using the Quick Start Jet option and observe
the alignment of the jet. If the jet is still out of alignment or the nozzle is still
blocked, stop the jet.
6 Repeat Items 3 and 4 a maximum of a further nine times, or until the jet is
perpendicular to the nozzle face, with an attempt to start the jet carried out after
each routine. The Clear Nozzle sequence should not be performed more than a
total of 30 (10 x 3) times.
7 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.
8 If after 10 Clear Nozzle routines 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.

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4800 Maintenance Instruction

Jet Alignment and Nozzle Cleaning

Nozzle Soaking
CAUTION: Extreme care must be taken when handling the nozzle assembly to avoid
introducing any contamination. The tube on the rear of the nozzle assembly must not
come into contact with any fibres, and skin contact should be avoided. It is
recommended that powder-free latex gloves are worn. Removing and handling of the
nozzle assembly should be carried out in a clean, dust free environment. If a Clean
Room is available, then it should be used.
CAUTION: In the following procedure, use the correct solvent type that corresponds to
the ink type being used in the printer.
1 Shut down and switch off the printer, and disconnect it from the mains electrical
supply.
2 Remove the two nuts and shakeproof washers from the printhead nozzle
protection cover and remove the cover.
3 Clean the printhead thoroughly with the correct solvent 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 twenty 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.
8 Switch the printer on and start the jet using the Quick Start Jet option in the
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”.

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Jet Alignment and Nozzle Cleaning

Nozzle Washing
This procedure is intended for use on nozzles which are experiencing jet misalignment due
to severe blockages, which cannot be cleared using the normal Nozzle Clear 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.
CAUTION: Extreme care must be taken when handling the nozzle assembly to avoid
introducing any contamination. The tube on the rear of the nozzle assembly must not
come into contact with any fibres, and skin contact should be avoided. It is
recommended that powder-free latex gloves are worn. Removing and handling of the
nozzle assembly should be carried out in a clean, dust free environment. If a Clean
Room is available, then it should be used.
CAUTION: In the following procedure, use the correct solvent type that corresponds to
the ink type being used in the printer.

Solvent Wash
1 Shut down and switch off the printer, and disconnect it from the mains electrical
supply.
2 Remove the two nuts and shakeproof washers from the printhead nozzle
protection cover and remove the cover.
3 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.
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.

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4800 Maintenance Instruction

Jet Alignment and Nozzle Cleaning

Hot Water Wash

11 Fill a clean beaker or similar container with hot water (preferably de-ionized 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.
17 Switch the printer on.
18 In the DIAGNOSTICS menu, set the Set Pressure option to 120.
19 In the VALVE TEST menu, select the Feed valve and switch it on by pressing and
holding the [enter] key. Hold the Feed valve on for 5 seconds, during which time
ink will be ejected from the gun.
20 Set the Set Pressure option to 0.
21 Switch off the printer.
22 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.
23 Disconnect the syringe from the PTFE tube and remove the tube from the pipe at
the rear of the nozzle assembly.
24 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.
25 Switch the printer on and start the jet using the Quick Start Jet option in the
DIAGNOSTICS menu.

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Jet Alignment and Nozzle Cleaning

26 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.
27 If jet alignment is correct carefully refit the nozzle protection cover ensuring that
the jet alignment is not disturbed.
28 Shut down and switch off the printer.
29 Refit the printhead cover tube.

Nozzle Realignment
1 Remove the two nuts and shakeproof washers from the printhead nozzle
protection cover and 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 using the [start] key on the control panel.
Repeat this four times to ensure that the jet alignment is maintained and that 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.
5 Shut down and switch off the printer.
6 Refit the printhead cover.
7 The “Jet Alignment and Nozzle Cleaning” is now completed.

Gutter Alignment
Only in extreme circumstances, when the nozzle and jet alignment are correct but gutter
alignment cannot be achieved, should adjustment of the gutter be considered, and then
only by a minute amount, otherwise gutter clearance problems or blockages may result.
The Micro and Midi printheads have solid gutters which are not adjustable.
The Macro printhead has a tube gutter which is adjusted to the jet. Therefore, adjust the Jet
to the Phase and TOF sensors and then adjust the gutter to the jet if it is required.
checks the quality of the printed message and ensures that the Reference Modulation
setting is set such that optimum print quality will be maintained with varying ink viscosity.
It can also be used to assess the relative viscosity of the ink.

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Jet Alignment and Nozzle Cleaning

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4800 Maintenance Instruction

Modulation Range Checks

Introduction
This instruction checks the quality of the printed message and ensures that the Reference
Modulation setting is set such that optimum print quality will be maintained with varying
ink viscosity. It can also be used to assess the relative viscosity of the ink.

Procedure
1 Switch on the printer.
2 Load the Standard Test Pattern and select the largest pattern available.
3 In order to carry out the following checks, the Shaft Encoder and Photocell options
(SETUP menu) must be set to Off. Set as necessary noting the original settings.
4 In Diagnostics, start the jet using the Quick Start Jet option and then select the Start
Print option.
5 Note the Ref Modulation setting in the SETUP menu (figure 1).

48167

SETUP
Conduit Length : 2m
Head Height : 0.5m
Print Head Code : 11850010001962
> Ref Modulation : 150

Figure 1. Ref Modulation Option in the Setup Menu

6 Carry out a modulation range analysis using the following method. Produce a
series of print samples, starting at the original Ref Modulation setting and then
decreasing the Ref Modulation in steps of 10 (steps of 5 for a Micro printhead) until
the print quality just starts to deteriorate, and record the setting (Vm1). Then
increase the Ref Modulation from the original setting in steps of 10 (steps of 5 for a
Micro printhead) until the print quality just starts to deteriorate, and record the
setting (Vm2). Figures 2 and 3 show examples of deterioration of print quality
caused by modulation variations:
48168

Figure 2. Under Modulation—Expected Deterioration when Reference Mod is < Vm1

48169

Figure 3. Over Modulation—Expected Deterioration when Reference Mod is > Vm2

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4800 Maintenance Instruction

Modulation Range Checks

7 IMPORTANT: Set the Shaft Encoder and Photocell options back to their
original settings as noted in Item 3.
8 Check that the original Ref Modulation setting is approximately equal to the
calculated modulation, as follows:
Vm1 + (Vm2 – Vm1) = Vmc
__________________________

3
9 Record the calculated value (Vmc).
10 Reset the Ref Modulation to the original value noted in Item 5.
11 The “Modulation Range Checks” are now completed.

Evaluating the Relative Viscosity

1 Compare the Ref Modulation to 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.
2 If the printer has been failing because the viscosity is too low or too high,
appropriate action should be taken to determine the root cause of the viscosity
problem.

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4800 Maintenance Instruction

Nozzle O-ring Replacement

Parts Required
FA20011 Nozzle Sealing O-ring

Equipment Required
BP900003 Solvent Cleaning Bottle
BP900005 Beaker 0.25 Litre
BP940003 Eyeglass x9 Magnification
BP999066 Gloves Latex Powder-Free (small) )
BP999067 Gloves Latex Powder-Free (medium) ) as required
BP999068 Gloves Latex Powder-Free (large) )
BP999076 Safety Spectacles Blue
Tweezers
Correct solvent for the printer as required

Procedure

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.

O-Ring Replacement
1 Shut down and switch off the printer, and disconnect it from the mains electrical
supply.
2 Remove the printhead from its cover tube.
3 Remove the two nuts and shakeproof washers from the printhead nozzle
protection cover and remove the cover.
CAUTION: Extreme care must be taken when handling the replacement nozzle
assembly to avoid introducing any contamination. The tube on the rear of the nozzle
assembly must not come into contact with any fibres, and skin contact should be
avoided. It is recommended that powder-free latex gloves are worn. Removing and
handling of the nozzle assembly should be carried out in a clean, dust free environment.
If a Clean Room is available, then it should be used.
4 Remove the two securing screws and shakeproof washers from the nozzle
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.

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4800 Maintenance Instruction

Nozzle O-ring Replacement

CAUTION: 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 Examine the new O-ring for any damage/flash.
CAUTION: In the following operation, use the correct solvent type that corresponds to
the ink type being used in the printer.
7 Thoroughly clean the nozzle assembly, its location on the printhead, and the O-
ring 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.
10 Adjust the nozzle alignment until the jewel is visible through the slot in the charge
electrode when viewed from the gutter.
CAUTION: Do not use pliers or any other tool to adjust the nozzle position as this may
cause damage to the nozzle.
11 Fully tighten the two nozzle assembly securing screws.

Jet Realignment
12 Switch the printer on and start the jet using the Quick Start Jet option in the
DIAGNOSTICS menu.
13 Examine the alignment of the jet with an eyeglass. The jet should pass exactly
through the centre of the charge electrode, exactly over the centre of the phase and
TOF sensors and enter the centre of the gutter, when viewed from the front (figure
1).

Micro Midi Macro 6218

Gutter Alignment Gutter Alignment Gutter Alignment
70% 30% 60% 40%
50% 50%
50% 50% 50%
50% 50% 50%

The jet must pass

exactly over the centre The clearance
of the sensors between the jet
and the sensors
must be equal

The jet must pass exactly

through the centre of
the charge electrode

Figure 1. Correct Alignment of the Jet into the Gutter

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4800 Maintenance Instruction

Nozzle O-ring Replacement

The Micro printhead has different tolerances for the gutter entry; the left/right
alignment is 70%/30%. The Macro printhead is manufactured with a tube gutter,
which requires a different gutter entry offset to the solid gutters used on the Micro
and Midi printheads. The Macro printhead gutter left/right alignment is offset by
60%/40% (figure 1).
The Macro jet alignment must always be carried out in the normal printhead
orientation, i.e. as it would be when mounted on the production line. This is to
eliminate the effect of gravity on the jet due to the longer flight path and slower jet
velocity.
14 If the jet is not aligned as shown in figure 1, 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 1.
15 If the jet cannot be successfully aligned into the gutter, examine the jet to establish
if it is perpendicular to the nozzle face (figure 2). If the jet is misaligned due to
dried ink or debris in the nozzle, carry out the procedures detailed in the “Jet
Alignment and Nozzle Cleaning”. maintenance instruction.

Misaligned jet

For correct jet alignment

this angle must be
90 degrees

6219

Figure 2. Correct Alignment of the Jet from the Nozzle

16 Shut down the printer and then restart using the [start] key. Repeat this four times
to ensure that the jet alignment is maintained and that the jet is stable during the
start and stop operations, and that no error messages are reported.
17 Carefully refit the nozzle protection cover using the two nuts and shakeproof
washers, ensuring that the jet alignment is not disturbed.
18 Shut down and switch off the printer.
19 Refit the printhead cover tube.
20 The “Nozzle O-ring Replacement” is now completed.

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Nozzle O-ring Replacement

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4800 Maintenance Instruction

Calibrated Nozzle Replacement

Parts Required
FA74070/1240 Calibrated Nozzle Assembly 62 µm

Equipment Required
BP900003 Solvent Cleaning Bottle
BP940003 Eyeglass x9 Magnification
BP999066 Gloves Latex Powder-Free (small) )
BP999067 Gloves Latex Powder-Free (medium) ) as required
BP999068 Gloves Latex Powder-Free (large) )
BP999076 Safety Spectacles Blue
Tweezers
Correct solvent for the printer as required

Introduction
This instruction is primarily designed for replacing the nozzle on a Midi 62 µm printhead
after carrying out the full “Jet Alignment and Nozzle Cleaning” maintenance instruction
and it has not been possible to clear the blocked nozzle.

Procedure

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.

Nozzle Replacement
1 Shut down and switch off the printer, and disconnect it from the mains electrical
supply.
2 Remove the printhead from its cover tube.
3 Remove the two nuts and shakeproof washers from the printhead nozzle
protection cover and remove the cover.
CAUTION: Extreme care must be taken when handling the replacement nozzle
assembly to avoid introducing any contamination. The tube on the rear of the nozzle
assembly must not come into contact with any fibres, and skin contact should be
avoided. It is recommended that powder-free latex gloves are worn. Removing and
handling of the nozzle assembly should be carried out in a clean, dust free environment.
If a Clean Room is available, then it should be used.
4 Remove the two securing screws and shakeproof washers from the nozzle
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.

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Calibrated Nozzle Replacement

CAUTION: 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.
CAUTION: In the following operation, use the correct solvent type that corresponds to
the ink type being used in the printer.
7 Thoroughly clean the printhead 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.
10 Adjust the nozzle alignment until the jewel is visible through the slot in the charge
electrode when viewed from the gutter.
CAUTION: Do not use pliers or any other tool to adjust the nozzle position as this may
cause damage to the nozzle.
11 Fully tighten the two nozzle assembly securing screws.

Jet Realignment
12 Switch the printer on and start the jet using the Quick Start Jet option in the
DIAGNOSTICS menu.
13 Examine the alignment of the jet with an eyeglass. The jet should pass exactly
through the centre of the charge electrode, exactly over the centre of the phase and
TOF sensors and enter the centre of the gutter, when viewed from the front (figure
1).

Micro Midi Macro 6218

Gutter Alignment Gutter Alignment Gutter Alignment
70% 30% 60% 40%
50% 50%
50% 50% 50%
50% 50% 50%

The jet must pass

exactly over the centre The clearance
of the sensors between the jet
and the sensors
must be equal

The jet must pass exactly

through the centre of
the charge electrode

Figure 1. Correct Alignment of the Jet into the Gutter

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Calibrated Nozzle Replacement

NOTE: The nozzle has already been aligned during the calibration process at Linx
and should only need slight adjustment to obtain the correct position.
14 If the jet is not aligned as shown in figure 1, 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 1.
15 If the jet cannot be successfully aligned into the gutter, examine the jet to establish
if it is perpendicular to the nozzle face (figure 2). If the jet is misaligned due to
dried ink or debris in the nozzle, carry out the procedures detailed in the “Jet
Alignment and Nozzle Cleaning”. maintenance instruction.

Misaligned jet

For correct jet alignment

this angle must be
90 degrees

6219

Figure 2. Correct Alignment of the Jet from the Nozzle

16 Shut down the printer using the [stop] key.
17 Using the figures on the supplied Flag Label, enter the new calibration code and
reference modulation value into the Print Head Code and Ref Modulation options
of the HARDWARE SETUP sub-menu (SETUP menu).
18 Restart the printer using the [start] key.
19 Shut down the printer and then restart using the [start] key. Repeat this four times
to ensure that the jet alignment is maintained and that the jet is stable during the
start and stop operations, and that no error messages are reported.
20 Carefully refit the nozzle protection cover using the two nuts and shakeproof
washers, ensuring that the jet alignment is not disturbed.
21 Refit the printhead cover tube and carry out the “Modulation Range Checks”
maintenance instruction.
22 Shut down and switch off the printer.

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Calibrated Nozzle Replacement

Flag Label Fitting

23 Using a pen enter the date of the nozzle fitting onto the Flag Label in the space
provided.
24 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.
25 Remove the backing paper from the completed Flag 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 clear tail (see figure 3).
NOTE: The Flag Label is also available as an individual spare (part number
FA20012—pack of 5 labels) and, therefore, can also be used after an
ink conversion has been carried out on a printer.

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 3. Correct fitting of the Flag Label on the conduit

26 The “Calibrated Nozzle Replacement” instruction is now completed.

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4800 Maintenance Instruction

System Flush Procedure

Equipment Required
BP900005 Beaker 0.25 Litre
BP940021 Syringe Polypropylene 50 ml as required
BP999045 Gloves Latex Medical (large) )
BP999046 Gloves Latex Medical (medium) ) as required
BP999047 Gloves Latex Medical (small) )
BP999076 Safety Spectacles Blue
Correct solvent for the ink used in the printer as required
Absorbent, lint-free paper towel
Empty solvent bottle—base removed

Introduction
NOTE: The System Flush option referred to in this maintenance instruction describes
the option as it existed prior to Version 1.1 software. With v1.1 this option was
modified. Once the System Flush option in this instruction has been
understood the new option in v1.1 will be self-explanatory, as the on-screen
prompts guide the operator easily through the procedure in a similar manner.
Refer to Section 5: “Maintenance” > The Diagnostics Menu > System Flush
(v1.1 software).
It is important to ensure that the procedures outlined in this maintenance instruction are
followed carefully to achieve reliable printer operation.
This maintenance instruction provides the procedures to completely flush a 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 preparation for calibration.
4. To convert a “new”, unused printer to a new ink, in preparation for
calibration.
The individual “Preparation”, “Short Cycle Procedure” and “Flush Cycle Procedure”
operations, associated with the procedures for the above circumstances, are provided
separately, later in this maintenance instruction.
The operations for emptying the ink tank and purging the main ink filter are referred out to
the “Draining the Ink System” and “Main Ink Filter Replacement—Main Ink Filter
Purge” maintenance instructions contained elsewhere in Section 5.

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System Flush Procedure

Printer Conditions During the Cycle

• The System Flush cycle will not run if the pressure test at the beginning of the
cycle fails.
• The level of solvent in the ink tank will be checked at each stage of the cycle,
and the cycle will terminate if this is low. If this error is detected the warning
message, “Flush Cycle Stopped” will be reported in the screen status line.
• The cycle will terminate with all valves off and zero pressure.

• The cycle may be terminated by the operator at any stage by the selection of
the Stop Cycle option. This action will take immediate effect, so no message,
such as “Stopping Cycle : Please Wait”, will be displayed. It is used for speed
in preference to the power switch and is expected to be used, for example, in
situations where a pressurized leak has occurred. Use of the Stop Cycle option
will leave the ink system in an undefined state. If the cycle is terminated for
any reason, the “use count” will not be incremented.

Procedures

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.

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.
1 Carry out the “Preparation” actions detailed in this maintenance instruction.
2 Prior to the system being flushed with solvent, all ink (or as much ink as possible)
should be removed from the ink tank. Carry out the “Draining the Ink System”
maintenance instruction, but use a waste container of at least 15 litres capacity
instead of the 5 litres specified in the instruction. Note that this procedure will be
repeated so the printer top cover should be left off.
3 Carry out the “Short Cycle Procedure” detailed in this maintenance instruction.
4 Repeat the “Draining the Ink System” maintenance instruction.
5 Repeat the “Short Cycle Procedure”.
6 Repeat the “Draining the Ink System” maintenance instruction.
7 Carry out the “Flush Cycle Procedure” detailed in this maintenance instruction.
8 Repeat the “Draining the Ink System” maintenance instruction. The solvent tank
should be empty, but if it is not, any remaining solvent should be syphoned off.
9 The printer is now flushed ready for packing.

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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.
1 Carry out the “Preparation” actions detailed in this maintenance instruction.
2 Prior to the system being flushed with solvent, all ink (or as much ink as possible)
should be removed from the ink tank. Carry out the “Draining the Ink System”
maintenance instruction, but use a waste container of at least 15 litres capacity
instead of the 5 litres specified in the instruction. Note that this procedure will be
repeated so the printer top cover should be left off.
3 Carry out the “Short Cycle Procedure” detailed in this maintenance instruction.
4 Repeat the “Draining the Ink System” maintenance instruction.
5 Repeat the “Short Cycle Procedure”.
6 Repeat the “Draining the Ink System” maintenance instruction.
7 Carry out the “Flush Cycle Procedure” detailed in this maintenance instruction.
8 Repeat the “Draining the Ink System” maintenance instruction. The solvent tank
should be empty, but if it is not, any remaining solvent should be syphoned off.
9 Replace the main ink filter and the pre-pump filter/ink tank dip tube.
Maintenance instructions for these tasks can be found elsewhere in Section 5.
10 The printer may now be recommissioned with fresh ink (one or two bottles, until
low ink status warning has cleared) and fresh solvent (one or two bottles, until low
solvent status warning has cleared).
11 Carry out the Main Ink Filter Purge element of the “Main Ink Filter
Replacement” maintenance instruction.
NOTE: If the main ink filter or damper do not fill with ink, the pump needs to
be primed. This should be done with the printer switched OFF. Insert
the nozzle of a syringe (Linx part number BP940021—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.
12 Carry out at least six Clear Nozzle sequences.
13 Start the jet using the [start] button.
14 The printer is now clear of contaminated ink and ready for use.

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System Flush Procedure

3. To Convert an “In Use” Printer to a New Ink, in Preparation for

Calibration
1 Carry out the “Preparation” actions detailed in this maintenance instruction.
2 Prior to the system being flushed with solvent, all ink (or as much ink as possible)
should be removed from the ink tank. Carry out the “Draining the Ink System”
maintenance instruction, but use a waste container of at least 15 litres capacity
instead of the 5 litres specified in the instruction. Note that this procedure will be
repeated so the printer top cover should be left off.
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.
3 Carry out the “Short Cycle Procedure” detailed in this maintenance instruction.
4 Repeat the “Draining the Ink System” maintenance instruction.
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.
5 Repeat the “Short Cycle Procedure”.
6 Repeat the “Draining the Ink System” maintenance instruction.
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.
7 Carry out the “Flush Cycle Procedure” detailed in this maintenance instruction.
8 Repeat the “Draining the Ink System” maintenance instruction. The solvent tank
should be empty, but if it is not, any remaining solvent should be syphoned off.
9 Replace the main ink filter and the pre-pump filter/ink tank dip tube.
Maintenance instructions for these tasks can be found elsewhere in Section 5.
CAUTION: In the following operation, ensure that the solvent type added to the ink
tank corresponds to the ink type which will be added to the printer during the
recommissioning process.
10 Repeat the “Short Cycle Procedure”.
11 Repeat the “Draining the Ink System” maintenance instruction.
CAUTION: In the following operation, ensure that the solvent type added to the ink
tank corresponds to the ink type which will be added to the printer during the
recommissioning process.
12 Repeat the “Flush Cycle Procedure”.
13 Repeat the “Draining the Ink System” maintenance instruction.
CAUTION: In the following operation, ensure that the solvent type added to the ink
tank corresponds to the ink type which will be added to the printer during the
recommissioning process.
14 Repeat the “Flush Cycle Procedure”.
15 Repeat the “Draining the Ink System” maintenance instruction. The solvent tank
should be empty, but if it is not, any remaining solvent should be syphoned off.
16 The printer may now be recommissioned with the new ink (one or two bottles,
until the low ink status warning has cleared) and the new solvent (one or two
bottles, until the low solvent status warning has cleared).

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17 Carry out the Main Ink Filter Purge element of the “Main Ink Filter
Replacement” maintenance instruction.
NOTE: If the main ink filter or damper do not fill with ink, the pump needs to
be primed. This should be done with the printer switched OFF. Insert
the nozzle of a syringe (Linx part number BP940021—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.
18 Carry out at least six Clear Nozzle sequences.
19 From the DIAGNOSTICS menu, set the TOF Correction option to Off so that there
will be no possibility of solvent being added.
20 Using the Quick Start Jet option, run the jet for 10 minutes.
21 Set the TOF Correction option back to On.
22 Repeat the “Draining the Ink System” maintenance instruction.
NOTE: It is important to ensure that the ink tank, damper and main ink filter are
drained completely of ink.
23 The printer may now be recommissioned with fresh, new ink (one or two bottles,
until the low ink status warning has cleared) which must be of the same batch and
viscosity, as marked on the ink bottle label.
NOTE: Items 16 to 23 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.
24 Repeat the Main Ink Filter Purge element of the “Main Ink Filter Replacement”
maintenance instruction.
NOTE: If the main ink filter or damper do not fill with ink, the pump needs to
be primed. This should be done with the printer switched OFF. Insert
the nozzle of a syringe (Linx part number BP940021—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.
25 Place an earthed container under the printhead because solvent will be present in
the pipes.
26 The printer is now ready for calibration. Refer to the “Ink Conversion
Calibration” maintenance instruction.

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System Flush Procedure

4. To Convert a “New”, Unused Printer to a New Ink, in Preparation for

Calibration
1 Replace the main ink filter and the pre-pump filter/ink tank dip tube.
Maintenance instructions for these tasks can be found elsewhere in Section 5.
2 Carry out the “Preparation” actions detailed in this maintenance instruction.
CAUTION: In the following operation, ensure that the solvent type added to the ink
tank corresponds to the ink type which will be added to the printer during the
recommissioning process.
3 Carry out the “Short Cycle Procedure” detailed in this maintenance instruction.
4 Carry out the “Draining the Ink System” maintenance instruction, but use a waste
container of at least 15 litres capacity instead of the 5 litres specified in the
instruction. Note that this procedure will be repeated so the printer top cover
should be left off.
CAUTION: In the following operation, ensure that the solvent type added to the ink
tank corresponds to the ink type which will be added to the printer during the
recommissioning process.
5 Carry out the “Flush Cycle Procedure” detailed in this maintenance instruction.
6 Repeat the “Draining the Ink System” maintenance instruction.
CAUTION: In the following operation, ensure that the solvent type added to the ink
tank corresponds to the ink type which will be added to the printer during the
recommissioning process.
7 Repeat the “Flush Cycle Procedure”.
8 Repeat the “Draining the Ink System” maintenance instruction. The solvent tank
should be empty, but if it is not, any remaining solvent should be syphoned off.
9 The printer may now be recommissioned with the new ink (one or two bottles,
until the low ink status warning has cleared) and the new solvent (one or two
bottles, until low solvent status warning has cleared).
10 Carry out the Main Ink Filter Purge element of the “Main Ink Filter
Replacement” maintenance instruction.
NOTE: If the main ink filter or damper do not fill with ink, the pump needs to
be primed. This should be done with the printer switched OFF. Insert
the nozzle of a syringe (Linx part number BP940021—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.
11 Carry out at least six Clear Nozzle sequences.
12 From the DIAGNOSTICS menu, set the TOF Correction option to Off so that there
will be no possibility of solvent being added.
13 Using the Quick Start Jet option, run the jet for 10 minutes.
14 Set the TOF Correction option back to On.

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15 Repeat the “Draining the Ink System” maintenance instruction.

NOTE: It is important to ensure that the ink tank, damper and main ink filter are
drained completely of ink.
16 The printer may now be recommissioned with fresh, new ink (one or two bottles,
until the low ink status warning has cleared) which must be of the same batch and
viscosity, as marked on the ink bottle label.
NOTE: Items 9 to 16 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.
17 Repeat the Main Ink Filter Purge element of the “Main Ink Filter Replacement”
maintenance instruction.
NOTE: If the main ink filter or damper do not fill with ink, the pump needs to
be primed. This should be done with the printer switched OFF. Insert
the nozzle of a syringe (Linx part number BP940021—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.
18 Place an earthed container under the printhead because solvent will be present in
the pipes.
19 The printer is now ready for calibration. Refer to the “Ink Conversion
Calibration” maintenance instruction.

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System Flush Procedure

Preparation
Before commencing the flushing procedures, the printer should be raised by approximately
50 mm at the front left-hand side to aid drainage of the tanks, as the ink and solvent dip
tubes are situated at the rear right-hand side of the tanks. Note that it may be necessary to
syphon the remaining solvent from the solvent tank after carrying out the System Flush.
During the flush, the solvent tank needs to contain 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, the solvent tank should be filled
just until the System Warning error message “3.04 Solvent Low” is cleared. This may
necessitate drawing off some solvent first to see the error message appear and then refilling
with solvent until the error message clears. As a precautionary measure, an empty solvent
bottle, with its base removed, should be fitted 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.

Short Cycle Procedure

1 Ensure that the ink tank is empty before continuing with the following Short Cycle
procedure.
2 Select the System Flush option from the DIAGNOSTICS menu, which will display
the primary SYSTEM FLUSH menu:

48069

SYSTEM FLUSH
F1 : Empty Tank
F2 : Start Short Cycle – 0
F3 : Start Flush Cycle – 0

Figure 1. Primary System Flush Menu

3 The Short Cycle operation is used to remove the ink from the main ink filter and
the damper. Scroll to the Start Short Cycle option and select it by pressing [enter].
The SYSTEM FLUSH screen content will change to the following:

48186

SYSTEM FLUSH
Disconnect Bleed Line
F1 : Ok

Figure 2. System Flush Screen with “Disconnect Bleed Line” Message

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4 The operator is reminded to disconnect the bleed line from the damper (and refit
the damper drain cap) before proceeding. Then select Continue by pressing [enter]
and the following screen will be displayed:

48187

SYSTEM FLUSH
Fill Ink Tank With 1.5l Solvent
F1 : Ok

Figure 3. System Flush Screen with “Fill Ink Tank with 1.5l Solvent” Message
5 The operator is prompted to fill the ink tank with 1.5 litres of solvent. Then select
Continue by pressing [enter] and the following screen will be displayed:

48188

SYSTEM FLUSH
Short Cycle Running
F1 : Stop Cycle

Figure 4. System Flush Screen with “Short Cycle Running” Message

6 The Short Cycle operation is now being carried out. If the Stop Cycle option is
selected during this operation, the Short Cycle will be aborted.

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System Flush Procedure

Flush Cycle Procedure

1 Ensure that the ink tank is empty before continuing with the following Flush Cycle
procedure.
2 The Flush Cycle operation is used to thoroughly flush all the valves and pipework.
From the primary SYSTEM FLUSH screen scroll to the Start Flush Cycle option
and select it by pressing [enter]. The SYSTEM FLUSH screen content will change
to the following:

48186

SYSTEM FLUSH
Disconnect Bleed Line
F1 : Ok

Figure 5. System Flush Screen with “Disconnect Bleed Line” Message

3 The operator is reminded to disconnect the bleed line from the damper (and refit
the damper drain cap) before proceeding. Ensure that this is done before
continuing. Select Continue by pressing [enter] and the following screen will be
displayed:

48190

SYSTEM FLUSH
Fill Ink Tank With 1.0l Solvent
F1 : Ok

Figure 6. System Flush Screen with “Fill Ink Tank with 1.0l Solvent” Message
4 The operator is prompted to fill the ink tank with 1.0 litre of solvent. If this is the
first time this cycle has been run (use count is 0) and a “3.04 Solvent Low” error
message is displayed, the flush cycle cannot proceed. If necessary, fill the solvent
tank just until the “3.04 Solvent Low” error message is cleared. Then select
Continue by pressing [enter] and the following screen will be displayed:

48189

SYSTEM FLUSH
Flush Cycle Running
F1 : Stop Cycle

Figure 7. System Flush with “Flush Cycle Running” Message

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System Flush Procedure

5 The Flush Cycle operation is now being carried out. If the Stop Cycle option is
selected during this operation, the Short Cycle will be aborted.
NOTE: A “3.04 Solvent Low” error message may be reported during the flush
cycle as solvent is used to fill the system. This warning may be ignored,
except when the software will not allow the cycle to continue and action
is required.
6 When the Flush Cycle is finished, it will be necessary to flush the gutter line (from
the gutter through the gutter valve). In Diagnostics, set the Set Pressure option to
255 and apply solvent to the gutter using a wash bottle until the solvent in the
gutter line flows clear. Note that a minimum of 250 ml of solvent should be used.
7 Set the Set Pressure option to 0.

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4800 Maintenance Instruction

Ink Conversion Calibration

Equipment Required
BP999045 Gloves Latex Medical (large) )
BP999046 Gloves Latex Medical (medium) ) as required
BP999047 Gloves Latex Medical (small) )
BP999076 Safety Spectacles Blue
Celsius Thermometer

Introduction
This is a multi-printer maintenance instruction detailing the procedure to be used to
calibrate 4000, 4200, 4800, 6000 and 6200 printers following an ink conversion from one ink
to another. It only applies to Midi Mk4 printheads, or later (unless stated otherwise) and,
in the case of some inks, Macro Mk3 printheads, or later (refer to the table in figure 3).
Also, this procedure is only to be used for those ink conversions which are approved and
are indicated with a tick in the table in figure 1. For other approved ink conversions,
where the conversion calibration data is not available, the recommendation is to contact
Linx Technical Support for advice.
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 is contained elsewhere in this section.
It is most important that the procedures outlined in this maintenance instruction are
followed carefully to achieve reliable printer operation.

Preparation
To ensure that the printer is controlling the ink viscosity correctly, it is recommended that
both the gutter and purge valves are checked for leaks before starting the calibration
procedure. Refer to the “Fault Diagnosis” section for instructions.
IMPORTANT: Before proceeding, ensure that the printhead is mounted so that the
nozzle is level with the space bar on the printer keyboard.
If the height of the printhead needs to be altered after calibration, the Head Height option
in the SETUP menu should be used to compensate for this.

Main Ink Filter

If the ink conversion is from a non-pigmented ink to a pigmented ink, the 5 µm main ink
filter (if fitted) must be replaced with a 10 µm filter. Refer to the “Main Ink Filter
Replacement” maintenance instruction contained elsewhere in this section.

Software
Linx recommend that, where possible, the latest version of software should be used.
Earlier versions of software have startup and shutdown options in the SETUP menu which
must be set according to the ink being used, as detailed in the table in figure 3.
These earlier versions of software are:
• 4000—from v3.2c to v3.3 inclusive

• 4200—from v4.0 to v4.4a inclusive

• 6000—from v2.0a to v3.0 inclusive

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4800 Maintenance Instruction

Ink Conversion Calibration

Ink Conversion Calibration Record Form

When carrying out an ink conversion and calibration, this form should be used to record
information that may be required for future maintenance or fault diagnosis. Certain data
required on the form should be recorded before the calibration procedure is started as it
will change during the calibration.
Please return the form to your company head office and keep it on file with the records for
the particular the printer.

Procedure

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.
1 Carry out the “Preparation” instructions detailed above.
2 In the SETUP menu, ensure that the Ink Type/Ink Selection option is set to the
correct type for the ink that the printer has been converted to.
3 In the DIAGNOSTICS menu, set the TOF Correction option to Off so that there will
be no possibility of solvent being added.
4 Use the Quick Start Jet option in the DIAGNOSTICS menu and run the jet for 20
minutes. Add one more bottle of ink if the System Warning error message “3.03
Ink Low” is indicated.
CAUTION: Ensure that the bottle of ink added is of the same batch and is marked with
the same viscosity as the bottle(s) used during the ink recommissioning procedure.
5 Position the thermometer within 10 cm of the printhead, and measure and record
the printhead ambient temperature (T).
6 Adjust the Set Pressure option in the DIAGNOSTICS menu until the TOF reading
on the Monitor Jet screen is 18500 ±50 (Mk4 and Mk5 Midi) or 16000 ±80 (Macro).
Record the Set Pressure (P1) required to achieve this. To aid this operation (4000,
4200 and 4800 printers only), the Phase Period option in the DIAGNOSTICS menu
should be set to 1, which will cause the TOF reading to be updated more often.
7 Calculate the Actual Viscosity of the ink at the printhead (V2) from the viscosity
stated on the ink bottle (V1) and the temperature recorded at the printhead (T),
using the following method:
a) From the table in figure 2, select the Correction Factor (CV) that corresponds to
the measured Printhead Temperature (T).
b) Insert values for V1, T and CV into one of the following equations, depending
on the Printhead Temperature (T), to obtain the Actual Viscosity of the ink at
the printhead (V2):
If T is less than or equal to 25 °C: V2 = V1 + [(25 – T) x CV]
If T is greater than 25 °C: V2 = V1 – [(T – 25) x CV]

Amdt 03 MP65209–1
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4800 Maintenance Instruction

Ink Conversion Calibration

8 For the following calculation refer to the table in figure 3 for values of Reference
Viscosity (VREF) and Pressure Bits per Unit of Viscosity Change (PCP). Using the Set
Pressure value (P1) recorded previously at Item 6, calculate a Reference Pressure
value (P2) for the ink at its Reference Viscosity (VREF) using the following method:
Insert values for P1, V2, VREF and PCP into one of the following equations, depending
on the value of V2:
If V2 is less than or equal to VREF: P2 = P1 + [(VREF – V2) x PCP]
If V2 is greater than VREF: P2 = P1 – [(V2 – VREF) x PCP]
9 Stop the jet.
10 In the SETUP menu, enter a new Print Head Code using:
Printhead Type = 1 (Midi) or 2 (Macro)
Time Of Flight Reference = 18500 (Midi) or 16000 (Macro)
Charge Value = 1000
Pressure Reference = P2 (from calculation above)
Modulo 10 checksum = M (Recalculate from new code)
i.e. in the form: 1 18500 1000 P2 M (Midi)
2 16000 1000 P2 M (Macro)
NOTE: The Macro printhead has a two digit Pressure Reference figure, so this
should be prefixed with a zero when entering it in the code.
11 Restart the jet using the normal [start] key and run for at least 20 minutes, until the
Set Pressure is within the Reference Pressure and the Solvent Add Pressure range.
This may take some time depending upon ambient conditions and the original
viscosity of the ink (V1).
IMPORTANT: Do not change the printhead code Pressure Reference to achieve
this.
12 Carry out a modulation range analysis using the following method. Produce a
series of print samples, starting at the original Ref Modulation setting and then
decreasing the Ref Modulation in steps of 10 until the print quality just starts to
deteriorate, and record the setting (Vm1). Then increase the Ref Modulation from
the original setting in steps of 10 until the print quality just starts to deteriorate,
and record the setting (Vm2).
13 Using these two values in the following equation, calculate the new Reference
Modulation:
Reference Modulation = Vm1 + 0.33 (Vm2 – Vm1)
14 Enter this value against the Ref Modulation option in the SETUP menu.
15 Complete the Ink Conversion Calibration Record form.
16 The printer is now calibrated for use with the new ink.

MP65209–1 Amdt 03
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Sep 00
Amdt 03

Ink Conversion Calibration

4800 Maintenance Instruction
48192
INK CONVERSION “TO”

INK
CONVERSION 1009 1010 1013 1014 1018 1023 1024 1029 1035 1039 1055 1065 1070 1071 1121 1240 1270 1280 1290 2030 3103 3104 6100 6120
“FROM”

1009 – X X X X X X X X X X X X X X X X X X X X X X X
1010 ✔ – X L ✔ X X X ✔ L ✔ ✔ L ✔ L ✔ ✔ ✔ ✔ X ✔ L X X
1013 ✔ L – L ✔ X X X ✔ L ✔ ✔ L ✔ L ✔ ✔ ✔ ✔ X ✔ L X X
1014 ✔ L X – ✔ X X X ✔ L ✔ ✔ L ✔ L ✔ ✔ ✔ ✔ X ✔ L X X
1018 ✔ L X L – X X X ✔ L ✔ ✔ L ✔ L ✔ ✔ ✔ ✔ X ✔ L X X
1023 ✔ L X L ✔ – X X ✔ L ✔ ✔ L ✔ L ✔ ✔ ✔ ✔ X ✔ L X X

Linx Printing Technologies plc

1024 ✔ L X L ✔ X – X ✔ L ✔ ✔ L ✔ L ✔ ✔ ✔ ✔ X ✔ L X X
1029 X X X X X X X – X X X X X X X X X X X X X X X X
1035 ✔ L X L ✔ X X X – L ✔ ✔ L ✔ L L ✔ ✔ ✔ L ✔ L X X
1039 X X X X X X X X X – X X X X X X X X X X X X X X
1055 ✔ L X L ✔ X X X ✔ L – ✔ L ✔ L ✔ ✔ ✔ ✔ X ✔ L X X
5 — 120

1065 ✔ L X L ✔ X X X ✔ L ✔ – L ✔ L ✔ ✔ ✔ ✔ X ✔ L X X
1070 ✔ L X L ✔ X X X ✔ L ✔ ✔ – ✔ L ✔ ✔ ✔ ✔ X ✔ L X X
1071 ✔ L X L ✔ X X X ✔ L ✔ ✔ L – L ✔ ✔ ✔ ✔ X ✔ L X X
1121 ✔ L X L ✔ X X X ✔ L ✔ ✔ L ✔ – ✔ ✔ ✔ ✔ X ✔ L X X
1240 ✔ L X L ✔ X X X ✔ L ✔ ✔ L ✔ L – ✔ ✔ ✔ X ✔ L X X
1270 ✔ L X L ✔ X X X ✔ L ✔ ✔ L ✔ L ✔ – ✔ ✔ X ✔ L X X
1280 ✔ L X L ✔ X X X ✔ L ✔ ✔ L ✔ L ✔ ✔ – ✔ X ✔ L X X
1290 ✔ L X L ✔ X X X ✔ L ✔ ✔ L ✔ L ✔ ✔ ✔ – X ✔ L X X
2030 X L X L ✔ X X X ✔ X ✔ ✔ L ✔ L ✔ ✔ ✔ ✔ – ✔ L X X
3103 X L X L ✔ X X X ✔ X ✔ ✔ L ✔ L ✔ ✔ ✔ ✔ L – L X X
3104 X L X L ✔ X X X ✔ X ✔ ✔ L ✔ L ✔ ✔ ✔ ✔ L ✔ – X X
6100 X X X X X X X X X X X X X X X X X X X X X X – ✔
4800 Service Manual

6120 X X X X X X X X X X X X X X X X X X X X X X ✔ –

✔ Ink conversion approved—use Ink Conversion Calibration procedure.

L Ink conversion approved but conversion calibration data not available—contact Linx Technical Support.
X Ink conversion not approved.
MP65209–1

Figure 1. Approved ink conversion table

4800 Service Manual
MP65209–1

Ink Conversion Calibration

4800 Maintenance Instruction
48193
INK/CORRECTION FACTORS (CV)
PRINTHEAD
1009 1018 1035 1055 1065 1071 1240 1270 1280 1290 3103
TEMP. °C (T)
5.00 – 7.49 0.050 0.067 0.120 0.070 0.105 0.062 0.094 0.067 0.113 0.084 0.081
7.50 – 9.99 0.049 0.066 0.120 0.070 0.098 0.060 0.090 0.064 0.104 0.079 0.076
10.00 – 12.49 0.048 0.063 0.112 0.069 0.092 0.058 0.087 0.062 0.096 0.075 0.072

Linx Printing Technologies plc

12.50 – 14.99 0.047 0.060 0.112 0.067 0.088 0.054 0.083 0.060 0.090 0.071 0.069
15.00 – 17.49 0.046 0.058 0.088 0.065 0.081 0.050 0.080 0.059 0.085 0.068 0.065
17.50 – 19.99 0.042 0.059 0.088 0.062 0.064 0.045 0.080 0.057 0.082 0.066 0.061
20.00 – 22.49 0.038 0.059 0.082 0.060 0.050 0.041 0.080 0.055 0.079 0.065 0.058
5 — 121

22.50 – 24.99 0.038 0.059 0.082 0.060 0.050 0.041 0.080 0.055 0.079 0.065 0.058
25.00 – 27.49 0.034 0.048 0.050 0.056 0.058 0.044 0.080 0.045 0.064 0.057 0.050
27.50 – 29.99 0.034 0.048 0.050 0.056 0.058 0.044 0.080 0.045 0.064 0.057 0.050
30.00 – 32.49 0.034 0.046 0.046 0.054 0.056 0.042 0.076 0.043 0.063 0.056 0.049
32.50 – 34.99 0.035 0.043 0.046 0.053 0.055 0.040 0.070 0.042 0.063 0.056 0.048
35.00 – 37.49 0.036 0.042 0.042 0.051 0.053 0.039 0.067 0.041 0.062 0.055 0.046
37.50 – 39.99 0.036 0.041 0.042 0.050 0.052 0.038 0.065 0.040 0.060 0.053 0.045
40.00 – 42.49 0.036 0.040 0.036 0.049 – 0.038 0.062 0.039 0.059 0.051 0.043
42.50 – 44.99 0.034 0.039 0.036 0.048 – 0.038 0.059 0.038 0.057 0.050 0.042
45.00 – 47.49 0.033 0.039 – 0.046 – 0.037 0.057 0.037 0.055 0.048 0.040
47.50 – 50.00 0.033 0.039 – 0.044 – 0.036 0.055 0.036 0.054 0.046 0.039
Amdt 03
Sep 00

Figure 2. Ink conversion correction factors table

 48194
Sep 00
Amdt 03

Ink Conversion Calibration

4800 Maintenance Instruction
Startup & Shutdown Options Reference Viscosity Pressure Bits/cP
(depending on 4200 & 6200 s/w version) (VREF) (PCP)
Ink Linx Marque Solvent Ink Type Flush Extended Flush Mk4 Midi Mk3 Macro Mk4 Midi Mk3 Macro
Part No. Ink Name Part No. Selection Shutdown Shutdown Startup or later or later or later or later
1009 Black Pigmented 1505 Pigmented Auto Off Auto 3.2 4.0 14.0 7.0
1010 Black General Purpose 1505 MEK Auto Off Auto L L L L
1013 ** Black Alkali Removable 1590 MEK Auto On Auto X X X X
1014 Black Plastic-Adherent 1505 MEK Auto On Auto L L L L
1018 Red General Purpose 1505 MEK Auto Off Auto 2.8 X 17.0 X
1023 ** Blue General Purpose 1505 MEK Auto On Auto X X X X
1024 ** Green General Purpose 1505 MEK Auto Off Auto X X X X
1029 * White Pigmented 1505 Pigmented Auto Off Auto L L L L

Linx Printing Technologies plc

1035 Black Water Removable 1535 MEK Auto Off Auto 3.1 X 16.25 X
1039 Yellow Pigmented 1505 Pigmented Auto Off Auto L L L L
1055 Black Wet Process 1555 MEK Auto On Auto 3.0 X 13.2 X
1065 Black Dry Glass 1565 MEK Auto On Auto 3.0 X 17.6 X
1070 Black Reodourized Alkali Removable 1560 MEK Auto On Auto L L L L
5 — 122

1071 Red Reodourized Alkali Removable 1560 MEK Auto Off Auto 2.8 X 12.5 X
1121 Clear UV-Readable 1590 MEK Auto On Auto L L L L
1240 Black Fast Drying General Purpose 1512 MEK Auto Off Auto 3.6 3.7 10.0 6.7
1270 Thermochromic Blood Red to Brick Red 1540 MEK Auto Off Auto 3.1 X 15.0 X
1280 Thermochromic Purple to Pink 1540 MEK Auto On Auto 3.5 X 13 X
1290 Thermochromic Black to Blue 1540 MEK Auto On Auto 3.0 X 13.0 X
2030 Black Ethanol General Purpose 2500 Ethanol Auto Off Auto L L L L
3103 Black Mixed Base (Midi/Macro) 3501 3XXX Auto On Auto 2.8 3.4 14.0 (#16.67) 5.6
3104 Black Mixed Base (Micro) 3501 3XXX Auto On Auto X X X X
6100 Red Food Grade 6600 Ethanol Auto Off Auto † X † X
6120 Blue Food Grade 6600 Ethanol Auto Off Auto † X † X
4800 Service Manual

* Ink 1029 not available for use with 4200 and 4800 printers.
** Ink no longer available.
X Conversion not approved for this printhead type.
L Conversion calibration data not available—contact Linx Technical Support.
MP65209–1

# This figure to be used for Mk3 Midi printheads only.

† Conversion approved between inks 6100 and 6120 only and for Mk5 62 µm Midi printheads only. Conversion calibration calculations not necessary—use same Reference Modulation figure.

Figure 3. Ink conversion calibration data table

 Linx Printing Technologies plc

4800 Maintenance Instruction

Ink Conversion Calibration

INK CONVERSION CALIBRATION RECORD

PRIOR TO/DURING CALIBRATION AFTER CALIBRATION

DATE: SET PRESSURE:

MACHINE SERIAL NO.: PRESSURE REFERENCE:

PRINTHEAD SERIAL NO.: MEASURED TOF:

PRINTHEAD TYPE: REFERENCE TOF:

ORIGINAL PRINTHEAD CODE: CURRENT MODULATION:

ORIGINAL REF MODULATION: REF MODULATION:

ORIGINAL INK NAME: CURRENT PHASE:

NEW INK NAME: READ PRESSURE:

INK BATCH NO.: POWER ON TIME:

V1: JET RUNNING TIME:

T: FILTER CHANGE TIME:

P1: SERVICE TIME:

CV:

V2:

P2:

Vm1:

Vm2:

COMMENTS:

Issue 1
Jan 98

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4800 Maintenance Instruction

Ink Conversion Calibration

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4800 Maintenance Instruction

Positive Air Pump Fitting Instructions

Parts Required
FA67047 4800 Internal Positive Air Upgrade

Equipment Required
BP940060 4800 Security Key
BP940052 Tube Cutting Tool

Procedure

WARNING: LETHAL VOLTAGE. DANGEROUS VOLTAGES ARE PRESENT IN

THIS EQUIPMENT WHEN ELECTRICAL POWER IS APPLIED. THE CORRECT,
STANDARD ELECTRICAL SAFETY PRECAUTIONS MUST BE TAKEN. SWITCH
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
ELECTRICAL SAFETY PRECAUTIONS ARE NOT TAKEN.
1 Shut down and switch off the printer, and disconnect it from the mains electrical
supply.
2 Remove the ink and solvent filler caps.
3 Remove the three security screws from the rear of the top cover using the Security
Key and remove the cover.
4 Temporarily refit the ink and solvent filler caps to reduce evaporation of the ink
and solvent.
5 Locate the unconnected, yellow-striped PTFE tube which enters the printhead
conduit. Remove the tie wrap from the coiled tube and cut the tube to a length of
160 mm ±10 mm, measured from the printhead conduit exit point (see figure 1).

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4800 Maintenance Instruction

Positive Air Pump Fitting Instructions

Printhead protection
48170
enclosure grommet Printhead conduit
exit point

Yellow-striped tube

A1 – C1 barb

Positive Air
Pump

To
PL
13
on
IPM
PC
B

Figure 1. Fitting the Printhead Positive Air Pump

6 Ensure the tube is routed through the grommet in the printhead protection
enclosure into the electronics area of the printer.
7 Connect the tube to the A1 – C1 barb fitted to the short tube on the pump
assembly.
8 Position the pump assembly on the chassis in the orientation shown in figure 1,
and secure the pump assembly to the chassis using the two M4x6 pan head screws
supplied in the kit.
9 Connect the pump electrical supply cable to PL13 on the IPM PCB.
10 Tidy and secure the electrical cable and tubing using the tie wraps supplied in the
kit. Ensure the electrical cable is routed clear of the pump motor body.
11 Remove the ink and solvent filler caps.
12 Refit the top cover and the three security screws.
13 Refit the ink and solvent filler caps.
14 Connect the printer to the mains supply and switch the printer on.

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4800 Maintenance Instruction

Positive Air Pump Fitting Instructions

15 Remove the printhead cover tube and check for air flow from the positive air tube
outlet on the printhead (see figure 2):

48222

MIDI

Positive air tube outlet

Figure 2. Printhead Positive Air Tube

16 Switch off the printer.
17 Refit the printhead cover tube.
18 The “Positive Air Pump Fitting Instructions” are now completed.

MP65209–1 Amdt 03
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4800 Maintenance Instruction

Positive Air Pump Fitting Instructions

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4800 Maintenance Instruction

Alarm Beacon Fitting (Printer Mounted)

Parts Required
FA61081 Alarm Beacon 4800 24V Red

Equipment Required
BP940060 4800 Security Key

Procedure

WARNING: LETHAL VOLTAGE. DANGEROUS VOLTAGES ARE PRESENT IN

THIS EQUIPMENT WHEN ELECTRICAL POWER IS APPLIED. THE CORRECT,
STANDARD ELECTRICAL SAFETY PRECAUTIONS MUST BE TAKEN. SWITCH
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
ELECTRICAL SAFETY PRECAUTIONS ARE NOT TAKEN.
1 Shut down and switch off the printer, and disconnect it from the mains electrical
supply.
2 Remove the ink and solvent filler caps.
3 Remove the three security screws from the rear of the top cover using the Security
Key and remove the cover.
4 Temporarily refit the ink and solvent filler caps to reduce evaporation of the ink
and solvent.
5 Remove the Photocell PCB and fit the new Photocell PCB provided in the kit.

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4800 Maintenance Instruction

Alarm Beacon Fitting (Printer Mounted)

6 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)

Mounting bracket Stalk assembly

Figure 1. Alarm Beacon Mounting Bracket Fitted to the Stalk Assembly

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4800 Maintenance Instruction

Alarm Beacon Fitting (Printer Mounted)

7 Using the two remaining screws provided in the kit, fit the mounting bracket and
stalk assembly to the two holes in the ink system vent on the rear of the printer
(figure 2):

Alarm beacon 48174

stalk assembly

Printer base tray Ink system vent

on the rear of the printer

Alarm beacon
cableform

Figure 2. Fitting the Alarm Beacon to the Rear of the Printer

8 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.
9 Remove the ink and solvent filler caps.
10 Refit the top cover and the three security screws.
11 Refit the ink and solvent filler caps.
CAUTION: The printer ALARM OUTPUT connector (PL5) must not be connected to the
mains or any other power source after the installation of the alarm beacon upgrade kit.
Doing so could severely damage the printer.
12 Connect the stalk assembly cableform connector to the Alarm Output connector
(PL5) on the rear of the printer.
13 Connect the printer to the mains supply and switch the printer on.

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4800 Maintenance Instruction

Alarm Beacon Fitting (Printer Mounted)

14 Select the Alarm option from the SETUP menu and set the Mode option to
Continuous, as shown in the following screen:

48195

ALARM
> Mode : Continuous
Failure : Yes
Warning : Yes
Print Disabled : No

Figure 3. Alarm Option Settings for Testing the Alarm Beacon

15 Remove the printhead cover tube and ensure that the alarm beacon flashes on and
off continuously while the cover tube is removed. The System Warning error
message “3.07 Print Head Cover Off” should also be displayed in the status line.
16 Refit the printhead cover tube and ensure that, after a few seconds, the alarm
beacon stops flashing when the error message disappears.
17 Switch off the printer.
18 The “Alarm Beacon Fitting (Printer Mounted)” is now completed.

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4800 Maintenance Instruction

Alarm Beacon Fitting (Gantry Mounted)

Parts Required
One of the following two gantry alarm kits is required to convert a 4800 printer in order to
operate a Linx 24 volt, gantry mounted, alarm beacon:
FA74079 4800 Upgrade: Gantry Alarm (5 m) (includes a modified Photocell PCB
and a 5 meter alarm beacon cableform—AS61019).
FA74080 4800 Upgrade: Gantry Alarm (1.5 m) (includes a modified Photocell PCB
and a 1.5 metre alarm beacon cableform—AS61018).
In addition to FA74079 or FA74080 a gantry mounted alarm beacon is also required, which
is supplied in the following kits:
FA61069 Gantry Alarm Assembly—Long Pole (includes alarm beacon and long
pole).
FA61070 Gantry Alarm Assembly—Short Pole (includes alarm beacon and short
pole).
Combined gantry mounted alarm beacon and gantry kits are also available as an alternative
to the above two kits (these will also require the FA74079 or FA74080 upgrade kits):
FA62031 Free Standing Gantry Alarm Assembly (includes free standing gantry and
the long pole kit FA61069).
FA62032 Bolt-On Gantry Alarm Assembly (includes bolt-on gantry and the short
pole kit FA61070).

Equipment Required
BP940060 4800 Security Key

Procedure

WARNING: LETHAL VOLTAGE. DANGEROUS VOLTAGES ARE PRESENT IN

THIS EQUIPMENT WHEN ELECTRICAL POWER IS APPLIED. THE CORRECT,
STANDARD ELECTRICAL SAFETY PRECAUTIONS MUST BE TAKEN. SWITCH
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
ELECTRICAL SAFETY PRECAUTIONS ARE NOT TAKEN.
1 Shut down and switch off the printer, and disconnect it from the mains electrical
supply.
2 Remove the ink and solvent filler caps.
3 Remove the three security screws from the rear of the top cover using the Security
Key and remove the cover.
4 Temporarily refit the ink and solvent filler caps to reduce evaporation of the ink
and solvent.
5 Remove the Photocell PCB and fit the new Photocell PCB provided in the kit.

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4800 Maintenance Instruction

Alarm Beacon Fitting (Gantry Mounted)

6 Affix the new warning label over the existing “DO NOT USE ALARM SOCKET”
label, adjacent to the ALARM OUTPUT connector (PL5) on the printer rear panel.
CAUTION: The printer ALARM OUTPUT connector (PL5) must not be connected to the
mains or any other power source after the installation of the alarm beacon upgrade kit.
Doing so could severely damage the printer.
7 Connect the larger of the two connectors of the alarm beacon cableform to the
ALARM OUTPUT connector (PL5) on the printer rear panel.
8 Once the gantry mounted alarm beacon has been mechanically installed, connect
the smaller of the two connectors of the alarm beacon cableform to the alarm
beacon.
9 Remove the ink and solvent filler caps.
10 Refit the top cover and the three security screws.
11 Refit the ink and solvent filler caps.
12 Connect the printer to the mains supply and switch the printer on.
13 Select the Alarm option from the SETUP menu and set the Mode option to
Continuous, as shown in the following screen:

48195

ALARM
> Mode : Continuous
Failure : Yes
Warning : Yes
Print Disabled : No

Figure 1. Alarm Option Settings for Testing the Alarm Beacon

14 Remove the printhead cover tube and ensure that the alarm beacon flashes on and
off continuously while the cover tube is removed. The System Warning error
message “3.07 Print Head Cover Off” should also be displayed in the status line.
15 Refit the printhead cover tube and ensure that, after a few seconds, the alarm
beacon stops flashing when the error message disappears.
16 Switch off the printer.
17 The “Alarm Beacon Fitting (Gantry Mounted)” is now completed.

Amdt 03 MP65209–1
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4800 Maintenance Instruction

Pump Motor Brush Assembly Replacement

Parts Required
FA74117 4200/4800 Pump Motor Replacement includes tool kit and
Brushes—Pack quantity six end shield
assemblies
and thereafter:
FA74116 4200 Replacement Pump Motor Brush quantity one end shield
Assembly assembly

Equipment Required
BP940060 4800 Security Key
BP999045 Gloves Latex Medical (large) )
BP999046 Gloves Latex Medical (medium) ) as required
BP999047 Gloves Latex Medical (small) )
BP999076 Safety Spectacles Blue
Suitable cleaning brush or compressed air line
Pencil

Introduction
This procedure requires a degree of manual dexterity to complete and should not be
attempted by unskilled persons. The replacement can be completed within 30 minutes.
Before commencing this procedure it is recommended that service engineers study the
illustrations to familiarize themselves with the various names of the parts.

Procedure

WARNING: LETHAL VOLTAGE. DANGEROUS VOLTAGES ARE PRESENT IN

THIS EQUIPMENT WHEN ELECTRICAL POWER IS APPLIED. THE CORRECT,
STANDARD ELECTRICAL SAFETY PRECAUTIONS MUST BE TAKEN. SWITCH
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
ELECTRICAL SAFETY PRECAUTIONS ARE NOT TAKEN.
1 Shut down and switch off the printer, and disconnect it from the mains electrical
supply.
2 Remove the ink and solvent filler caps.
3 Remove the three security screws from the rear of the top cover using the Security
Key and remove the cover.
4 Temporarily refit the ink and solvent filler caps to reduce evaporation of the ink
and solvent.
5 Disconnect the pump motor assembly power supply cable from the IPM PCB
(PL8).

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4800 Maintenance Instruction

Pump Motor Brush Assembly Replacement

6 Remove the two pump motor assembly mounting screws and carefully, partially
withdraw the assembly from the ink system enclosure (the ink inlet and outlet
pipes do not need to be disconnected from the pump head). Care must be taken
to ensure that the inlet and outlet pipes do not become kinked.
7 Remove the two pump head and motor assembly screws and separate the pump
head from the motor.
8 Remove the rubber cover (spacer collar) from the motor portion.

End shield Motor end plate

assembly retaining screws
48198 (2 off)

Motor casing

Power supply
Pencil cable
orientation
marks

Motor end plate

Adaptor plate

Cup magnet

Grub screw

Figure 1. Motor Assembly Parts’ Identification

9 Remove the cup magnet from the motor armature shaft by loosening the grub
screw using the 3/32 in. hexagonal drive wrench supplied in the kit.
10 Remove the adaptor plate by unscrewing the four retaining screws using the flat
blade screwdriver supplied in the kit.
11 Using a pencil, mark the end shield assembly and motor casing, and the motor end
plate and motor casing to ensure that these components are correctly orientated
when reassembled (see figure 1).
12 Using the T20 Torx wrench, first loosen the two end plate retaining screws slightly,
then unscrew them fully and remove.
13 Holding the end shield assembly and motor casing together in one hand, carefully
remove the motor end plate.
14 Remove the shim washer from the armature shaft and retain with the end plate.

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4800 Maintenance Instruction

Pump Motor Brush Assembly Replacement

15 Carefully remove the motor casing, ensuring that the armature shaft remains
inserted in the end shield assembly. This can be achieved by placing the motor
upright on a flat surface and holding the armature shaft in place with a finger of
one hand, and then lifting the casing slowly (but firmly to overcome the pull of the
permanent magnets) clear of the armature (figure 2):

48199

Carefully lift
motor casing

Figure 2. Removing/Refitting the Motor Casing

16 Carefully remove the armature from the end shield assembly ensuring that the
shim washer is retained with the armature. Discard the old end shield assembly.

WARNING: IT IS RECOMMENDED THAT SAFETY GLASSES AND PROTECTIVE

GLOVES ARE WORN WHILE CLEANING THE MOTOR PARTS.
17 Thoroughly clean the motor casing, armature and end plate with a brush or a
compressed air line to remove carbon dust. Do not use solvent.
18 Clean the commutator segments with the fibreglass brush supplied in the kit.
Clean between the segments first and then clean each segment in turn, using the
brush in the direction of commutator rotation.

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4800 Maintenance Instruction

Pump Motor Brush Assembly Replacement

19 Prepare the replacement end shield assembly by pushing the motor brushes back
in their holders until they latch on the free end of the brush retaining springs.

Brush retaining
Brush retaining spring mounting (2 off)
spring (2 off) 48200

Brush (2 off)

Brush holder
Electrical supply (2 off)
connections

Figure 3. Motor End Shield Assembly

20 Ensure that the shim washer is fitted to the armature then carefully insert the
armature shaft into the new end shield assembly.
21 Carefully lift the free end of one brush retaining spring, push the brush forward on
to the commutator, then release the spring into the retaining notch on the rear face
of the brush. Repeat with the second brush. Ensure that the brushes are in full
contact with the commutator.
22 Carefully slide the motor casing over the armature ensuring that the armature
shaft remains inserted in the end shield assembly. Note that the permanent
magnets will attempt to pull the armature out of the end shield assembly which
will displace the brushes. This can be avoided by placing the motor upright on a
flat surface and holding the armature shaft in place with a finger of one hand (see
figure 2), and then sliding the casing carefully over the armature.
23 Refit the shim washer over the armature shaft followed by the end plate.
24 Align the pencil marks on the end shield assembly, motor casing and end plate.
NOTE: If accurate orientation marks are not used it is possible to fit the end
shield assembly 180° from its correct position. If this should occur the
motor will run backwards. The correct rotation of the motor shaft
should be anticlockwise when viewed from the end shield assembly.

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 Linx Printing Technologies plc

4800 Maintenance Instruction

Pump Motor Brush Assembly Replacement

25 Refit the two end plate retaining screws, gradually tightening each in turn, a little
at a time, until tight.
26 Refit the adaptor plate and the four retaining screws.
27 Slide the cup magnet onto the motor armature shaft.
28 Fit the cup magnet setting jig (supplied in the kit) to the motor assembly. Align the
cut out in the jig with the slot in the adaptor plate, then rotate the cup magnet to
align the grub screw with the slot. Place the assembly upright on a flat surface
(figure 4):

48201

Cup magnet
setting jig

Cup magnet flush

with flat surface

Figure 4. Motor Assembly with Cup Magnet Setting Jig Fitted

29 Insert the 3/32 in. hexagonal drive wrench into the grub screw and push the cup
magnet down until it is flush with the flat surface—this positions the cup magnet
at the correct distance on the armature shaft. Tighten the grub screw.
30 Remove the cup magnet setting jig.
31 Refit the rubber cover (spacer collar) to the motor assembly.
32 Reassemble the pump head to the motor and refit the two pump head and motor
assembly screws.
33 Carefully insert the pump motor assembly through its mounting aperture in the
ink system enclosure and secure with the two mounting screws.

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 Linx Printing Technologies plc

4800 Maintenance Instruction

Pump Motor Brush Assembly Replacement

34 Reconnect the pump motor assembly power supply cable to the IPM PCB (PL8).

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
SAFETY PRECAUTIONS ARE NOT TAKEN.
35 Reconnect the printer to the mains supply and switch on the printer.
36 Ensure that the pump motor is operating and rotating in the correct direction. If it
is not operating, switch off the printer and check that the pump power supply
cable is correctly connected to the IPM PCB (PL8). If the motor still does not
operate, disassemble the pump and motor assembly as described previously and
check that the motor brushes are in full contact with the commutator.
37 Switch off the printer.
38 Remove the ink and solvent filler caps.
39 Refit the top cover and the three security screws.
40 Refit the ink and solvent filler caps.
41 The “Pump Motor Brush Assembly Replacement“ is now completed.

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4800 Maintenance Instruction

Solvent Bottle Adaptor Fitting Instructions

Parts Required
FA72137 4600/4800 Solvent Bottle Adaptor & Cap

Equipment Required
BP940060 4800 Security Key
BP999045 Gloves Latex Medical (large) )
BP999046 Gloves Latex Medical (medium) ) as required
BP999047 Gloves Latex Medical (small) )
BP999076 Safety Spectacles Blue

Procedure

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.
1 Shut down and switch off the printer, and disconnect it from the mains electrical
supply.
2 Remove the ink and solvent filler caps. Discard the solvent filler cap.
3 Remove the three security screws from the rear of the top cover using the Security
Key and remove the cover.
4 Temporarily refit the ink filler cap to reduce evaporation of the ink.
5 Remove the bottle pierce from the solvent filler tube.
6 Remove the O-ring from the solvent filler tube and discard the O-ring.
7 Insert the new solvent bottle adaptor into the solvent filler tube, making sure that
the adaptor is pushed firmly into position and the retaining lugs locate fully into
the O-ring channel.
8 Fit the new O-ring (supplied in the kit) into the channel inside the solvent bottle
adaptor.
9 Refit the bottle pierce in the solvent filler tube.
10 Remove the ink filler cap.
11 Refit the top cover and the three security screws.
12 Refit the original ink filler cap and the new solvent filler cap.
13 Fit an adhesive ‘solvent type’ label to the solvent filler cap.
14 The “Solvent Bottle Adaptor Fitting Instructions” are now completed.

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4800 Maintenance Instruction

Solvent Bottle Adaptor Fitting Instructions

This page left intentionally blank

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 SECTION 6: ERROR & FAULT
MESSAGES

6.1 Introduction
This section describes the system error and fault messages for software Version 1.0 of the
4800 printers. System errors and faults are defined as those which can occur at any time
and are NOT a direct response to user commands. They are divided into three categories:
1. System Failures.
2. Print Failures.
3. System Warnings.
Each system error and fault is given a unique code number which identifies the type and
source of the error or fault, and is followed by a short description when displayed in the
status line of the screen, e.g.:
“2.00 Print Head Temperature”

6.2 Summary of Error & Fault Messages

6.2.1 System Failures
These faults prevent normal printer operation.

6.2.2 Print Failures

These faults occur when the software detects a problem which affects printing.

6.2.3 System Warnings

These are errors which are not serious enough to shut down the printer, but give advanced
warning of potential problems.

4800 Service Manual 6—1 Oct 97

6.3 Error & Fault Message Designations
48077

1. SYSTEM FAILURES 2. PRINT FAILURES 3. SYSTEM WARNINGS

1.01 Internal Failure 2.00 Print Head Temperature 3.00 No TOF Adjustments
1.02 Unexpected NMI 2.01 Deflector Voltage 3.01 Jet Shut Down Incomplete
1.03 Unexpected Interrupt 2.02 Charge 3.02 Over Speed (Print Go)
1.04 Unexpected RST 2.03 Time Of Flight 3.03 Ink Low
1.05 Stack Overflow 2.04 300V Power Supply 3.04 Solvent Low
1.06 Prog PROM Checksum 2.05 Temperature/Deflector 3.05 Print Go / Remote Date
1.07 System RAM 2.06 Ink Tank Empty 3.06 Service Time
1.09 Data PROM Not Fitted 2.16 Internal Spillage 3.07 Print Head Cover Off
1.10 Data PROM Checksum 3.08 Print Head Not Fitted
1.11 No Language 3.09 New Print Head Fitted
1.12 Language Version 3.10 Charge Calibration Range
1.13 No Rasters 3.11 Safety Override Detected
1.14 Raster Version 3.12 Low Pressure
1.15 Raster Data 3.13 Modulation
1.16 No Char Sets 3.14 Over Speed (Variable Data)
1.17 Char Set Version 3.15 Default Language
1.20 Logo Version 3.16 Memory Failure
1.21 Pixel RAM 3.17 Memory Corrupt
1.22 Date Format Version 3.18 No Message Stored In Memory
1.23 Option Version
1.34 Confuguration
1.99 Invalid Failure

Figure 6-1. Error Message designations table

Oct 97 6—2 4800 Service Manual

6.4 Error & Fault Reporting Configuration
This facility allows all current System Warning error messages to be viewed, and the
reporting of all System Warning errors and Print Failure faults to be configured. Access to
these options is achieved by pressing the [F2] key (Check Status) from the CURRENT
MESSAGE screen which will display the PRINT STATUS screen:
48037

CURRENT MESSAGE : MESSAGE 1

F1 : Change Message F2 : Check Status

F3 : New Message F4 : Change Setup 48079

PRINT STATUS
F1 : Error List Count : 9
F2 : Error Info. Status : Jet Off
F3 : Fault Info. Solvent : OK
Ink : OK

Figure 6-2. Accessing the Print Status screen

6.4.1 Print Status Screen

This screen contains information about the current status of the printer.
The options Error 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 LKC fitted on the IPM PCB. If these two conditions are not met the
PRINT STATUS screen will display only the “F1 : Error List” option. Also, the Password
option must be set to Off using the Service Level password before the “F2 : Error Info.” and
“F3 : Fault Info.” options will 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 been stopped.
Jet Running The jet is running but printing is stopped.
Printing 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 4800 User Manual for instructions on filling with ink and solvent.
NOTE: Only one bottle of ink or solvent should be added when the level is reported as
Low.

4800 Service Manual 6—3 Oct 97

 F1 : Error List
All current System Warning errors are logged and may be displayed by pressing the [F1]
key:

48080

ERROR LIST
> 3.07 Print Head Cover Off

Figure 6-3. Error List screen

This screen displays all System Warning errors which have occurred since the printer was
last switched on. An attempt can be made to clear an error message by selecting it from the
Error List menu and pressing [enter]. Some messages can be cleared, in which case the
front panel warning LED will extinguish. Other messages cannot be cleared and the front
panel warning LED will remain lit until the error has been rectified, e.g. “3.03 Ink Low”.
NOTE: A System Warning (error) message reports a problem with the printer that
does not immediately affect its ability to continue printing. A System Failure
or Print Failure (fault) will immediately initiate a fault shutdown (with the
exception of the “2.16 Ink Spill” fault) and reset the printer.

F2 : Error Info.
Pressing the [F2] key from the PRINT STATUS screen will access the ERROR
INFORMATION menu which lists all the possible System Warning error messages:

48081

ERROR INFORMATION
3.00 No TOF Adjustments
3.01 Jet Shut Down Incomplete
> 3.02 Over Speed (Print Go)
3.03 Ink Low

3.04 Solvent Low

3.05 Print Go / Remote Date
3.06 Service Time
3.07 Print Head Cover Off
3.08 Print Head Not Fitted
3.09 New Print Head Fitted
3.10 Charge Calibration Range
3.11 Safety Override Detected
3.12 Low Pressure
3.13 Modulation
3.14 Over Speed (Variable Data)
3.15 Default Language
3.16 Memory Failure
3.17 Memory Corrupt
3.18 No Message Stored In Memory

Figure 6-4. Error Information screen

Oct 97 6—4 4800 Service Manual

 The particular System Warning error message which is required to be configured can then
be selected, which will display the following menu:

48082

3.02 Over Speed (Print Go)

> Trigger : Once
Count : 0

Figure 6-5. Error Message configuration screen

The menu title corresponds to the currently selected error message, and the two options
available are Trigger and Count:

Trigger
The Trigger option can be altered to one of two settings—Once (the default) and Always:

Once
Selecting Once will result in the error message being reported only once in the
status line while the error is valid, and while it remains in the Error List (i.e. until it
is deleted from the Error List).

Always
Selecting Always will result in the error being reported every time it occurs
regardless of whether it has been deleted from the Error List.

Count
The Count option will record the number of times the error occurs (not the number of times
it is reported). This value will be stored in Non-Volatile RAM (NVR) and be remembered
while the power is off, and therefore is a continuous record of the number of times the
error has occurred.
NOTE: It is not possible to alter the Count value.
When the Trigger option is set to Always, and whilst an error is being reported in the
status line, any subsequent errors reported will not be displayed until the first error display
sequence is completed, although the error Count will increment on the occurrence of every
error.
For example, consider a situation where a “3.02 Over Speed (Print Go)” error is constantly
being reported. The first occurrence will cause the error message to be displayed, the
internal alarm tone (beeper) to sound and the error Count for that error to increment. If,
during the display sequence of the first error, two more over speed errors occur, the error
Count will increment a further two times. Once the error display sequence has completed,
the next occurrence (the fourth) of an over speed error will cause the error message to be
displayed for the second time, although four over speed errors have occurred since the
beginning of the first display sequence.
Each error message is displayed in turn for approximately 2 seconds before the next is
displayed. This allows all errors that have occurred to be easily seen. Confirmation of any
error (i.e. System Warnings) can then be checked by examining the Error List.

4800 Service Manual 6—5 Oct 97

 F3 : Fault Info.
Pressing the [F3] key from the PRINT STATUS screen will access the FAULT
INFORMATION menu which lists all the possible Print Failure fault messages:

48083

FAULT INFORMATION
2.00 Print Head Temperature
2.01 Deflector Voltage
2.02 Charge
> 2.03 Time Of Flight

2.04 300V Power Supply

2.05 Temperature/Deflector
2.06 Ink Tank Empty
2.16 Internal Spillage

Figure 6-6. Fault Information screen

The particular Print Failure fault message which is required to be configured can then be
selected, which will display the following menu:

48084

2.03 Time Of Flight

> Count : 0

Figure 6-7. Fault Message configuration screen

The menu title corresponds to the currently selected fault message, and the single option
available is Count:

Count
As with the Error Info. option, the Count option will record the number of times the fault
occurs (not the number of times it is reported). This value will be stored in Non-Volatile
RAM (NVR) and be 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.

Oct 97 6—6 4800 Service Manual

6.5 System Failures
System Failures occur when the software detects a condition which prevents normal
printer operation. 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.
Most System Failures will be reported while the software is performing the self test and
initialization routines which are carried out after power on, i.e. 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 1.01 AND 1.05

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 BE LEFT ON.
System Failures which occur during normal operation indicate a serious problem which
prevents further printer operation. The software will attempt to set the printer to a safe
state when the failure occurs, i.e.:
• set the pressure to zero;
• switch off the EHT;
• close all valves;
• switch off the 300 V d.c.
System Failures will cause the printer to stop printing by simply closing the ink system
Feed valve; a normal jet shutdown is NOT carried out. This will lead to a subsequent
messy startup but will not cause any permanent damage to the printhead.
When a System Failure occurs, the print ready line is set low and a System Failure fault
message is displayed in the screen status line. The front panel fail LED and the internal
alarm tone will be switched on continuously, but the alarm relay will not be activated since
the software cannot be certain of the alarm enable state following some System Failures.

6.5.1 “1.01 Internal 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 more commonly be expected to
occur when the printer is in operation, having successfully completed the normal switch-on
system checks.
Possible causes:
• EMC interference or spike on mains power supply;
• static discharge to the printhead from the operating environment;
• poor electrical connections.

4800 Service Manual 6—7 Oct 97

 6.5.2 “1.02 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 more commonly be expected to occur when the printer is in operation,
having completed the normal switch-on system checks.
Possible causes:
• EMC interference or spike on mains power supply;
• static discharge to the printhead from the operating environment;
• poor electrical connections.

6.5.3 “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 more commonly be
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 interrupt which is invalid;
• EMC interference or spike on mains power supply;
• static discharge to the printhead from the operating environment;
• poor electrical connections.

6.5.4 “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 more commonly be expected to
occur when the printer is in operation, having successfully completed the normal switch-on
system checks.
Possible causes:
• EMC interference or spike on mains power supply;
• static discharge to the printhead from the operating environment;
• poor electrical connections;
• faulty connection caused by poor seating of a socketed IC;
• dry solder joints;
• PCB contamination.

6.5.5 “1.05 Stack Overflow”

The software stack has exceeded the maximum expected size. The stack is the working
area of the microprocessor in which information is temporarily stored.
Possible causes:
• faulty Program PROM (IC31);
• faulty CPU peripheral issuing too many interrupts.

Oct 97 6—8 4800 Service Manual

 6.5.6 “1.06 Prog PROM Checksum”
The checksum stored in the program area of the Program PROM (IC31) does not agree
with the calculated checksum. During the switch-on routine the microprocessor will
recalculate the checksum and compare it to the stored data. If there is a discrepancy then
this fault will be reported.
Possible causes:
• corrupt or faulty Program PROM;
• faulty Program PROM addressing circuit.

6.5.7 “1.07 System RAM”

The non-destructive System RAM test has failed. During the switch-on sequence a non-
destructive test of the System RAM (IC83) is carried out and if any associated faults are
detected then this fault message will be reported.
Possible causes:
• faulty System RAM;
• faulty PROM addressing circuit.

6.5.8 “1.09 Data PROM Not Fitted”

The software cannot detect the Data area of the Program PROM (IC31).
Possible causes:
• Corrupt PROM;
• faulty PROM addressing circuit.

6.5.9 “1.10 Data PROM Checksum”

The checksum stored in the Data area of the Program PROM (IC31) does not agree with the
calculated checksum. During the switch-on routine the microprocessor will recalculate the
checksum and compare it to the stored data. If there is a discrepancy then this fault will be
reported.
Possible causes:
• corrupt PROM;
• faulty PROM addressing circuit.

6.5.10 “1.11 No Language”

There are no languages stored in the Data area of the Program PROM (IC31), or the data
has been corrupted.
Possible causes:
• corrupt PROM;
• incorrect data in the PROM.

4800 Service Manual 6—9 Oct 97

 6.5.11 “1.12 Language Version”
The language version data is incorrect or incompatible with the program data in the
Program PROM (IC31).
Possible causes:
• corrupt PROM;
• incorrect data in the PROM;
• corrupt Logo PROM (IC114);
• incorrect Logo PROM (IC114) fitted.

6.5.12 “1.13 No Rasters”

There is no raster information stored in the Data area of the Program PROM (IC31), or the
raster information does not contain the required raster for the currently fitted printhead
type.
Possible causes:
• corrupt PROM;
• incorrect data in the PROM.

6.5.13 “1.14 Raster Version”

The raster version data is incorrect or incompatible with the program data in the Program
PROM (IC31).
Possible causes:
• corrupt PROM;
• incorrect data in the PROM;
• corrupt Logo PROM (IC114);
• incorrect Logo PROM (IC114) fitted.

6.5.14 “1.15 Raster Data”

The raster information stored in the Data area of the Program PROM (IC31) cannot be read
by the software.
Possible causes:
• incorrect raster for printhead fitted;
• corrupt PROM;
• no Configuration GAL (IC88) fitted.

6.5.15 “1.16 No Char Sets”

There are no character sets stored in the Data area of the Program PROM (IC31), or the
data has been corrupted.
Possible cause:
• corrupt PROM;
• incorrect data in the PROM.

Oct 97 6 — 10 4800 Service Manual

 6.5.16 “1.17 Char Set Version”
The character set version data is incorrect or incompatible with the program data in the
Program PROM (IC31).
Possible causes:
• corrupt PROM;
• incorrect data in the PROM;
• corrupt Logo PROM (IC114);
• incorrect Logo PROM (IC114) fitted.

6.5.17 “1.20 Logo Version”

The logo version data is incorrect or incompatible with the program data in the Program
PROM (IC31).
Possible causes:
• corrupt PROM;
• incorrect data in the PROM;
• corrupt Logo PROM (IC114);
• incorrect Logo PROM (IC114) fitted.

6.5.18 “1.21 Pixel RAM”

The Pixel RAM (IC59 and IC60) startup test has failed.
Possible causes:
• either or both pixel RAMs are not fitted or are faulty;
• the Pixel RAM bank switching has failed.

6.5.19 “1.22 Date Format Version”

The date format version data is incorrect or incompatible with the program data in the
Program PROM (IC31).
Possible causes:
• corrupt PROM;
• incorrect data in the PROM;
• corrupt Logo PROM (IC114);
• incorrect Logo PROM (IC114) fitted.

6.5.20 “1.23 Option Version”

The configuration version data is incorrect or incompatible with the program data in the
Program PROM (IC31).
Possible causes:
• corrupt PROM;
• incorrect data in the PROM.

4800 Service Manual 6 — 11 Oct 97

 6.5.21 “1.34 Configuration”
The Configuration GAL (IC88) is incorrect or not fitted.
Possible causes:
• non-4800 Configuration GAL fitted;
• corrupt Configuration GAL;
• no Configuration GAL fitted.

6.5.22 “1.99 Invalid Failure”

An invalid system fault has occurred.
Possible causes:
• incorrect Program PROM (IC31) fitted;
• corrupt Configuration GAL (IC88);
• incorrect Configuration GAL (IC88) fitted.

Oct 97 6 — 12 4800 Service Manual

6.6 Print Failures
Print Failures occur when the software detects a problem which affects printing. When a
Print Failure occurs, the print ready line is set low, a Print Failure fault message is
displayed in the screen status line and a short jet shutdown sequence is initiated. The front
panel fail LED and the internal alarm tone will be switched on continuously and,
depending on the status of the Alarm Relay options in the SETUP menu, the alarm relay
may be activated continuously. The keyboard is inactive while the shutdown is taking
place.
When the shutdown sequence has been completed the Print Failure screen will be
displayed:

48078

PRINT FAILURE
Print Failure 2.00 Print Head Temperature

F1 : Reset Printer

Print Failure 2.00 Print Head Temperature

Figure 6-8. 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.
These settings cannot be altered until the Print Failure has been cleared, i.e. the jet cannot
be restarted.

6.6.1 “2.00 Print Head Temperature”

Excessive high temperature at the printhead indicating a high ambient temperature or a

possible fire condition. The trip temperature is approximately 75 °C.
Possible causes:
• printhead too close to source of high temperature;
• faulty printhead thermistor;
• faulty connection on printhead connector.
NOTE: Hot substrates should be printed on from the side to avoid heat convection to
the printhead.

4800 Service Manual 6 — 13 Oct 97

 6.6.2 “2.01 Deflector Voltage”
The EHT trip sensor is indicating that an EHT trip has occurred.
Possible causes:
• excessive build-up of ink on deflector plates, and the ink is shorting a plate to
another item in the printhead, e.g. 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.

6.6.3 “2.02 Charge”

This failure can only occur when the jet is being started or when it is running.
When the jet is being started or during printing the phase position must be adjusted to
ensure the correct charge is applied to the drops to give a good print. This takes place
every 3 seconds or after each print, whichever occurs first.
A charge failure will occur if the microprocessor has not received a phase feedback signal
to indicate the true phase position. Repeated attempts are made to find the phase position
after which the printer will fail.
If the failure occurs during jet startup the jet is stopped and three additional starts are
attempted. If these are unsuccessful then this failure is reported. During the restarts the
system will complete a Clear Nozzle sequence before each attempted start, but without the
operator applying solvent to the nozzle face. (Refer to the “Clear Nozzle” option in Section
5: “Maintenance” > The Diagnostics Menu.
NOTE: This fault detection can be disabled in Diagnostics by setting the Phase Fault
option to Off.
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, either through the
charge electrode or over the phase detector.

Oct 97 6 — 14 4800 Service Manual

 • no charge to electrode caused by bad connections, faulty Charge Amp or
incorrect charge DAC calibration;
• no signal from phase/TOF connections;
• faulty Phase Amp;
• conductivity problems due to contaminated ink;
• incorrect Configuration GAL fitted, or an error within the Configuration GAL
or associated logic;
• heavy build-up of dry ink on the deflector plates.

6.6.4 “2.03 Time Of Flight”

This failure can be caused by two different faults: when the jet is being started, and when
the jet is running. Both conditions are described as follows:
1. During the jet startup sequence this failure can occur if the microprocessor is
unable to obtain valid TOF readings. In order to reject spurious TOF
measurements, those outside a certain range (currently ±40% of the reference
TOF) are considered as invalid readings and will be rejected. Before the failure
is reported, three restarts are attempted during which the system will complete
a Clear Nozzle sequence before each attempted start.
2. When the jet is running the normal TOF adjustment routine may add solvent if
the Solvent Add conditions are met (see Section 3: “Technical Description” >
Ink System > Ink and Solvent Flows > Solvent Addition). A Solvent Add will
allow 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 will be adjusted to control the TOF.
However, if after this time the pressure is still greater than the Solvent Add
value, a further solvent addition is allowed. This is repeated until the pressure
is below the Solvent Add value. A maximum limit of successive solvent
additions (eight for MEK and Pigmented inks; 25 for Ethanol and 3XXX inks) is
allowed in any one TOF correction loop. If this limit is exceeded then this fault
is reported and the jet is shut down.
Possible causes:
• 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;
• solvent reservoir pick-up tube or 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 (eight for
MEK and Pigmented inks; 25 for Ethanol and 3XXX inks) which results in this
fault being reported;
NOTE: This only applies if the pressure failure occurs after jet startup. If
the pressure loss was detected at jet startup (see System Warning
“3.12 Low Pressure”) then no solvent will be added.
• heavy build-up of dry ink on the deflector plates;
• noise (EMC) interference.
NOTE: This fault detection can be disabled in Diagnostics by setting the Phase Fault
option to Off.

4800 Service Manual 6 — 15 Oct 97

 6.6.5 “2.04 300V Power Supply”
The 300 volt sense signal has identified that the 300 V EHT PSU output is not present.
Possible causes:
• the 300 V EHT PSU output has failed;
• faulty 5 volt reference, which is compared with a proportion of the 300 volt
line to determine the presence of the 300 volts;
• printhead modulation/charge short circuit;
• faulty 300 volt control circuit on IPM PCB;
• faulty 300 volt sense comparator (IC93A).

6.6.6 “2.05 Temperature/Deflector”

Indicates that a temperature failure, or a deflector EHT failure of very short duration, has
occurred. The software has not responded fast enough to detect which of the two failures
occurred.
See also: Print Failures 2.00 and 2.01.

6.6.7 “2.06 Ink Tank Empty”

Occurs when the ink level sensor has been indicating low for a predetermined time:
Micro: 8 hours
Midi: 8 hours
Macro: 3 hours
These times prevent the ink from running out completely if the user fails to refill the ink
reservoir following a System Warning “3.03 Ink Low” error message. This failure only
occurs when the jet is running since the jet cannot be started when the ink is low.

6.6.8 “2.16 Internal Spillage”

This failure will occur within 5 seconds of an ink spillage being detected and will stop the
printer immediately without performing a jet shutdown.
Possible causes:
• ink or solvent reservoir overflow;
• incorrect ink replenishment procedure;
• leak within ink system;
• faulty spillage detection circuit.

Oct 97 6 — 16 4800 Service Manual

6.7 System Warnings
System Warnings inform the user of problems which may affect the operation of the
printer but are not serious enough to require a shutdown. When a System Warning occurs,
a warning error message is displayed in the screen status line for a minimum of
approximately 3 seconds. The front panel warning LED will be switched on and off twice
and then remain on. The internal alarm tone will be switched on and off twice and,
depending on the status of the Alarm Relay options in the SETUP menu, the alarm relay
may be activated twice.
The error message will remain displayed in the screen status line after the 3 second interval
until the user presses any key, or another error occurs, or a standard warning message (see
note) is displayed.
NOTE: A standard warning message is a message without a number designator,
which appears in the screen status line, e.g. “Invalid Key Pressed” or “Message
Start”. It is not an error or a fault.
All System Warning errors are logged and may be displayed by selecting the “F1 : Error
List” option from the PRINT STATUS window (“F2 : Check Status” in CURRENT
MESSAGE screen). This screen displays all System Warning error messages which have
occurred. The user may attempt to clear an error by selecting the error message from the
Error List and pressing [enter]. Some messages can be cleared, in which case the front
panel warning LED will extinguish. Other messages cannot be cleared and the front panel
warning LED will remain lit until the error has been rectified, e.g. “3.03 Ink Low”. See
“Error & Fault Reporting Configuration” earlier in this section.

6.7.1 “3.00 No TOF Adjustments”

This warning can occur when the jet is being started, or when the jet has been running for
some time. It indicates that the printer has been unable to obtain the correct TOF in the
time allowed, or that no TOF readings have been received in 15 minutes and that the TOF
may be out of range.
When the jet is started the system attempts to attain the correct TOF value (i.e. ±0.5% of the
TOF reference value). If it fails to attain the correct TOF after 125 seconds then this
warning is reported and the jet continues to run. The normal operational TOF correction
software will then continue to adjust the pressure to attain the correct TOF. However, this
means that initial printing may take place with the wrong TOF which may result in poor
print quality.
This warning will also be displayed when the jet is running if the pressure reaches the
maximum allowable for the printhead fitted. Normally, solvent is added after the warm-
up period when the pressure exceeds the Solvent Add pressure. If, however, the solvent
reservoir level is low, and no solvent can be added, the pressure will be increased to
maintain the TOF. If the solvent reservoir level remains low the pressure will eventually
reach the maximum (255 for Micro and 62 µm Midi printheads; 200 for 70 µm Midi
printheads; 150 for a Macro printhead) and this warning will be displayed. The jet will
continue to run but without any further adjustments to the TOF. The warning will clear
itself when the TOF is back within the normal range and the pressure is no longer at the
maximum level, e.g. if the solvent reservoir is refilled.
This warning may also occur if a pressure loss has been detected, since no solvent will be
added in this case (see System Warning “3.12 Low Pressure”).
Possible causes:
• the printhead code is incorrectly entered;
• the ink viscosity is high or low at startup;
• blocked filters;
• heavy build-up of dry ink on the deflector plates;
• ink contamination.

4800 Service Manual 6 — 17 Oct 97

 6.7.2 “3.01 Jet Shut Down Incomplete”
This warning is reported at startup. It indicates that the printer was previously switched
off while the jet was still running or before the printer had completed the shutdown
routine. Printer start problems may be experienced if the shutdown routine was
incomplete; these could be a blocked nozzle, a dirty start or a misaligned jet.
The warning will be reported on every subsequent printer startup until a jet shutdown
routine is fully completed. The error is not cleared when a Print Failure shutdown occurs.
NOTE: If a System Failure occurs while the jet is running then the jet is simply turned
off and this warning is reported in the status line. Since most System Failures
occur during printer initialization at switch-on, the probability of System
Failures occurring while the jet is running is low.

6.7.3 “3.02 Over Speed (Print Go)”

This indicates that the printer has received a print trigger when it is currently printing a
message.
When the Photocell option (SETUP menu) is set to Triggered each print delay is started
following the photocell trigger. At the end of the delay a ‘print go’ is issued to start
printing, and if the printer has not printed the last message by this time then the warning is
reported and the new message is not printed. In effect this will mean that alternate objects
may not be printed upon.
This error may also occur when the Photocell option is set to Enable or Off. In these modes
the print delay specifies the space between messages. The error applies to the message
currently being printed.
Possible causes:
• the photocell is providing triggers or an incorrect photocell is being used for
the application;
• the next object for printing has arrived at the printhead before the last message
is complete, because:
1. the line speed is too fast;
2. the message is too long compared to the size of the objects to be
printed upon.
• the print delay is too small for the Photocell options Enable and Off.

6.7.4 “3.03 Ink Low”

If the level sensor indicates that the ink level in the reservoir is low then this warning is
reported. The warning is cleared automatically when a sufficient quantity of ink is added
to the reservoir.
If this error is detected before the jet is started then the jet cannot be started until the error
is cleared (i.e. the ink reservoir is refilled). If the error is detected while the jet is running,
the jet will continue to run for several hours until the ink is dangerously low, at which
point a failure will occur (see Print Failure “2.06 Ink Tank Empty”).
NB: The ink reservoir should be refilled only when this warning is reported (one
bottle of ink only).

Oct 97 6 — 18 4800 Service Manual

 6.7.5 “3.04 Solvent Low”
If the level sensor indicates that the solvent level in the reservoir is low then this warning is
reported. The warning is cleared automatically when a sufficient quantity of solvent is
added to the reservoir.
If this error is detected before the jet is started then the jet cannot be started until the error
is cleared (i.e. the solvent reservoir is refilled). If the error is detected while the jet is
running, the jet will continue to run regardless, but no attempt will be made by the printer
to add solvent (the pressure will be increased to maintain TOF instead).
NB: The solvent reservoir should be refilled only when this warning is reported (one
bottle of solvent only).

6.7.6 “3.05 Print Go/Remote Data”

A ‘print go’ has occurred and printing data has not been received from the remote
interface.

6.7.7 “3.06 Service Time”

When the printer is switched on, the time remaining to the next 1400 Hour Service is
checked. If it is zero or a negative value then this warning is reported and the jet is started
as normal.
The time to the next 1400 Hour Service can be reset by the service engineer in the System
Times option of the DIAGNOSTICS sub-menu (SETUP menu). This warning will be
reported every time the printer is switched on until the Service time has been reset.
See also: Section 5: “Maintenance” > The Diagnostics Menu > System Times option.

6.7.8 “3.07 Print Head Cover Off”

WARNING: LETHAL VOLTAGE. DANGEROUS VOLTAGES EXIST IN THE

PRINTHEAD. EXTREME CARE MUST BE TAKEN WHEN WORKING ON THE
PRINTHEAD WITH THE COVER REMOVED AND LK6 FITTED. THE CORRECT
ELECTRICAL SAFETY PRECAUTIONS MUST BE FOLLOWED.
LINK LK6 IS TO BE FITTED ONLY UNDER MAINTENANCE CONDITIONS AND IT
MUST NEVER REMAIN FITTED WHEN THE PRINTER IS LEFT UNATTENDED. IT
MUST NEVER BE FITTED DURING NORMAL OPERATION.
This warning is reported if the printhead cover is removed. The ±5 kV EHT supply to the
deflector plates is automatically switched off and printing is suspended when the cover is
removed, and is resumed a few seconds after the cover is refitted.
Link LK6 (Cover Override), when fitted, disables the automatic EHT switch-off for fault
diagnosis purposes.

4800 Service Manual 6 — 19 Oct 97

 6.7.9 “3.08 Print Head Not Fitted”
When the printer is switched on the software checks the type of printhead that is fitted. If
it does not recognize the printhead type then this error is reported.
The system will continue to operate and will assume that the printhead has not been
changed, and will continue with the same printhead type data as used last time (i.e. the
currently stored NVR printhead type).
If a different type of printhead has been fitted, then printhead compatible software must be
installed and the correct printhead and modulation codes must be entered. If this is not
carried out the jet will not break up correctly.
Possible causes:
• no printhead fitted;
• faulty printhead connector/connection;
• incorrect software version fitted.

6.7.10 “3.09 New Print Head Fitted”

When the printer is switched on the software checks the type of printhead that is fitted (the
last printhead type data is stored in NVR). If the currently fitted printhead type is not the
same as the type stored in NVR then this warning is reported.
Under normal circumstances this warning just confirms that the printhead type has been
changed. In this case the default settings of TOF reference and modulation will be used
until the correct printhead code is entered against the Print Head Code option in the
SETUP menu. If the wrong type of printhead has been detected for any reason, then the
TOF reference and modulation will be incorrect and, therefore, the jet will not break up
properly.
Possible causes:
• printhead type changed;
• incorrect software version fitted;
• NVR faults;
• faulty printhead connector/connection.

6.7.11 “3.10 Charge Calibration Range”

The charge calibration DAC is used to apply a gain in the range of 0.8 – 1.2 to the charge
DAC. This gain is made up of two components: the printhead gain (entered with the
printhead code) and the IPM PCB’s calibration gain. Both gains are stored in the NVR and
at jet startup the gains are multiplied together and the resultant overall gain applied to the
charge DAC. If the resultant overall gain is outside the permitted range this warning error
message is reported.
The system will continue to operate with the default gain of 1.0 when this error occurs.
Possible cause:
• An out-of-range PCB calibration gain has been set up (i.e. outside 0.895 –
1.095) using the Service Diagnostics. (The printhead gain is automatically
checked when the new printhead code is entered).

Oct 97 6 — 20 4800 Service Manual

 6.7.12 “3.11 Safety Override Detected”

WARNING: WHEN LINK LK4 IS FITTED, THE SAFETY CIRCUITS ARE

OVERRIDDEN. THIS MEANS THAT PRINTHEAD OVER TEMPERATURE WILL
NOT BE DETECTED, AND WHEN THE PRINTHEAD COVER IS REMOVED, THE ±5
KV EHT TO THE DEFLECTOR PLATES AND THE 300 VOLTS D.C. TO THE CHARGE
ELECTRODE WILL NOT BE INHIBITED.
THE FITTING OF LK4 IS FOR FAULT DIAGNOSIS PURPOSES ONLY AND IT MUST
NOT BE FITTED PERMANENTLY.
This error message is displayed when the software detects that the Safety Override link
LK4 is fitted. If this error is reported, the printer will not start up (normal startup) if the
password level is lower than the Service Level. A Quick Start will not be affected by the
link being fitted. If the jet is already running and the link is then fitted, it will not affect the
printer operation although this error will still be reported.
When attempting to start the jet with the Safety Override link fitted, the following standard
warning message will be displayed:
“Jet Not Started : Safety Override”

6.7.13 “3.12 Low Pressure”

Each time the jet is started a pressure and filter check is carried out: the pressure is set to
235 and the pressure ADC is used to check that this pressure is actually reached. If the
difference between the pressure DAC setting and the pressure ADC reading is greater than
a predetermined value (currently 14), then this warning is reported. The jet will continue
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 pre-pump filter is blocked (most probable);
• the ink pick-up tube is blocked;
• some other loss of pressure in the ink system;
• faulty pump;
• faulty pump drive circuit.

6.7.14 “3.13 Modulation”

The printer has detected a modulation error. Re-enter the Ref Modulation value from the
printhead conduit label.

4800 Service Manual 6 — 21 Oct 97

 6.7.15 “3.14 Over Speed (Variable Data)”
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 (e.g. sequential numbers)
before the next ‘print go’; i.e. the printer was still generating the pixel data for the next
message.
When this warning is reported one message may be missed but the printer will continue to
print.
Note that this warning indicates that the printer cannot generate pixels fast enough,
whereas System Warning “3.02 Over Speed (Print Go)” indicates that the printer cannot
print the rasters fast enough. This error is only likely to occur with fast rasters (e.g. rasters
smaller than 16 drops for micro printheads) where pixel generation by the software is
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 photocell triggers.

6.7.16 “3.15 Default Language”

When the printer is switched on, a check is made to determine if the currently selected
language stored in the back-up NVR exists in the Data area of the Program PROM (IC31).
If it does not then this warning is reported and the default language (normally English) is
used. The warning will be reported each time the printer is switched on until the
Language Setup option in the SETUP menu is used to select a valid language.
Possible cause:
• incorrect PROM fitted.

6.7.17 “3.16 Memory Failure”

When the printer is switched on a security message stored in the back-up NVR is
compared to one stored in the Program PROM (IC31). If they are not the same then this
error will be reported. The NVR will be initialized with default values, and the NVR
message will be set to be the same as the PROM message. The warning will not be
repeated at the next power-up unless the NVR is faulty.
After this error has occurred the system will still function, but stored values such as TOF
reference, DAC calibration values and modulation values will be set to the defaults.
Possible causes:
• a new version of the Program PROM has been fitted;
• the battery back-up has failed (flat battery);
• the battery link LK2 on the IPM PCB has been removed.

6.7.18 “3.17 Memory Corrupt”

When the printer is switched on each individual object stored in the back-up NVR is
checked. If one or more objects are corrupt then the default values for those objects are
loaded and the error 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);
• electrical spikes;
• faulty memory ICs.

Oct 97 6 — 22 4800 Service Manual

 6.7.19 “3.18 No Message Stored In Memory”
This error is reported if there is no message stored in memory. Printing cannot be started if
there is no message stored.
Possible causes:
• the user has cleared the message by selecting “F3 : New Message” on the
CURRENT MESSAGE screen, and has then failed to enter a new message;
• the Clear Message Area command in the DIAGNOSTICS menu has been used
to delete all messages from the 5 message store.

4800 Service Manual 6 — 23 Oct 97

 This page left intentionally blank

Oct 97 6 — 24 4800 Service Manual

 SECTION 7: FAULT DIAGNOSIS

7.1 Introduction
This section provides general advice on fault diagnosis on the LINX 4800 Ink Jet Printers,
as well as specific procedures for identifying and rectifying faults. Fault diagnosis is
complicated by the number of variables involved in producing good print quality. Fast,
non-contact printing involves fluid dynamics, physics, electronics, computing and
chemistry.
Many of the faults that could occur within the printer are self-diagnosed by the integral
software. Upon diagnosis, the operator is alerted by way of an error or fault message
which appears in the status line of the display screen.
Before attempting any fault diagnosis for the first time, operators are advised to familiarize
themselves with the “Error and Fault Messages” section of this manual, as it contains
information which is useful in rectifying many simple faults.
Problems can be found to have either a single cause or several combined causes. The
complications arising from the simultaneous failure of several different components make
it impossible to consider such faults in this service manual. In this section, individual
problems are linked to their most probable causes. The most successful fault diagnosis
technique will be found by investigating each problem, separately, in turn. Do not begin
by assuming the most complicated combination of faults; always start by investigating the
most simple possibilities first.

7.2 Where to Start

All problems with printer operation are distinguished from each other by the symptoms
displayed. These symptoms can be obvious faults with the print quality; error or fault
messages on the display; or any other signs by which it is apparent that the machine is not
functioning correctly. When the symptoms have been correctly identified, the possible
cause(s) of the symptoms the printer is displaying can be investigated.
The recommended fault diagnosis sequence is as follows:
1. Collect as much information as possible on ALL the symptoms that the printer
is displaying, including error and fault messages, print samples and signs of
electrical or mechanical malfunctions.
2. Use the “Identifying Faults” sub-section to identify all the possible causes of
the symptoms that the printer is displaying.
3. Start with the most probable cause, and investigate each of the possible causes
in turn. This will eliminate all the possible causes that are not responsible for
the problem, until the actual cause is established.
4. When the actual cause of the failure symptoms has been established, use the
“Problem Solving” sub-section to perform the necessary adjustments and
repairs to rectify the fault.
5. Finally, check that the printer operates correctly and that any error or fault
messages have been cleared, and that there is not a second fault causing
supplementary failure symptoms.
If, after rectifying one fault the symptoms have not been eliminated, continue with the fault
diagnosis until all faults have been identified and rectified. Only when all faults have been
eliminated, and the printer is operating correctly, has the fault diagnosis been completed.
The “Identifying Faults” sub-section includes lists of symptoms (by print sample and by
description), and gives references to fault codes which identify the particular type of fault.

4800 Service Manual 7—1 Oct 97

 The “Problem Solving” sub-section provides problem solving instructions for each fault
code number, and defines check, adjustment and repair procedures for all the faults
identified in “Identifying Faults”. These procedures explain how to check whether the
fault is present and how to rectify it.
Use the following list of action points to approach fault diagnosis in a logical way:
• Ask the customer to describe the problem in detail, including any action taken.
Remember that the person who discovered the fault may have been on a
different shift.
• Do not jump to conclusions. Take the time to examine the printer carefully. Is
there sufficient ink and solvent? Are there any signs of ink leakage? Are there
any loose wiring connections (particularly between circuit boards)?
• Check the Print Status option for any error and fault messages that have been
logged.
• Make use of the Monitor Jet option to check and record the jet monitoring
parameters of Pressure, Time Of Flight, Modulation and Phase. Compare
these with the reference values and identify any out-of-specification
measurements.
• Make print samples (if possible) and examine the prints carefully for signs of
print quality problems.
• Only when all of the symptoms have been noted should an attempt be made to
identify the possible cause of the problem.

7.3 Identifying Faults

Some faults are best identified by the appearance of the print when a sample of the test
pattern is printed. Other faults may not permit a print to be made, or may produce other
symptoms such as error and fault messages. To accommodate these differences, this sub-
section is divided into two parts: “Identifying Faults by Print Sample” and “Identifying
Faults by Symptom”.

7.3.1 Identifying Faults by Print Sample

This part of the manual is intended to help distinguish between different types of print
fault, in order to identify the possible causes.
There are several ways in which print quality can be affected, and in some cases print
quality problems can be caused by more than one fault. For most faults, it is not difficult to
identify the cause of the problem, but some faults have similar symptoms, making accurate
diagnosis a little more difficult. For example, a low modulation problem can give similar
symptoms to high viscosity.
In cases where the cause of the print fault is not immediately obvious from the print
sample, secondary symptoms should always be sought that will help to distinguish
between the possible causes. In the example above, the current modulation would need to
be checked, and the pressure, the Time Of Flight, and the operation of the ink system
components investigated. These additional pieces of information will then enable you to
decide which of the possible causes is the reason for the print fault.
The following list classifies faults by the appearance of the print samples they produce.
The list shows print samples of the standard test pattern which can be compared with
samples taken from the printer under investigation. Below each sample, or set of samples,
is a brief description of the fault symptoms. Also provided are the possible causes of the
fault and a reference to a particular fault code number in the “Problem Solving – Print
Samples” part, where the problem and its method of rectification is described in more
detail.
NOTE: Throughout this manual, reference to the “top” of the print means the part of
the pattern closest to the negative deflector plate of the printhead (i.e. the least
deflected drop).

Oct 97 7—2 4800 Service Manual

 Print Sample Fault and Possible Cause Fault Code
___________________________________________________________________________________________________
6251

Regular pattern of missing drops.

Character Generation Faults ......................................................................................... FC8
___________________________________________________________________________________________________
6252

Guard drops printing (lateral line at bottom of print). Break up of pattern.

High Viscosity ................................................................................................................ FC1
Modulation Problems (low modulation) .................................................................... FC3
___________________________________________________________________________________________________

6253

Blurred print. Lateral line at top of pattern.

Low Viscosity ................................................................................................................. FC2
Modulation Problems (high modulation) ................................................................... FC3
___________________________________________________________________________________________________
6254

Squashed print. Blurred print.

Low Viscosity ................................................................................................................. FC2
Modulation Problems (high modulation) ................................................................... FC3
___________________________________________________________________________________________________

6255

Drops printed equally on all lines.

Charge Faults .................................................................................................................. FC7
___________________________________________________________________________________________________
6147

Section of the pattern missing or distorted.

Printhead Cover Catch (obstruction in cover slot) .................................................... FC6

4800 Service Manual 7—3 Oct 97

 ___________________________________________________________________________________________________

6148

Top (or bottom) of pattern missing.

Gutter Clipping .............................................................................................................. FC5
___________________________________________________________________________________________________

6256

Pattern break up; lateral line.

Modulation Problems (low modulation) .................................................................... FC3
___________________________________________________________________________________________________

6257

Irregular occurrences of erratic drop displacement.

Phasing Errors ................................................................................................................ FC4
___________________________________________________________________________________________________
6149

Uneven stretching of the pattern.

Shaft Encoder Faults (shaft encoder slipping) ........................................................... FC9
___________________________________________________________________________________________________
6150

Squashed print. Pattern not blurred.

Deflector Voltage Faults .............................................................................................. FC10
___________________________________________________________________________________________________
6151

Product tilting along the axis of the conveyor travel.

Vibration Problems ......................................................................................................FC36

Oct 97 7—4 4800 Service Manual

 ___________________________________________________________________________________________________

6152

Product tilting across the axis of the conveyor travel.

Vibration Problems ...................................................................................................... FC36
___________________________________________________________________________________________________
6153

High frequency vibration along the axis of the conveyor travel.

Vibration Problems ...................................................................................................... FC36
___________________________________________________________________________________________________
6154

High frequency vibration across the axis of the conveyor travel.

Vibration Problems ...................................................................................................... FC36
___________________________________________________________________________________________________

7.3.2 Identifying Faults by Symptom

When it is not possible to identify a fault by the visible effect on the print sample, it
becomes necessary to look for other symptoms. For example, it may not be possible to start
the jet satisfactorily, so it will be impossible to obtain any sort of print. However, in most
circumstances there will be some obvious indication as to the nature of the fault, the best
example being the error and fault messages displayed in the LCD screen status line.
Section 6 of this manual lists all the error and fault messages, and gives a detailed
explanation of the condition that the printer control logic has detected which has resulted
in the particular message being displayed.
If there is no error or fault message, or if the message on its own is not enough to identify
the problem, refer to the following list of symptoms to identify the possible cause of the
fault. The list is organised to group the symptoms into the five different stages of printer
operation:
1. Before switching on.
2. After switching on.
3. When the jet is started.
4. During printing.
5. After the jet is stopped.
Note that these groupings only indicate the earliest point at which the symptom could be
observed; the symptom could also be observed later in the cycle of printer operation. For
example, solvent contamination might be observed at any time, but it is included in the
first group because it is possible to check this symptom before switching on.
The text below each symptom describes the different types of fault that can give rise to the
symptom, with references to fault code numbers by which the faults are identified in the
“Problem Solving” sub-section, where the problem and its method of rectification is
described in more detail.

4800 Service Manual 7—5 Oct 97

 Symptom and Possible Causes Fault Code
___________________________________________________________________________________________________

1. BEFORE SWITCHING ON
Ink draining from nozzle during storage.
Leaking Feed Valve .....................................................................................................FC13
Solvent reservoir contaminated with ink.
Solvent Contamination ................................................................................................FC19
Excess ink in ink reservoir.
Solvent Contamination (overfilling) .........................................................................FC19
Ink deposits in the printhead or on the cover slot.
Jet Alignment Problems .............................................................................................. FC32
Ink leaking from gutter.
Gutter Problems ...........................................................................................................FC35

2. AFTER SWITCHING ON
Power failure.
Power Failures ..............................................................................................................FC38
Ink Low warning permanently displayed.
Ink Low Warning ......................................................................................................... FC23
Solvent Low warning permanently displayed.
Solvent Low Warning ..................................................................................................FC24
No ink flow after fitting new pump.
New Pump Requiring Priming .................................................................................. FC20
No Ink Low warning when either draining the tank, or on switch-on with
low ink.
Ink Low Warning ......................................................................................................... FC23
Low Pressure warning on start-up.
Pressure Loss (mechanical) .........................................................................................FC12
Pressure Loss (electrical) ............................................................................................. FC22
Partial or total pressure loss.
Pressure Loss (mechanical) .........................................................................................FC12
Pressure Loss (electrical) ............................................................................................. FC22
Discrepancy between Set and Read Pressures.
Pressure Loss (mechanical) .........................................................................................FC12
Pressure Loss (electrical) ............................................................................................. FC22
Ink leaking from jet nozzle.
Leaking Feed Valve .....................................................................................................FC13
Leaking around valve seals or plungers.
Solenoid Valve Faults .................................................................................... FC13 – FC18
Reduced pressure reading.
Leaking Purge Valve or Gutter Valve .......................................................................FC16
Leaking Solvent Top-Up Valve .................................................................................. FC18

Oct 97 7—6 4800 Service Manual

 3. WHEN THE JET IS STARTED
No jet at start-up.
Inactive Feed Valve ..................................................................................................... FC14
Inoperative Feed Valve ............................................................................................... FC25
Jet Alignment Problems (nozzle blockage) ..............................................................FC32
Messy printhead at start-up.
Inactive Purge Valve ................................................................................................... FC15
Jet Alignment Problems (nozzle out of alignment) ................................................. FC32
Charge failure – Phase fault.
Charge Problems (electrical) ......................................................................................FC29
Charge Problems (mechanical) .................................................................................. FC34
Jet Alignment Problems .............................................................................................. FC32
Modulation Problems (electrical) .............................................................................. FC28
Modulation Problems (mechanical) ..........................................................................FC33
Leaking Purge Valve or Gutter Valve ....................................................................... FC16
Charge failure – TOF fault.
Charge Problems (electrical) ......................................................................................FC29
Charge Problems (mechanical) .................................................................................. FC34
Jet Alignment Problems .............................................................................................. FC32
Modulation Problems (electrical) .............................................................................. FC28
Modulation Problems (mechanical) ..........................................................................FC33
Leaking Purge Valve or Gutter Valve ....................................................................... FC16
No TOF adjustment on start-up.
Pressure Loss (mechanical) ......................................................................................... FC12
Pressure Loss (electrical) ............................................................................................. FC22
No Modulation.
Modulation Problems (electrical) .............................................................................. FC28
Modulation Problems (mechanical) ..........................................................................FC33
Jet alignment problems.
Jet Alignment Problems .............................................................................................. FC32
Charge electrode strobe LED failure.
No Strobe LED ..............................................................................................................FC30
Blocked gutter.
Gutter Problems ........................................................................................................... FC35
Jet catching printhead cover slot.
Printhead Cover Catch .................................................................................................. FC6
Jet Alignment Problems .............................................................................................. FC32
Ink leaking from gutter or poor gutter action.
Gutter Problems ........................................................................................................... FC35
(faulty venturi) ............................................................................................................. FC35

4800 Service Manual 7—7 Oct 97

 Sticking valves.
Solenoid Valve Faults .................................................................................... FC13 – FC18

4. DURING PRINTING
Poor print quality .................................. Refer to “Identifying Faults by Print Sample”
See also Charge failure – Phase fault (When The Jet Is Started)
See also Charge failure – TOF fault (When The Jet Is Started)
Printable modulation range poor.
Modulation Problems (electrical) ..............................................................................FC28
Modulation Problems (mechanical) ..........................................................................FC33
(see also Print Sample fault FC3)
Jet velocity increases – reduced TOF reading.
Incorrect Viscosity Control (thin ink) ........................................................................FC27
Leaking Purge Valve or Gutter Valve .......................................................................FC16
Leaking Solvent Top-Up Valve .................................................................................. FC18
Jet velocity reduces – increased TOF reading.
Incorrect Viscosity Control (thick ink) ...................................................................... FC27
Modulation Problems (electrical) ..............................................................................FC28
Modulation Problems (mechanical) ..........................................................................FC33
(see also Print Sample fault FC3)
Gutter Problems ...........................................................................................................FC35
Solvent Pick-up Pipes Clogged with Dust ............................................................... FC21
No drop deflection.
No Drop Deflection .....................................................................................................FC31
Deflection faults.
Deflector Voltage Faults .............................................................................................. FC10
Incorrect Viscosity Control .........................................................................................FC27
Leaking Purge Valve or Gutter Valve .......................................................................FC16
Gutter Clipping .............................................................................................................. FC5
Jet Alignment Problems .............................................................................................. FC32
Machine shuts down (various error messages).
Leaking Purge Valve or Gutter Valve .......................................................................FC16

5. AFTER THE JET IS STOPPED

Ink emitting from the nozzle shortly after shutdown.
Leaking Feed Valve .....................................................................................................FC13
Poor purge of nozzle at shutdown.
Leaking Gutter Valve ..................................................................................................FC17
Gutter Problems ...........................................................................................................FC35

Oct 97 7—8 4800 Service Manual

7.4 Problem Solving
This sub-section describes the faults identified in the previous sub-section “Identifying
Faults”.
For each fault, identified by a fault code (FC) number, procedures are given for confirming
the presence of the fault, and also for carrying out the adjustments or repairs necessary to
rectify the fault.
The faults are divided into the following categories:
• Problem Solving – Print Samples (FC1 to FC11);
• Problem Solving – Ink System Mechanical Faults (FC12 to FC21);
• Problem Solving – Ink System Electrical Faults (FC22 to FC27);
• Problem Solving – Printhead Electrical Faults (FC28 to FC31);
• Problem Solving – Printhead Mechanical Faults (FC32 to FC36);
• Problem Solving – Electronics System Faults (FC37 to FC38).

7.4.1 Problem Solving – Print Samples (FC1 to FC11)

This part begins with a description of how viscosity and modulation can affect drop break-
up, as the interaction of these two variables can make it difficult to distinguish one fault
from another. The particular fault descriptions follow in fault code numerical sequence.

The Effects of Viscosity and Modulation on Drop Break-up

The stream of ink from the printhead nozzle must break up into drops at approximately
the centre point of the charge electrode slot for good print quality to be produced.
The diagram below illustrates correct drop break-up, and shows the effects of viscosity
and/or modulation on the jet break-up pattern.

48119

Jet nozzle
HIGH VISCOSITY INK LOW VISCOSITY INK

Increased Reduced
modulation pressure
improves improves
drop drop
Jet stream break-up break-up
affected by
piezoelectric Charge
crystal electrode

Drop breakup
beginning to occur

Actual point of jet breakup.

This must occur within the
central region of the charge
electrode to achieve optimum
drop charging
Charged
drops
Satellite drop

Figure 7-1. The Effects of viscosity and modulation on drop break-up

4800 Service Manual 7—9 Oct 97

 In extreme cases of high or low viscosity, the jet may be affected to the point of causing
TOF failures or EHT faults. However, if the viscosity has wandered outside its calibrated
range by only a moderate amount, it is possible to diagnose the problem by looking for the
following features on the print samples:
• dark lines running laterally through the print. These will tend to appear at the
top of the print if viscosity is low, or at the bottom of the print if viscosity is
high;
• misplaced drops in the print;
• dark lines printed above the top of the printed characters;
• loss of the bottom part of the print;
• blurring or fuzziness of the print.
As the viscosity increases or decreases, the Time Of Flight will rise or fall respectively. As
a result, the printer will adjust the operating pressure to compensate, resulting in the drop
break-up point occurring too early in the charge electrode slot (high viscosity), or too late
(low viscosity). It is this alteration in the drop break-up position that causes the visible
deterioration in print quality.

FC1 High Viscosity

Diagnosis
Refer to the following print samples to observe how the print quality deteriorates as the
viscosity increases.

Print Samples
___________________________________________________________________________________________________

6258

This sample shows the early stage of high viscosity, with individual drops being displaced
randomly in the larger characters.
___________________________________________________________________________________________________

6259

As the viscosity increases, lines appear over the larger characters due to printing of the
guard drops. It is also noticeable that a dark lateral line occurs at the bottom of the print,
and the displaced drops tend to follow this line.
In the later stages of high viscosity problems, printing of the guard drops becomes more
obvious, and the lower part of the pattern will either disappear (if printing small
characters) or become compressed (if printing large characters).
If the viscosity continues to increase, the printer will almost certainly shut down and report
a phase fault, as the break-up point will not allow correct charging of the drops.

Oct 97 7 — 10 4800 Service Manual

 Checks to Make
To confirm that the problem is related to viscosity, check the Pressure and the Time Of
Flight and compare these readings with the values on the printhead conduit label. If the
pressure and/or the TOF are above their reference values, the viscosity is high; if the
pressure and/or the TOF are below their reference values, the viscosity is low.

Cause and Cure

Initially, viscosity problems can be corrected by adjusting the modulation setting to
compensate for the shift in drop break-up position. However, this is only a short term
solution; in the long term, the ink viscosity must be corrected. Refer to FC27 in “Problem
Solving – Ink System Electrical Faults.

FC2 Low Viscosity

Diagnosis
The visible signs of low viscosity tend to appear more suddenly than those of high
viscosity. The first indication is a displacement of drops with a fuzziness or blurring of the
print. This will be associated with a dark lateral line at the top of the pattern.

Print Samples
The following samples are typical of increasingly low viscosity:
___________________________________________________________________________________________________

6260

6261

6262

6253

The first print sample shows a dark line at the top of the print. The second and third
samples show the increasing displacement of drops, and the fourth sample shows the
printer being unable to maintain the correct phasing position, as the print starts to break up
completely.

Checks to Make
Refer to FC1 above.

Cause and Cure

Refer to FC1 above.

4800 Service Manual 7 — 11 Oct 97

 FC3 Modulation Problems

Diagnosis
Print quality problems can be caused by the modulation voltage being too high or too low.
As mentioned at the beginning of this part, modulation and viscosity problems can have
similar effects on print quality. It is therefore essential to check the viscosity before
assuming that the fault is due to modulation problems.

Checks to Make
First make sure that the ink viscosity is correct by checking the pressure and the TOF, as
described for FC2. If the viscosity is correct, modulation problems can then be
investigated.
Use the Calibrate Print Head option in the Setup menu to force the printer to choose the
optimum modulation value. Check the current modulation value against the reference
value specified on the printhead conduit label.
Take a set of print samples with the modulation set at a range of values to “bracket” the
intended operating value for the printhead type. This should establish the optimum
setting; for example, if good quality is achieved between 80 and 220, the ideal setting is 150.
If good print quality can only be achieved at the highest or the lowest end of the
modulation range, the ink viscosity may be seriously out of specification. If not, the
modulation output from the IPM PCB may be at fault. Check this using an oscilloscope, as
described in “Problem Solving – Electronics System Faults”.

Print Samples
The following first two print samples show problems with low and high modulation, with
a further eight samples showing a range of prints from a printer with a deteriorated piezo
crystal, or a faulty nozzle jewel, either of which would prevent the modulation voltage
from producing the correct drop break-up:
___________________________________________________________________________________________________

6263

This shows a print sample where the modulation is too low. Note how the symptoms are
similar to those of a high viscosity problem.
___________________________________________________________________________________________________
6264

This shows a print sample where the modulation is too high. Note how the symptoms are
similar to those of a low viscosity problem.

Oct 97 7 — 12 4800 Service Manual

 ___________________________________________________________________________________________________
6265

6266

6267

6268

6269

6256

6270

6271

These samples show a range of modulation values using a Micro printhead which is unable
to produce good print quality at any reasonable modulation value. This could be caused
by a faulty piezo crystal, a faulty nozzle jewel, or a fault on the IPM PCB, any of which
could cause irregular drop formation.

Cause and Cure

In the example above, the printhead was faulty. However, checks should be made to
eliminate viscosity or electronics problems before rejecting the printhead. This can be
simply done by substituting the suspected printhead with another. If the symptoms
persist, the fault is not due to the printhead, and the ink viscosity or the electronics must be
investigated. Refer to FC27 for viscosity control problems; refer to FC28 and FC33 for
modulation problems; and refer to FC38 for IPM PCB problems.

4800 Service Manual 7 — 13 Oct 97

 FC4 Phasing Errors

Diagnosis
Phasing errors occur when the printer cannot find or maintain its phase position. This can
happen as a result of a printhead fault, or a failure on the IPM PCB.

Checks to Make
Use the Diagnostics options to check the phase reading; if it fluctuates erratically, the fault
is possibly on the IPM PCB.
Phase errors can also be caused if an operator has corrupted the Auto Phase or Phase
Offset options. Check these using Diagnostics before assuming a PCB failure.
Check the jet alignment to ensure that the drops are not clipping the phase sensor, but also
that they are not too far away to produce a satisfactory signal. If the absence of the phase
signal is suspected, check the continuity of the phase sensor wiring (refer to FC29).

Print Samples
The following samples show various phasing problems, with their respective causes and
cures:
___________________________________________________________________________________________________

6272

At irregular points in this sample, the drops are displaced erratically as the phase shifts
and the drops become over or under charged as a result.
NOTE: In the bad sections of the print, it is important to note that ALL the drops of ink
are present, but misplaced (by the erroneous charge they have been given).
This distinguishes phase error print samples from other faults, such as a
printhead cover slot obstruction, where some of the drops are misplaced and
some fail to be printed at all.

Cause and Cure

This particular fault was caused by a failure on the IPM PCB (but note that a leaking
printhead can cause the same symptoms). However, be sure to check the Diagnostics
options, the jet alignment and the phase sensor wiring before assuming a PCB failure.
___________________________________________________________________________________________________

6273

6274

Oct 97 7 — 14 4800 Service Manual

 6275

6276

6277

6278

These print samples show the gradual deterioration of the print as the phase position is
artificially set further and further from the optimum position (by increasing the offset).
The normal phase offset is 0 (top sample), and the remaining five samples show the
successive degradation of print quality as the offset is increased. Note, again, that ALL the
drops are printed, but in the wrong position.

Cause and Cure

Check that the phase offset is correct; the normal setting for the 4800 printers is 0.
However, certain future ink releases may require a phase offset setting other than 0.

4800 Service Manual 7 — 15 Oct 97

 FC5 Gutter Clipping

Diagnosis
This fault is also known as “gutter catch” and is similar to the associated problem of
Printhead Cover Catch. The problem occurs when the least deflected drops clip the gutter
and are thus not printed.
If the jet is misaligned on the gutter, the least deflected drops may catch the edge of the
gutter. This will cause the loss of the drops from the top of the print pattern. As printing
continues, the ink will build up on the gutter edge and the print loss will increase,
sometimes leading to deflector plate shorting and EHT failures.
The following diagram illustrates the situation:

Misalignment
(anticlockwise) 6155
MIDI

This drop obstructed by gutter

Figure 7-2. Gutter clipping

Print Sample
___________________________________________________________________________________________________

6148

This print sample shows gutter clipping, resulting in loss of the top part of the print.

Cause and Cure

Check the EHT settings (refer to “Problem Solving – Electronics System Faults”). Check
the jet alignment.

Oct 97 7 — 16 4800 Service Manual

 FC6 Printhead Cover Catch

Diagnosis
This problem is caused by the most deflected drops catching the edge of the exit slot in the
printhead cover, and thus failing to be printed.
The following diagram illustrates the situation:

Misalignment
(clockwise) 6156

MIDI

This drop obstructed by cover

Cover
clipping
zone

Figure 7-3. Printhead cover catch

NOTE: It is sometimes possible for the least deflected drops to clip the cover slot, in
which case the effect is similar to the Gutter Clipping fault FC5.

Print Sample
___________________________________________________________________________________________________

6157

Most commonly, the drops are lost at the bottom of the print, as in the above print sample.
Whether the top or the bottom of the print is missing, a typical result of printhead cover
catch is a fine diffuse spray of drops.

Cause and Cure

Check the EHT settings and connections. Check the printhead cover slot for an
obstruction, which may be a build up of ink. If the printhead cover is badly out of place on
the printhead, the drops to be printed may miss the cover slot altogether. Ensure that the
conduit is not pulling the printhead out of line with the cover slot.

4800 Service Manual 7 — 17 Oct 97

 Print Samples
___________________________________________________________________________________________________

6158

6279

6280

6281

6282

The above print samples show what can happen if the printhead cover slot is obstructed by
dried ink, dust or some other contaminant, such as a hair.

Cause and Cure

Clean the clearance slot using the appropriate solvent for the type of ink being used in the
printer. Make sure that the printhead cover is correctly positioned and securely fitted on
the printhead.
NOTE: Some of the Printhead Cover Catch print samples show similarities with
Phasing Errors problems. The fundamental difference to note is that phasing
errors still print ALL the drops, although not in the correct positions, while
printhead cover catch (or clipping) problems show a considerable loss in the
number of drops printed.

Oct 97 7 — 18 4800 Service Manual

 FC7 Charge Faults

Diagnosis
Charge faults can give rise to a number of different print quality problems, and can also
have a number of different causes. For more details on fault diagnosis, refer to “Problem
Solving – Printhead Electrical Faults”; “Problem Solving – Printhead Mechanical Faults”;
and “Problem Solving – Electronics System Faults”.

Print Samples
The following print samples show various types of print problems caused by charge faults:
___________________________________________________________________________________________________
6283

This print sample shows a relatively small number of drops being incorrectly charged.
___________________________________________________________________________________________________

6284

This print sample shows the effect when the printer is unable to correctly charge a
significant number of the drops.
___________________________________________________________________________________________________

6285

This print sample shows very few of the drops being charged at all.
___________________________________________________________________________________________________

6286

In this print sample, the drops are being charged in such a way that they are being printed
equally on all lines.

Cause and Cure

Incorrect charging can be caused by poor jet stability, or jet velocity problems, as well as by
electrical or mechanical problems with the charging components in the printhead, or
electronic problems on the IPM PCB.
Check all the jet monitoring Diagnostic readings to ensure that the viscosity control and
TOF control functions are operating correctly before attempting to investigate the charging
components. Refer to FC29, FC34 and FC37 for further information on possible causes.

4800 Service Manual 7 — 19 Oct 97

 FC8 Character Generation Faults

Diagnosis
Faults in character generation are almost entirely due to failures on the IPM PCB, but these
are not very common.

Print Samples
The following print samples show effects that can occur if the character generation
functions on the IPM PCB are not operating correctly:
___________________________________________________________________________________________________

6287

Although the drops are being printed, they show a regular pattern of displacement.
___________________________________________________________________________________________________

6288

The pattern area is being printed with some parts legible and some parts diffuse.

Cause and Cure

In both cases the cause is a fault on the IPM PCB, which must be replaced. However,
replacing the drop generation ICs 108 and 111, or the Charge Prom IC94 should be
considered before replacing the IPM PCB.

FC9 Shaft Encoder Faults

Diagnosis
The most common cause of problems with shaft encoders is slipping due to inadequate
coupling between the encoder and the production line conveyor system. Gear ratios
between the shaft encoder and the production line must also be carefully calculated for
correct printing. Refer to the Shaft Encoder option in Section 4: “The Setup Menu” for
details on calculating the Print Width.

Print Sample
___________________________________________________________________________________________________
6159

Cause and Cure

The print sample above shows the result of the shaft encoder slipping on the drive from the
production line conveyor system. The cure is to improve the coupling between the encoder
and the conveyor. Also, recheck the gear factor calculations, if necessary.

Oct 97 7 — 20 4800 Service Manual

 FC10 Deflector Voltage Faults

Diagnosis
If the EHT PSU fails, or a wiring fault causes power to be received by only one of the two
deflector plates, the print will appear compressed, as the diminished electric field will not
provide the correct deflection for the charged drops. If the pattern contains more than one
line of print, the lines may overlap.
NOTE: If ink splashes, or other faults, cause shorting of either of the deflector plates’
voltages the printer reports the Print Failure fault message “2.01 Deflector
Voltage”.

Print Sample
___________________________________________________________________________________________________

6288

In the print sample above, the print is compressed and the lines are overlapping. In this
case, the fault was in the wiring to one of the deflector plates.

Cause and Cure

The fault can be caused by printhead wiring problems, or by a failure in the EHT PSU or
the IPM PCB. Disconnect the printhead and check for continuity of the EHT leads before
investigating the signals from the EHT PSU to the IPM PCB.
If the deflector plates have been shorting, the most likely cause is a build-up of ink
deposits, which can be easily cured by cleaning the printhead with the appropriate solvent.
If the problem persists, check the jet alignment as the plates should not normally become
contaminated with ink.

FC11 Other Faults

With experience in the field, most print quality faults can be quickly identified. It is
important to exhaust the simple possibilities before assuming that the problem is
complicated. However, there will always be the possibility of an unprecedented problem,
as the following example shows:

Print Sample
___________________________________________________________________________________________________
6290

This unusual fault shows a “bowing” in the print, where the centre appears to be pulled
from the left.

Cause and Cure

This problem was caused by the negative deflector plate being too close to the jet. As a
result, a small build-up of ink occurred on the negative plate, thereby causing a distorted
displacement charge on drops at the centre of the pattern.
In the short term, cleaning the deflector plates with solvent cured the immediate problem.
However, in the long term it would be necessary to check that the deflector plate was
securely fitted in its correct position.

4800 Service Manual 7 — 21 Oct 97

 7.4.2 Problem Solving – Ink System Mechanical Faults
(FC12 to FC21)

FC12 Pressure Loss

There are several ways in which a pressure loss can manifest itself:
• a Low Pressure warning on start-up (error 3.12);
• a No TOF Adjustments warning (error 3.00);
• a significant discrepancy between Set Pressure and Read Pressure when the
pressure is set to 255 by the engineer in Diagnostics;
• an obvious leak of ink from around the pump, the tubing or the manifold.
The following identifies how each of the ink system components can contribute to a loss of
pressure in the system:

Ink Tank Reservoir

• debris in the ink tank can cause either a partial or a total pressure loss. The
debris can be pieces of foil seals from ink bottles, or other extraneous material
that has fallen into the reservoir.

Pre-Pump Filter
• debris from the ink tank reservoir that has been drawn into the body of the
filter can cause a total, or more usually a partial, pressure loss;
• overtightening of the connectors onto the threaded stud of the filter body can
cause a partial pressure loss by constricting the olive and reducing the size of
the flow aperture;
• the actual filter membrane may have become blocked; it has done its job and
protected the pump.

Pump Assembly
The pump assembly is an electromagnetically-coupled gear pump.
• the pump motor has failed, resulting in loss of drive and hence total pressure
loss;
• the motor has decoupled from the pump, so that the motor is spinning wildly
but not turning the gears in the pump head, again resulting in a total pressure
loss;
• the gears in the pump are worn, resulting in less than totally efficient drive
and a partial pressure loss;
• a leak has developed on the output side of the pump.
NOTE: If the pump motor is turning but the pump itself is not, there will
be a normal reading for Set Pressure, but a zero reading for Read
Pressure.

Oct 97 7 — 22 4800 Service Manual

 Main Ink Filter
• the filter has fulfilled its task and has eventually collected an excess of debris
and become blocked;
• the PTFE tubing has been incorrectly fitted to the filter. If the tubing is pushed
too far into the elbow assembly, a pressure loss can result due to reduced flow;
• the stainless steel inserts, when pushed into the PTFE tubing, have pared off a
little of the inner wall of the tubing causing a blockage which reduces flow,
and hence pressure;
• a leak has developed at an assembled or welded joint.

Manifold Assembly
• the pressure transducer is faulty. Check the transducer and its associated
wiring before suspecting a fault in the pressure circuit hybrid of the IPM PCB;
• the vacuum venturi has either become blocked, or the stainless steel insert has
been lost through incorrect assembly;
• a leak has developed at an assembly joint or crack. The manifold has simply
become worn-out after years of ink flow.

Solenoid Valve Faults (FC13 to FC18)

There are several different types of problems that can be experienced with solenoid valves
and their operation, as follows:
• leaking around the seals which indicates an ‘O’ ring sealing problem;
• sticking valves causing them not to open or close properly, possibly due to ink
drying within the valve, or a weak or broken return spring;
• leaking around the internal valve plunger seal.
NOTE: Leaking round the seals is not a very common problem. More
likely problems involve valves sticking due to debris or dried ink.
The plunger seal can leak due to dried ink, but this can usually be
cured by thoroughly cleaning the valve with the appropriate
solvent.
The following individual faults describe the particular problems that occur when specific
valves develop leaks or fail to operate correctly.

FC13 Leaking Feed Valve

If the internal seal of the feed valve is leaking, it will be apparent when the pump is
running and the valve is closed, and ink will be seen leaking from the printhead nozzle.
The fault can be checked by using the Set Pressure option in Diagnostics to set the pressure
to 255, and then observing the nozzle for leakage. If leakage is observed, replace the feed
valve.
NOTE: If the printhead is stored or mounted lower than the printer, a leaking feed
valve could cause all the ink to drain from the reservoir.

FC14 Inactive Feed Valve

If the feed valve does not activate during start-up, there will be no jet. This can be tested as
follows: connect an open tube to the feed line to the printhead, start the jet and observe for
ink flow from the tube. If the valve is working ink will be emitted under pressure, so care
should be taken to direct the tube into an empty container for collection.

4800 Service Manual 7 — 23 Oct 97

 FC15 Inactive Purge Valve
If the purge valve does not activate during start-up, air will not be purged from the nozzle
chamber and the feed and purge lines during the start-up purge procedure. This will
result in lower pressure at start-up, as the air is compressed, and quite possibly a messy
start to the jet.
It should be possible to feel or hear the valve operating during the start-up purge
procedure.

FC16 Leaking Purge Valve or Gutter Valve

If either the purge valve or the gutter valve is leaking, pressure will be reduced in the
nozzle chamber, affecting the velocity of the jet. The printer automatically tries to
compensate for a leaking valve, in response to a change in the Time Of Flight. The printer
first increases pressure to maintain the correct TOF. However, this increased pressure is
interpreted by the printer as a high viscosity ink condition, and it will add solvent in an
attempt to restore the pressure to its correct operating value.
This, in fact, will make the situation worse, as the thinner ink will now leak more quickly
from the faulty valve. After eight solvent top-ups, the printer will shut down. This is an
automatic safety process to ensure that the ink is not over-diluted. If the situation were to
continue for a period of time, one of the following fault messages is likely to be reported:
“2.01 Deflector Voltage”
“2.03 Time Of Flight”
To check for a leak in either the purge valve or the gutter valve, use the following
procedure:
1. Enter Diagnostics and stop printing.
2. Take several Time Of Flight readings, note the average, and note the pressure
at which the readings were taken.
3. Shut down the printer and disconnect the purge line Swagelok union fitting in
the ink system enclosure.
4. Restart the printer, set the pressure to the pressure noted in Item 2 above, and
take TOF readings to obtain a new average.
If either of the two valves is leaking, the jet velocity will increase (so the TOF will decrease)
and the pressure reading will be significantly lower than the previous reading.
To rectify the fault carry out the following:
1. Replace the purge valve and repeat the entire check, as described above. It is
essential to check again, because this is the only way to determine which valve
is leaking. If the problem persists, replace the gutter valve and repeat the
check again.
2. When the faulty valve has been identified and replaced, drain some of the ink
from the reservoir and replace with fresh ink to improve the viscosity.

FC17 Leaking Gutter Valve

A leaking gutter valve results in poor purge of the nozzle during the shutdown routine, as
the vacuum is lost to the gutter. To test for this situation, enter Diagnostics and perform a
Clear Nozzle sequence. Monitor the activation of the gutter valve as it transfers the
vacuum from the gutter to the nozzle and, at this time, apply a little solvent to the gutter.
The solvent should not be drawn into the gutter at all, except at the start and end of the
nozzle clear cycle. If there is any evidence of the solvent being drawn in, the gutter valve is
leaking. To correct the problem, replace the gutter valve and repeat the test.

Oct 97 7 — 24 4800 Service Manual

 FC18 Leaking Solvent Top-Up Valve
Use the following procedure to check for a leaking solvent top-up valve:
1. Introduce a small amount of ink into the solvent tank to colour the solvent;
only use ink of the same type being used in the printer. Use sufficient ink to
give the solvent enough colour to be seen.
2. Set pressure to 255 for 5 minutes and observe the tubing between the solvent
tank and solvent top-up valve for signs of coloured solvent moving along the
tube. If the solvent is coloured when starting this operation, drain the solvent
tank, refill with fresh clean solvent, and look for clean solvent moving along
the tubing.
To rectify the fault, replace the Solvent Top-Up Valve and repeat the check.

Miscellaneous Ink System Problems (FC19 to FC21)

FC19 Solvent Contamination

Contamination of the solvent reservoir with ink can be caused by an excess level of ink in
the ink reservoir which, under pressure, is forced through the condenser and thus into the
solvent reservoir. The excess level of ink may be the result of overfilling, or the result of a
faulty solvent top-up valve, or any other problem which causes a lot of solvent to be added
to the ink when high pressure is detected. To rectify the problem, the source of the
contamination will have to be identified and corrected, and the contaminated solvent will
have to be replaced with fresh solvent.

FC20 New Pump Requiring Priming

A new ink system pump may need to be primed. If there is no ink flow when a new pump
has been installed, follow this procedure:
1. Connect the inlet side of the new pump, then attach a short length of PTFE
tubing (with the appropriate fitting—do not overtighten) to the outlet side.
2. Fit a plastic syringe to the tubing and draw the syringe plunger back.
Assuming that there are no blockages and there is sufficient ink in the
reservoir, the syringe will fill with ink drawn through the pump.
3. The pump is now primed and ready to be correctly connected and tested.

FC21 Solvent Pick-up Pipes Clogged with Dust

Solvent addition can be forced when the printer is in the warm-up period, by switching off
the TOF Warm Up option in Diagnostics, and switching the TOF Correction option off then
on again. This will only be effective if the TOF value is within tolerance and the pressure is
at, or above, the solvent add value.
Carry out the procedure detailed in FC18 above before forcing a solvent addition. Be sure
to watch the tubing between the solvent tank and the solvent top-up valve. Correct top up
is taking place if a quick transition from clear to coloured solvent can be seen in the tubing.
If pressure is below the Solvent Add value, then re-enter the printhead code with an
artificially low Pressure Reference value; for example, 8 points below the correct Pressure
Reference shown on the printhead conduit label. This will create an artificial condition of
very high ink viscosity, causing the printer to respond by adding solvent.
IMPORTANT
1. Be sure to re-enter the correct printhead code after completion of the tests.
2. Do not force solvent addition too many times in this way as it will result in low
viscosity ink.
3. Remember to reset the TOF Warm Up option to On if it was altered.

4800 Service Manual 7 — 25 Oct 97

 7.4.3 Problem Solving – Ink System Electrical Faults
(FC22 to FC27)

Most ink system problems are mechanical in nature, however, this section describes the
additional electrical or electronic problems that may be encountered when fault diagnosing
the ink system.

FC22 Pressure Loss

A common pressure loss check is to use Diagnostics to set the pressure to 255 and check
that the attained Read Pressure is also 255 (with the permitted maximum 14 points
difference). However, not all apparent pressure losses are mechanical; it may be an
electrical fault.
The electronics system converts the signal transmitted back from the pressure transducer
into a digital signal (Read Pressure). This is carried out by the MAX165 ADC (IC2) on the
IPM PCB. If this is suspected as the cause of the fault, the IC may be replaced before
resorting to replacing the IPM PCB.

FC23 Ink Low Warning

If a “3.03 Ink Low” warning is not reported when draining the tank or switching on, check
the following:
1. Disconnect the electrical connection to the Ink Low sensor and check that the
warning is now displayed. Replace the sensor if the warning appears when
the connection is broken, but not when the connection is made.
2. If no Ink Low warning occurs even when the electrical connection is broken,
replace the IPM PCB and retest for the Ink Low warning.
If an Ink Low warning is permanently displayed, even when the ink level is satisfactory,
check the continuity of the connection from the Ink Low sensor to the IPM PCB, and also
check the electrical supplies to the sensor.

FC24 Solvent Low Warning

The Solvent Low sensor is the same type of device (a float switch) as the Ink Low sensor. If
a “3.04 Solvent Low” warning is either not reported when solvent is low, or is reported
when solvent is present, use the same procedure as described for the Ink Low sensor in
FC23 above.

Oct 97 7 — 26 4800 Service Manual

 FC25 Inoperative Feed Valve
If the nozzle is clear and there is ink in the system, but no jet is established when
attempting to start the jet, check the following:
1. Remove the feed valve solenoid cap and expose the diode and wiring.
2. Check that the diode is correctly orientated, i.e. the bar end (cathode) to the
orange wire, and the non-bar end (anode) to the brown wire.
3. Connect the DVM, set to DC Volts, across the diode. Plug the disassembled
solenoid cap onto the feed valve solenoid. Start the jet and check that the
DVM reads +24 volts d.c., switching to approximately +8.5 volts d.c.
4. If the voltage is correct but there is still no jet, check the mechanical operation
of the feed valve (see FC14).
5. If no voltage is present, check the following:
6. Connect the DVM negative lead to a 0 V test point and the positive lead to pin
1 of IC97A. Check that the DVM reads approximately 5 volts d.c.
7. If the voltage is present and correct continue to check from Item 8 below. If the
reading is 0 volts, the printer has experienced an EHT sense trip. In this case,
switch off the printer and wait 1 minute before reattempting to establish the
jet.
8. Check that IC95 pin 16 on the IPM PCB drops to 0 volts on executing start jet.
9. If the voltage does drop to 0 volts, check that +24 volts is present (with respect
to 0 volts) on pin 1 of the 25-way ink system D-type connector, then proceed to
Item 11 below.
10. If the voltage does not drop to 0 volts, and assuming that Items 3 and 6 are
correct, then replace the IPM PCB.
11. If Item 9 revealed that the +24 volts is not present, replace the IPM PCB.

FC26 Incorrect Valve Operation

Refer to the “Ink System” sub-section in Section 3: “Technical Description” for a
description of the correct sequences of operation of the ink system valves.
NOTE: It is highly improbable that the valves sequences will be incorrect. It is much
more likely that an individual valve is sticking or inoperative. Refer to faults
FC13 to FC18.

4800 Service Manual 7 — 27 Oct 97

 FC27 Incorrect Viscosity Control
If the ink is persistently becoming too thick or too thin, check the following:

Thick Ink
Check that the solvent top-up and solvent flush valve caps are connected to the correct
solenoid valve assemblies.
Check that the solvent add routine works, using the following method:
1. Enter a temporary printhead code that is guaranteed to make the ink appear
thick to the printer, by entering an artificially low pressure reference.
2. Enter Diagnostics and switch off the TOF Correction option.
3. Quick Start the jet.
4. Set the pressure so that the measured TOF is roughly equal to the TOF
reference.
5. In Diagnostics, switch the Phase Fault option on and switch the TOF Warm Up
option off.
6. In Diagnostics, switch the TOF Correction option on again.
7. Observe the solvent top-up valve for operation and, when it operates, check
that solvent is drawn into the system (see FC21)
If the valve does not operate or solvent is not drawn up, check the mechanical operation of
the valve. If solvent is drawn up satisfactorily, stop the jet and re-enter the correct
printhead code.
IMPORTANT: Remember to reset the TOF Warm Up option to On if it was altered.

Thin Ink
Provided that there is no mechanical fault with the solvent top-up valve (see FC18), check
that the valve is not being switched on unexpectedly. For example, on start-up, the top-up
valve may be switching on with the purge valve. For a description of correct valve
sequencing, refer to the “Ink System” sub-section in Section 3: “Technical Description”.
A genuine pressure loss could be causing solvent to be added unnecessarily. Refer to FC12
Pressure Loss for further details.
NOTE: A fault with the pressure transducer signal would not cause excess solvent to
be added. The printer will not add solvent if it cannot be certain of the
pressure readings.

Oct 97 7 — 28 4800 Service Manual

 7.4.4 Problem Solving – Printhead Electrical Faults
(FC28 to FC31)
FC28 Modulation Problems
First make sure there are no mechanical or viscosity related problems, then check the
following:

No Modulation
1. Ensure that the Modulation mini coax connector (PL2) is securely connected to
the IPM PCB.
2. Use the DVM, set to OHMS or Diode Test, to check that there is not a short
circuit between the outer braid and the inner conductor.

WARNING: LETHAL VOLTAGE. UNDER NORMAL CONDITIONS THERE WILL

BE 300 VOLTS D.C. PRESENT ON LINK LK8 AND TP17. THE CORRECT
ELECTRICAL SAFETY PRECAUTIONS MUST BE USED.
3. Check that link LK8 is fitted on the IPM PCB. Check for the 300 volts d.c.
modulation amplifier supply at TP17.
4. Use the Diagnostics options to check that the modulation is set to the correct
value. Monitor the jet and use the Calibrate Print Head option to force the
printer to choose the optimum modulation setting. Compare this with the
modulation reference value.
5. Use an oscilloscope to check the modulation output signal at TP1 on the IPM
PCB.

Poor Modulation Output Range

1. Vary the modulation voltage over a wide range and watch the effect on drop
break-up. The position of the break-off point should vary in relation to the
modulation voltage. If it does not, there may be a fault with the modulation
output from the IPM PCB. Examine the modulation output signal at TP1.
2. If it is suspected that the IPM PCB is faulty, replace the PCB and retest as
detailed in Item 1 above. If no improvement is made, refit the original PCB
and investigate mechanical or ink-related possibilities.
3. Use an alternative printhead to isolate the fault to either an ink system
problem or a printhead problem. If the fault persists with the replacement
printhead, the problem lies in the ink or the ink system components. If not, the
problem relates to the original printhead.
NOTE: An oscilloscope is ideal for examining the modulation signal at TP1 on the IPM
PCB for waveform irregularities and restricted output.

4800 Service Manual 7 — 29 Oct 97

 FC29 Charge Problems
Charge problems, resulting in either TOF errors or Phase errors, are the most commonly
reported failures. When you have eliminated the possibility of failure due to mechanical or
ink viscosity related problems, check the following:
1. If the print shows poor quality with the most deflected drops being
compressed together or even missing, perform a full calibration of the charge
amplifier, as detailed in the “Maintenance Instructions” sub-section of Section
5: “Maintenance”. If the calibration cannot be successfully performed, replace
the IPM PCB.
2. Ensure that the Charge mini coax connector (PL1) is securely connected to the
IPM PCB.
3. Use the DVM, set to OHMS or Diode Test, to check that there is not a short
circuit between the outer braid and the inner conductor on PL1.
4. Ensure that the Phase mini coax connector (PL3) is securely connected to the
IPM PCB.
5. Use the DVM, set to OHMS or Diode Test, to check that there is not a short
circuit between the outer braid and the inner conductor on PL3.

Continuity of the Printhead Phase and TOF Sensor Wiring

The following procedure explains how to test the continuity of the printhead phase and
TOF sensors’ wiring, using the DVM set to the OHMS or Diode Test range:
1. Disconnect the Phase mini coax connector (PL3) from the IPM PCB.
2. Test for a short circuit between the phase plug inner and both the TOF sensor
inner and the phase sensor inner.
3. Test for an open circuit between the phase plug inner and both the TOF sensor
outer and the phase sensor outer.
4. Test for a short circuit between the TOF sensor inner and the phase sensor
inner.
5. Test for an open circuit between the TOF sensor inner and the phase sensor
outer.
NOTE: It is important to measure directly between the sensors, as the internal wiring
is such that the phase plug may be connected to the phase sensor, but both
may be disconnected from the TOF sensor.

Continuity of the Printhead Charge Electrode Wiring

The charge electrode continuity is easily tested using the DVM set to the OHMS or Diode
Test range, as follows:
1. Disconnect the Charge mini coax connector (PL1) from the IPM PCB.
2. Test for a short circuit between the charge plug inner and the charge electrode.
3. Test for an open circuit between the charge plug outer and the charge
electrode.

Oct 97 7 — 30 4800 Service Manual

 Miscellaneous Problems (FC30 to FC31)

FC30 No Strobe LED

If the charge electrode strobe LED fails to light when the printhead cover is removed, check
the following:
1. Examine the charge electrode slot for any potting compound residue.
2. Ensure that the Cover Override link LK6 is not fitted.
3. Test fuse F1 on the IPM PCB.
4. Check the wiring to the printhead 15-way D-type connector.
5. Confirm that the Hall effect switch has not failed in an unsafe state, i.e. such
that it fails to detect the removal of the printhead cover.

FC31 No Drop Deflection

If there is no deflection of the drops when printing, check the following:
1. Ensure that the EHT leads to the printhead are not disconnected at either the
printer or the printhead end. Test for continuity between the inner pin on each
EHT connector and its respective deflector plate. Because of the in-line resistor
in each EHT lead, the DVM reading should be 10 MΩ ±5%.
2. Ensure that the printhead cover is correctly fitted and the Hall effect switch
Cover Override link LK6 is not been fitted on the IPM PCB.
3. If the printhead cover is fitted but there is still no deflection, investigate the
following:
a) ensure that the cover has a magnet which is perpendicular to the face
of the cover;
b) ensure that the Hall effect switch is present and is also perpendicular
to the face of the cover;
c) check that the magnet has not lost its magnetism;
d) examine the Hall effect switch for physical damage.
4. Check the Print Height setting in the Setup menu to make sure the print height
has not been set very low.
5. If the deflector plate field is being produced and there is still no deflection, it is
possible that the drops are not being charged. Investigate the faults associated
with charge problems: FC29 and FC34. Also check the calibration of the
charge amplifier, as detailed in the “Maintenance Instructions” sub-section of
Section 5: “Maintenance”.

4800 Service Manual 7 — 31 Oct 97

 7.4.5 Problem Solving – Printhead Mechanical Faults
(FC32 to FC36)

FC32 Jet Alignment Problems

There are several ways in which a jet alignment problem can occur:
• the jet has been shut down incorrectly;
• ink has been leaking from the nozzle during a period of non-use (refer to FC13
Leaking Feed Valve in “Ink System Mechanical Faults”);
• the ink is contaminated causing quantities of salt deposits to build up around
the nozzle;
• a nozzle blockage has been only partially cleared;
• the nozzle cap has become loose;
• the jewel in which the nozzle orifice is machined has become cracked or
deformed causing jet instability;
• the nozzle assembly has been knocked out of alignment.
Before attempting to rectify a jet alignment problem, it is advisable to investigate which of
these possible causes is most likely to have occurred, and to take the appropriate steps to
ensure it does not reoccur.

Nozzle Realignment
Before realignment is considered, refer to “Clearing a Nozzle Blockage” below. Clearing
the nozzle should remove any deposits of ink or debris which could be causing an
obstruction in the nozzle orifice, resulting in jet misalignment.
If clearing the nozzle does not solve the problem and it is considered necessary to realign
the jet, only the fingers should be used, with very little force applied. The nozzle will move
a little, and will very probably spring back to its original position. Apply a little greater
force, such that the nozzle will be deflected but will return only part way to its original
position.
The correct alignment of the nozzle is such that the jet passes exactly through the centre of
the charge electrode slot (this is essential for correct charging), exactly over the centre of
the phase and TOF sensors, and into the gutter. The point of entry into the gutter should
be offset from the centre of the gutter, so that approximately 30% of the gutter is to the left
of the jet (when viewing the printhead from the front) and 70% is to the right of the jet. In
the case of Macro printheads with a tube gutter, this offset should be 40% and 60%
respectively.

Oct 97 7 — 32 4800 Service Manual

 These alignment criteria are shown in the following illustration:

6293
End view showing offsets
Drop offset Drop offset
towards tubular towards solid
gutter edge 60% 40% gutter edge 70% 30%

50% 50%
Use only the thumb
and fingers to align 50% 50%

Plan view nozzle with the gutter

Jet

Jet
MIDI

From

From
MACRO MICRO & MIDI
Jet housing removed offsets offsets
for access to nozzle
Entry to gutter Gap between
(from side elevation) drop and PCB
Drop stream to be dead centre surface to be 5 mm
Centre line of
must be directed gutter opening Gap between
off-centre drop and sensors
towards outer to be equidistant
edge of gutter

Solid Gutter
(or tubular)

Side view

Figure 7-4. Correct alignment of the jet into the gutter

NOTE: It is most important that only the fingers are used to align the nozzle. Never
use pliers or any other form of tool to clamp or move the nozzle. Also,
remember that the solid block gutters are not adjustable and cannot be aligned
with the jet. If the jet cannot be correctly aligned with the gutter, the printhead
must be returned to LINX for factory readjustment.

Clearing a Nozzle Blockage

For any of the three main printhead types, the nozzle has a very small orifice. It is possible
for this orifice to become blocked by a number of causes, for instance: dried ink, foreign
debris introduced into the ink supply, or contamination of ink types.
The most common occurrence is when ink has dried within the nozzle and caused a
restriction or a total blockage. In this situation, the first course of action is to perform a
series of nozzle clear sequences. In normal operation, ink is supplied to the nozzle under
pressure and is emitted from the orifice as a jet. When a nozzle clear is performed, vacuum
is applied to the nozzle, and air and solvent can be drawn into the nozzle to clear any
restrictions.
To perform a series of nozzle clears, carry out the following procedure:
1. Enter Diagnostics and scroll to the Clear Nozzle option.
2. Remove the printhead cover. Wrap some absorbent material around the
printhead at the point where it connects to the conduit and invert the
printhead holding it in a vertical position.

4800 Service Manual 7 — 33 Oct 97

 3. It is recommended that a minimum of three Clear Nozzle sequences are
carried out in an attempt to clear an obstruction or blockage. This can be
performed as a continuous routine by entering “3” in the Clear Nozzle option
and pressing [enter]. The routine of three sequences lasts for 60 seconds and
the message status line display will indicate that the printer is clearing the
nozzle.
4. While the Clear Nozzle routine is in operation, apply small amounts of solvent
to the inverted nozzle face. It should be observed that, when a small drop of
solvent is applied to the nozzle face, it will be drawn in through the nozzle
orifice and back into the ink gun.
NOTE: Be certain to use the correct solvent type that corresponds to the
ink type being used in the printer.
5. Continue applying solvent in small amounts so that the solvent, and some air,
is drawn in through the nozzle. This causes a small pressure build-up when
the solvent (which acts as a restrictor) is cleared, causing air to rush through to
fill the vacuum. This has the effect of carrying any foreign debris with the air
back into the purge line of the printhead. When the three nozzle clears have
been performed and solvent is no longer drawn into the nozzle, the pump will
stop.
6. Exit from Diagnostics, start the printer and observe the alignment of the jet. If
the nozzle is still out of alignment or blocked, repeat the above procedure a
maximum of a further nine times, with an attempt to start the jet carried out
after each routine. The Clear Nozzle sequence will then have been performed
a total of 3 x 10 = 30 times.
If, after carrying out the above procedure the nozzle is still blocked, refer to and carry out
the additional cleaning procedure contained in the “Jet Alignment and Nozzle Cleaning”
maintenance instruction in Section 5: “Maintenance”. The above Clear Nozzle procedure is
also contained in the same maintenance instruction.
If, after carrying out the full cleaning procedure the nozzle is still blocked, the printhead
should be flushed and returned to LINX.

FC33 Modulation Problems

There are several possible causes of modulation problems. The first four in the following
list relate to problems in the main printer. When these have been eliminated, investigate
the fifth possibility of a printhead internal fault.
• The ink is too thick or too thin. Try altering the pressure and the modulation
to improve drop break-up. For thin ink, reduce the pressure and the
modulation in even steps; for thick ink, increase the pressure and the
modulation in even steps.
• The start-up sequence is faulty. Refer to the “Ink System” sub-section in
Section 3: “Technical Description” of this manual for a description of the
correct sequences of operation of the ink system valves.
NOTE: It is highly improbable that the valves sequences will be incorrect.
It is much more likely that an individual valve is sticking or
inoperative. Refer to faults FC13 to FC18.
• The modulation voltage from the IPM PCB is incorrect. Refer to the
description for FC28 in the “Problem Solving – Printhead Electrical Faults”
part of this sub-section.
• The feed line Swagelok union fitting is partially blocked, resulting in reduced
pressure. Examine the Swagelok union fitting for free flow of ink.
• There is a printhead internal fault. Examine the nozzle, piezo crystal and the
modulation wiring to the piezo crystal for damage. Ink leaks in the printhead
or the conduit can cause damage to wiring insulation.

Oct 97 7 — 34 4800 Service Manual

 FC34 Charge Problems
Charge problems can be identified by a number of symptoms, usually poor print quality,
and either “2.02 Charge” or “2.03 Time Of Flight” fault messages. As the charging process
is electrical, most of the possible causes of charge problems are also electrical in nature. If
the possible electrical causes have been eliminated (see FC29 in the “Problem Solving –
Printhead Electrical Faults” part of this sub-section) consider the following mechanical
possibilities:
• Jet misalignment. If the jet is not centred in the charge electrode slot, the drops
will not receive the correct charge. It is also possible that the low charged
phase and TOF checking drops will not be detected by the phase and TOF
sensors if the jet is not correctly aligned over the sensors. Refer to FC32 for jet
alignment problems.
• Printhead internal fault. Examine the nozzle, piezo crystal and the modulation
wiring to the piezo crystal for damage. Ink leaks in the printhead or the
conduit can cause damage to wiring insulation.
• Feed or purge line Swagelok union fittings leaking or partially blocked,
resulting in reduced pressure and jet instability. Examine the Swagelok union
fittings for leaks or blockages.

FC35 Gutter Problems

The faults which can occur in the gutter line are as follows:
• Blocked gutter which can be due to:
• incorrect shutdown not purging the gutter;
• printhead mounted lower than the printer (causing siphoning effect);
• faulty gutter line Swagelok union fitting.
• Ink leaking from the gutter during a period of non-use:
• faulty gutter valve (see FC16 and FC17 in the “Problem Solving – Ink
System Mechanical Faults” part of this sub-section);
• printhead mounted lower than the printer (causing siphoning effect).
• Poor gutter action (inadequate suction):
• very thick ink, e.g. pressure is 40 points above the reference pressure
value;
• faulty venturi;
• leaking gutter valve (see FC16 and FC17 in the “Problem Solving – Ink
System Mechanical Faults” part of this sub-section).
• Ink pouring from gutter on jet start-up:
• incorrectly connected printhead fluid union fittings;
• worn manifold, resulting in positive pressure at the venturi instead of
the intended vacuum.

4800 Service Manual 7 — 35 Oct 97

 Clearing a Gutter Blockage
If the gutter has become physically blocked, for example with dried ink, it can be cleared
using small gauge piano wire and a pair of snipe-nose pliers. Hold a short length of the
piano wire with the pliers and insert the wire into the gutter orifice, as far as possible.
CAUTION: Extreme care must be taken not to break off or leave any part of the piano
wire in the gutter line.
Remove the wire and start the jet, or set the pressure, to determine if the gutter is now
clear. If this fails to clear the blockage, try the following procedure:

WARNING: DURING THE FOLLOWING PROCEDURE INK WILL BE FORCED

FROM THE GUTTER AT MAXIMUM PRESSURE. THE PRINTHEAD MUST BE
ENCLOSED IN A SUITABLE CONTAINER AND FULL HAND AND EYE
PROTECTION MUST BE WORN.
This procedure is best carried out with the printhead positioned in an empty ink or solvent
bottle with paper wrapped around the top (to contain ink spillage), or a large container.
Make sure the gutter is upside down so that the ink can pour into the bottle or container:
1. Switch off the printer.
2. Disconnect the feed and gutter line Swagelok union fittings.
3. Connect the feed line union fitting (printer end) to the gutter line union fitting
(printhead end).
4. Switch on the printer and press [start]; the full force of the start pressure is
now applied to the gutter.
5. As soon as ink pours from the gutter, switch off the printer at the mains input
switch.
Sometimes, the use of both piano wire and the above procedure is required to effect a
successful gutter clearance.

FC36 Vibration Problems

Vibration can cause a number of problems, the most prominent of which are described
here.
Poor print quality is the most common indicator of vibration problems. This is because the
print drops are relatively stable while in flight, so vibration in either the product being
marked or the printhead itself, will result in the drops being misplaced or obstructed.
The various types of vibration and their effects are described in the following:

Product Vibration/Tilting
The product can tilt from one side to the other, either along the axis of the conveyor travel
or at 90 degrees to it (i.e. across the conveyor width).
When the product tilts along the axis of the conveyor travel, the width of some characters
will be contracted and some expanded, as the product tilts first one way then the other.
Similarly, when the product tilts at 90 degrees to the axis of the conveyor travel, the height
of some characters will be contracted and some expanded, as the product tilts first one way
then the other.

Oct 97 7 — 36 4800 Service Manual

 This is shown in the following illustrations:

Product tilting from side to side

Notice how characters along the axis of conveyor travel
are distorted in width
as the product tilts
under the printhead
6160

Figure 7-5. Vibration problems: product tilting along axis of conveyor travel

Product tilting from side to side

Notice how characters at 90 degrees to the axis of
are distorted in height conveyor travel
in a sinusoidal form

6161
6
23 4
5
1

Figure 7-6. Vibration problems: product tilting across axis of conveyor travel

4800 Service Manual 7 — 37 Oct 97

 High Frequency Vibration
High frequency vibration will show as a regular displacement of drops, without
necessarily distorting character height or width. The illustration below shows the
displacement of rasters in response to high frequency vibration:

Character without high

frequency vibration
6162

Character with high frequency

vibration across the conveyor

Character with high frequency

vibration in direction of conveyor travel

Figure 7-7. Vibration problems: high frequency vibration

To determine whether high frequency vibration is affecting the product or the printhead,
simply pass a piece of paper under the printhead and trigger the print. Take care to move
the paper at a steady speed.
If it is the product which is vibrating, then the print quality will be good. If the print
quality is poor, the vibration is likely to be coming from the printhead.
To test for printhead vibration, pass a piece of paper under the printhead in the same way
as described above, but this time hold the printhead with your other hand to dampen any
vibration in it. If print quality improves as a result, then the printhead is suffering from the
effects of vibration.
The following illustrates these tests:

6294

Push paper steadily Hold printhead steady Push paper steadily

under the printhead to damp any vibration under the printhead

12 3 4 5 6 12 3 4 5 6

Testing for product vibration Testing for printhead vibration

Figure 7-8. Vibration problems: testing for product or printhead vibration

Oct 97 7 — 38 4800 Service Manual

 Knocks and Strong Vibrations
Strong vibration and knocking to the printhead is the most serious vibration problem likely
to occur, since this will affect operation of the printer itself. Severe vibration or knocking
will lead to the printer shutting itself down and displaying one or more of the following
fault messages:
“2.01 Deflector Voltage”
“2.02 Charge”
“2.03 Time Of Flight”
It will also be found necessary to clean the printhead more often than would be expected.
To understand what is happening, consider that the stream of drops is relatively stable
once in flight. Therefore, if the printhead suffers vibration or sudden movement, the drops
will be obstructed either by the TOF sensor or the edge of the gutter. This will cause ink to
be splashed on the TOF sensor and deflector plates, and to build up deposits on the gutter.
This is shown in the following illustration:

6165

MIDI

FORCE FORCE FORCE FORCE

Impact or vibration
in this direction causes
drops to collide with
Gutter moves out the TOF sensor and
of drop stream gutter edge
causing drops to
dirty the head by SIDE B

colliding with either

side of the gutter

Figure 7-9. Vibration problems: high impact knock or excessive vibration

4800 Service Manual 7 — 39 Oct 97

 7.4.6 Problem Solving – Electronics System Faults (FC37
to FC38)
Ink jet printers require a large amount of digital and analogue control. This part of
Problem Solving covers some of the more typical problems associated with the printer’s
electronics system. However, it is not possible to predict every possible manner in which
the software and electronic components can fail. Before attempting fault diagnosis of the
electronics system, make sure that all mechanical or ink viscosity related problems have
been eliminated.

FC37 Poor Print

1. If the print shows poor quality with the most deflected drops being
compressed together or even missing, a full calibration of the charge amplifier
should be carried out, as detailed in the “PCB Calibration” maintenance
instruction in Section 5: “Maintenance”. If the calibration cannot be
successfully performed, examine the charge amplifier output at TP9 on the
IPM PCB, using an oscilloscope.
2. If the printable modulation range is very poor, check the modulation amplifier
output at TP1 on the IPM PCB, using an oscilloscope.

FC38 Power Failures

The IPM PCB is the most common source of power failure. The following procedure
should be adopted, to isolate the cause:

WARNING: LETHAL VOLTAGE. THE CORRECT ELECTRICAL SAFETY

PRECAUTIONS MUST BE OBSERVED AT ALL TIMES WHEN WORKING ON THE
PRINTER WITH POWER APPLIED. BEFORE REMOVING OR REFITTING ANY
COMPONENT OR LINK, SWITCH THE PRINTER OFF.
1. Remove the two amplifier 300 volt power supply links LK8 (Modulation amp)
and LK9 (Charge amp).
2. If the failure is still apparent, the fault is in either the 300 volt stabilized power
supply on the IPM PCB, or the 300 volt supply to the PCB from the EHT PSU.
3. If no failure is reported, refit the Modulation amplifier link LK8.
4. If no failure is reported after refitting LK8, refit the Charge amplifier link LK9
(the printer should now fail again).
5. Disconnect the Modulation mini coax plug PL2 and check for failure. If no
failure is apparent, check continuity on the Modulation mini coax plug PL2.
6. If Item 5 still resulted in a failure, disconnect the Charge mini coax plug PL1
and check for failure. If no failure is apparent, check continuity on the Charge
coax plug.
7. If the printer still fails after Item 5 and 6 have been thoroughly investigated,
the IPM PCB may be replaced.
8. When replacing the IPM PCB, make sure that the replacement is correctly
configured with the correct links fitted, and a full calibration is carried out as
detailed in the “PCB Calibration” maintenance instruction in Section 5:
“Maintenance”.
9. See also fault message “2.04 300V Power Supply”.

Oct 97 7 — 40 4800 Service Manual

SECTION 8: ILLUSTRATED PARTS
LIST

8.1 Introduction
The following section illustrates the 4800 Ink Jet Printer and its assemblies. 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.

8.2 Abbreviations
The table shown below explains the abbreviations used in the “Description” column of the
parts lists.
48085
A Ampere M/FOLD Manifold
AF Across Flats mA Milliamp
AMP Amplifier MIL Military
ASSY Assembly mm Millimetre
AUX Auxiliary MOD Modification
BKT Bracket NAT Natural
BSP British Standard Pipe NPT National Pipe Thread
BSPT British Standard Taper Pipe O/P Output
BTN Button OD Outside Diameter
C/F Cableform PAN Pan Head
CER Ceramic PCB Printed Circuit Board
CONN Connector P/CELL Photocell
CSK Countersunk PLT Plated
DEG Degree POZ Pozidriv
DIA Diameter PSU Power Supply Unit
EHT Extra High Tension PTFE Polytetrafluoroethylene
EPDM Ethylene Propylene Diene Monomer PVC Polyvinyl chloride
EURO European R/I Remote Interface
F Female REP Replacement
GSKT Gasket RETRO Retrofit
HD Head RH Right Hand
HEX Hexagonal S/A Self Adhesive
I/F Interface SCR Screw
INT Internal S/E Shaft Encoder
I/P Input SEC Security
IPM Integrated Processor Module SKT Socket
I/S Ink System SQ Square
ID Inside Diameter SPRF Shake Proof
in. Inch SS Stainless Steel
LCD Liquid Crystal Display ST Steel
LG Long STD Standard
LH Left Hand STRT Straight
LRG Large TES Teflon Encapsulated Silicon
m Metre THRU Through
M Male V Volt
M/F Metric Fine WSH Washer

Figure 8-1. Part description abbreviations table

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4800 Printer

The following parts list refers to all 4800 printers

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4800 Service Manual

LINX PRINTING TECHNOLOGIES PLC

BURREL ROAD, ST IVES
CAMBS. PE17 4LE
TITLE: 4800 TOP COVER ASSEMBLY
DRAWING NO: PLATE 4800–1
SHEET: 1 OF 1
4800 Service Manual

4800 TOP COVER ASSEMBLY

Item Part Description Pack Comments
Number Number Quantity

1 FA74097 NUT FULL HEX M3 SS–PACK 50

2 FA74093 WSH SPRF INT M3 SS–PACK 50
3 FA72121 4800 KEYPAD ASSEMBLY (EURO) 1 Includes keypad assembly, keypad clamps and screws
3 FA72122 4800 KEYPAD ASSEMBLY (JAP) 1 Includes keypad assembly, keypad clamps and screws
4 MP13087 4800 COVER HINGE 1

5 FA77068 SCR M3X5 LG PAN HD POZ SS–PACK 10

6 FA70074 4800 DISPLAY PCB ASSY 1 Includes LCD
7 FA74084 PILLAR 6 OD X 18 X M3 NYLON–PACK 10 Display PCB spacers
8 FA73037 NUT M3 NYLOC - PACK 20
9 FA74098 LABEL EARTH WARNING–PACK 10

10 BP406034 4800 LCD 160MM X 68MM X 12MM 1

8—5

11 FA74092 PILLAR 8 OD X 11.3 X M3 NYLON–PACK 10 LCD spacers

12 MP13086 4800 KEYPAD CLAMP 1
13 FA74099 SCR 4G X 5/16 POZ PAN HD PLASTITE ZINC 20 Quantity of 16 used to secure keypad clamps
14 FA74113 4800 KEYPAD SEAL 1.2 metres

15 FA72120 4800 TOP COVER ASSY (COMMON) 1 Includes top cover, keypad seal, EMC seal and cover hinge
16 FA74081 4800 COVER/FILLER SEALS–PACK 10 Circular seals fitted to top cover to seal the filler tubes
17 BP940060 WRENCH TO SUIT PIN HEX M3 (ANTI-TAMPER) 1 For removing top cover security screws
18 FA74090 SCR M5X20 SKT SEC PIN HEX BTN HD–PACK 20
19 FA74091 WSH PLASTIC RETAINING M3–PACK 50

20 FA74082 4800 EMC SEAL KIT 1 Top cover EMC seal comprising silicone tubing with neoprene cord insert
21 AS13355 4800 EARTH STRAP CABLEFORM 1 Display PCB to chassis cableform
22 BP399033 4800 INK SYSTEM/COVER SEAL 6X4MM S/A EPDM 1 metre Fitted to top cover to seal the ink system when the cover is fitted
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LINX PRINTING TECHNOLOGIES PLC
6 BURREL ROAD, ST IVES
CAMBS. PE17 4LE
TITLE: 4800 CABINET ASSEMBLY
22 1 DRAWING NO: PLATE 4800–2
SHEET: 1 OF 1
4800 Service Manual

4800 CABINET ASSEMBLY

Item Part Description Pack Comments
Number Number Quantity

1 FA74115 4800 RUBBER FOOT–PACK 4 Foot contains threaded insert for easy fitting
2 FA72076 STARLOCK FASTENER 3MM UNCAPPED –PACK 10
3 AS13356 4800 FAN ASSY 1
4 MP10319 DUST FILTER 1 4200, 4800, 6000R, 6200R & 6200S. Rectangular pull-out filter.
5 MP13076 POWER SUPPLY UNIT BRACKET 1

6 FA74100 SCR M3X6 LG CSK HD POZ SS–PACK 50

7 FA74086 SCREW M4X6 LG PAN HD POZ SS–PACK 50
8 FA74023 PUMP SCR M5X50 PAN POZ SS–PACK 20
9 FA73060 4800 LOW VOLTAGE PSU ASSY 1 Includes bracket, cableform, fuses, fuse holders and carriers.
9 MP15008 4800 LOW VOLTAGE PSU SMLC111 1 PSU only
10 FA77042 SCR M3X6 LG PAN HD POZ SS–PACK 20
8—7

11 FA74093 WSH SPRF INT M3 SS–PACK 50

12 AS13352 4800 MAINS CABLEFORM INTERNAL 1 Internal cableform interconnecting fuses and mains filter
13 FA74085 FUSE HOLDERS AND CARRIERS (MAINS) 10 each
14 FA71043 FUSE 4A 250V ANTISURGE CERAMIC–PACK 10 For use with 4800 low voltage PSU (MP15008), or wide range PSU MP10
wide range PSU MP10195 set to 110V
15 FA74111 NUT FULL HEX M4 SS–PACK 50

16 FA74112 M4 NYLOC NUT–PACK 50

17 BP461006 ELECTRICAL SUPPLY FILTER 3A 1 4800, 5000 Mk2, 6000
18 FA70075 4800 PHOTOCELL PCB 1
19 MP13060 EHT PSU 3001 1 EHT PSU only
20 FA67047 POSITIVE AIR UPGRADE KIT INTERNAL 4800 1 Air supply by internal pump. Mk5 Midi or Mk3B Micro/Macro printhead req

21 FA74109 SCR M4X12 LG PAN HD POZ SS–PACK 50

22 FA74110 SCR M5X16 LG PAN HD POZ SS - PACK 50
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LINX PRINTING TECHNOLOGIES PLC
BURREL ROAD, ST IVES
CAMBS. PE17 4LE
TITLE: 4800 REAR CABINET
4 5 DRAWING NO: PLATE 4800–3
SHEET: 1 OF 1
4800 Service Manual

4800 REAR CABINET

Item Part Description Pack Comments
Number Number Quantity

1 FA74101 SCREWLOCK 4.7 (4800 PHOTOCELL PCB)–PACK 20

2 BP549130 9 WAY D-TYPE PLUG IP67 1 Plug to connect to shaft encoder or photocell
3 BP470024 4800 MAINS ROCKER SWITCH 1 Mains power on/off switch
4 FA71032 CABLE GLAND ASSY M20 1
5 FA71039 4800/6000 MAINS POWER CABLE 220V 1 External mains power cable

5 FA71040 4800/6000 MAINS POWER CABLE 110V 1 External mains power cable
6 AS13357 4800 ALARM CABLEFORM 1 Internal cableform
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3 LINX PRINTING TECHNOLOGIES PLC
BURREL ROAD, ST IVES

18 2 CAMBS. PE17 4LE

TITLE: 4800 INK SYSTEM ASSEMBLY (1)
20 1 DRAWING NO: PLATE 4800–4
SHEET: 1 OF 2
4800 Service Manual

4800 INK SYSTEM (1)

Item Part Description Pack Comments
Number Number Quantity

1 FA73003 CONN STRT 1/8 BSP SLF SEAL–PACK 10

2 FA73007 A1 BARB STAINLESS STEEL–PACK 10
3 FA73004 CONN ELBOW 1/8 BSP SLF SEAL–PACK 10
4 FA73012 TUBE SUPPORT ELBOW 6MM–PACK 10
5 BP100006 TUBE PTFE 6MM OD X 4MM ID NATURAL 1 metre

6 FA73044 MAIN INK FILTER 10µm 1 For pigmented inks

6 FA73046 MAIN INK FILTER 5µm 1
7 BP100006 TUBE PTFE 6MM OD X 4MM ID NATURAL 1 metre
8 FA72050 FEED DAMPER ASSY 1 Integral filter; includes A1 barb and tube support elbow
9 FA73005 A1 SS BARB LONG THREAD–PACK 10 For damper only

10 BP100001 TUBE PTFE 1/8 OD X 1/16 ID NATURAL 1 metre Gutter line and manifold
8 — 11

11 FA73006 MINIATURE BARB Y CONN 1/16–PACK 10

12 BP320005 FILTER IN-LINE STAINLESS STEEL 1 Solvent pick-up. (Not originally fitted to 5000 series, but can be fitted to so
13 FA73013 SEAL BONDED WSH MILD ST/EPDM–PACK 10
14 MP10469 VALVE 3-WAY HEXAGONAL 1

15 FA73040 SCREW M3X20 CSK POZ–PACK 20 Valve screws

16 FA73010 VALVE O RING SMALL EPDM–PACK 10
17 FA73009 VALVE O RING LARGE EPDM–PACK 10
18 FA72093 6/4200CE/4800 MANIFOLD ASSY COMPLETE 1 Includes venturi, five valves, pressure transducer, solvent pick-up filter, da
18 AS10513 MANIFOLD/BARB ASSEMBLY 1 White manifold block with push fit barbs; does not include pipes, valves, ve
transducer.

19 BP200002 PRESSURE TRANSDUCER (HIRSCHMANN CONN) 1 4000, 4200, 4800, 5000 Mk2, 6000 & 6200
20 AS10301 VENTURI 1
BP100002 TUBE PTFE 1/8 OD X 1/16 ID BLUE 1 metre Purge line
BP100003 TUBE PTFE 1/8 OD X 1/16 ID RED 1 metre Feed line
BP100009 TUBE PTFE 3/16 OD X 1/8 ID NATURAL 1 metre

FA65006 TOOL KIT 1/8 UNION FITTING Various Includes 3 caps, 3 plugs, gap gauge, tube cutter
Amdt 01
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FA65007 BLANKING KIT 1/8 UNION FITTING 3 each Includes 3 caps and 3 plugs for blanking union fittings
FA65008 FERRULES KIT 1/8 UNION FITTING–PACK 10 each 10 front & 10 rear replacement ferrules
FA69009 LUBRICANT KIT – MAIN INK FILTER 1 Includes 1litre of lubricant and 20 small bottles
FA74005 DAMPER DRAIN TUBE KIT 1 Used to drain the ink system
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35 LINX PRINTING TECHNOLOGIES PLC
BURREL ROAD, ST IVES
2 CAMBS. PE17 4LE
36 TITLE: 4800 INK SYSTEM ASSEMBLY (2)
DRAWING NO: PLATE 4800–5
37 38 1 SHEET: 2 OF 2
4800 Service Manual

4800 INK SYSTEM (2)

Item Part Description Pack Comments
Number Number Quantity

1 FA74107 PLUG SCREW 700A/M12X1–PACK 10 Ink tray drain plug

2 FA72083 4200/4800 INK TANK PLASTIC 1
3 FA73003 CONN STRT 1/8 BSP SLF SEAL–PACK 10
4 FA73016 CONN STRT M 1/4 BSP SELF SEAL–PACK 10
5 FA73014 O-RING 7.66 X 1.78 EPDM–PACK 10

6 FA72085 INK DIP TUBE 1 Includes dip tube and o-rings

7 BP320003 FILTER PRE-PUMP 1
8 FA73017 O-RING 26.64X2.62 EPDM–PACK 10
9 FA73059 4800 INK FILLER TUBE ASSY 1 Includes filler tube insert, bottle pierce, barb fitting and two o-rings
10 FA73011 FILTER TUBE INSERT–PACK 10

11 BP365002 4800 O-RING FILL TUBE BS223 FEP/SIL CORE 1 Used on openings of ink and solvent filler tubes
8 — 13

12 MP10512 4200CE INK / SOLVENT FILLER TUBE INSERT 1

13 MP10109 4000 BOTTLE PIERCE 1 4000, 4200, 4200CE & 4800
14 FA74114 4800 INK AND SOLVENT CAPS’ SEALS–PACK 10 Seal fitted to neck of filler cap
15 FA73061 4800 INK FILLER CAP 1 Includes o-ring seal

16 FA74094 4800 INK/SOLVENT CAP LABELS - 1240/3103–PACK 5 sheets Each sheet contains one each of the following labels: 1240 ink, 3103 ink, b
3501 solvent, blank solvent
17 FA74095 4800 INK CAP LABELS - VARIOUS–PACK 5 sheets Each sheet contains 19 labels for ink types other than those in FA74094, a
18 FA74096 4800 SOLVENT CAP LABELS - VARIOUS–PACK 5 sheets Each sheet contains 19 labels for solvent types other than those in FA740
labels
19 FA73062 4800 SOLVENT FILLER CAP 1 Includes o-ring seal
20 MP10527 P/HEAD PIPES SEALING GLAND — INSERT 1

21 FA72091 I/S C/F LOCKNUT & SEALING WASHER–KIT 1

22 BP570021 CABLE GLAND M25 NYLON 1
23 FA73058 4800 SOLVENT FILLER TUBE ASSY 1 Includes filler tube insert, bottle pierce, barb fitting and two o-rings
24 FA73015 C1 BARB FITTING NYLON–PACK 10
25 FA73007 A1 BARB STAINLESS STEEL–PACK 10
Amdt 01
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26 FA13002 4200CE/4800 SOLVENT DIP/FILTER TUBE ASSY 1 Includes dip tube, filter, o-rings and A1 barb fitting
27 FA74083 O-RING 4.47 X 1.78 EPDM–PACK 10 Used on solvent dip tube in-line filter
28 MP13064 4800 SOLVENT TANK 1
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4800 Service Manual

4800 INK SYSTEM (2) (CONTINUED)

Item Part Description Pack Comments
Number Number Quantity

29 FA74104 45DEG SINGLE 250 TERMINAL–PACK 50

30 FA74102 SCR M3X8 LG PAN HD POZ SS–PACK 50
31 FA74106 SCREW INSULATOR M3X2–PACK 50
32 FA74105 UNIFIED FLAT WASHER–PACK 50
33 FA74093 WSH SPRF INT M3 SS–PACK 50
34 FA74097 NUT FULL HEX M3 SS–PACK 50
35 FA72082 4200CE/4800 COMPLETE PUMP ASSY 1 Includes fittings and securing screws

36 FA71052 4200/4800 PUMP MOTOR SPARE 1 4200, 4200CE, 4800.

37 FA72101 4200/4800 PUMP HEAD SPARE 1 4200, 4200CE & 4800. Includes fittings.
38 MP13109 4800 PUMP SPACER 1
8 — 15
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LINX PRINTING TECHNOLOGIES PLC
BURREL ROAD, ST IVES
CAMBS. PE17 4LE
TITLE: 4800 ELECTRONICS ASSEMBLY
DRAWING NO: PLATE 4800–6
SHEET: 1 OF 1
4800 Service Manual

4800 ELECTRONICS ASSEMBLY

Item Part Description Pack Comments
Number Number Quantity

1 FA70076 4800 IPM PCB + SOFTWARE 1 Includes hardwired software

2 FA74089 PILLAR BRASS 35MM M4–PACK 10
3 FA74087 WASHER SPRF INT M4 SS–PACK 50
4 FA74086 SCREW M4X6 LG PAN HD POZ SS–PACK 50
5 AS13351 4800 PSU CABLEFORM 1

6 AS13354 4800 300V CABLEFORM 1

7 AS13350 4800 INK SYSTEM CABLEFORM 1 Includes ink & solvent float switches, pressure transducer and five valve ca
8 AS13349 4800 PHOTOCELL CABLEFORM 1
9 FA74112 M4 NYLOC NUT–PACK 50
10 FA74088 HEXAGONAL PILLAR M4X57–PACK 10

11 AS13353 4800 DISPLAY CABLEFORM 1

8 — 17
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 Linx Printing Technologies plc

Index

Symbols
1400 Hour Scheduled Maintenance 5—27
1400 Hour Scheduled Maintenance Checklist 5—25

A
Abbreviations 1—5
Air Filter 3—19
Alarm Beacon Fitting (Gantry Mounted) 5—133
Alarm Beacon Fitting (Printer Mounted) 5—129, 5—130, 5—131, 5—132
Alarm option 4—16
Alarm Output 3—73
Alarm Relay 3—73
Alarm Test 5—19
Amendments iii
Antistatic Precautions 5—23
Approvals 1—4
Auto Phase 5—17
Auxiliary Photocell 3—71

B
Baud Rate 4—19
Blocked Gutter Clearance Procedure 5—83
Bold Ratio 4—8
Buffer Threshold 4—19

C
Cabinet 3—14
Calculating the Print Width 4—10
Calibrate Print Head 4—15
Calibrated Nozzle Replacement 5—101, 5—102, 5—103, 5—104
Cautions (Safety) 2—2
CE Approval Checklist 5—24
Change Language 4—17
Change Password 4—17
Changing Menu Options 4—4
Char Set Version 6—11
Character Generation Faults 7—20
Character Height Range 1—3
Charge 6—14
Charge Amplifier Calibration 5—64
Charge Calibration Range 6—20
Charge, Drop 3—9
Charge Electrode 3—3
Charge Faults 7—19
Charge Problems 7—30, 7—35
Charge Strobe 3—4
Circuit Diagrams 3—62
Clear Message Area 5—16
Clear Nozzle 5—6
Clear Nozzle (Diagnostics Menu) 3—59
Clear Nozzle and Restart Sequence 3—39
Clear Remote Buffers 4—23
Clearing a Gutter Blockage 7—36
Clearing a Nozzle Blockage 7—33

MP65209–1 Amdt 03
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 Linx Printing Technologies plc

Conduit Length 4—12

Configuration 6—12
Configuration Software Sets 3—67
Control Panel LEDs 3—17
Cooling Fan 3—19
Current Message Screen 4—1

D
D-type Connector Assembly 3—75
DAC Cal Mode 5—18
DAC Cal Value 5—19
Data PROM Checksum 6—9
Data PROM Not Fitted 6—9
Data PROMs 5—13
Date Format Version 6—11
Default Language 6—22
Deflector Plates 3—3
Deflector Voltage 6—14
Deflector Voltage Faults 7—21
Diagnostics 4—24. See also Diagnostics Menu
Diagnostics Menu 5—1
Alarm Test 5—19
Auto Phase 5—17
Clear Message Area 5—16
Clear Nozzle 5—6
DAC Cal Mode 5—18
DAC Cal Value 5—19
Filter Purge 5—16
Flush Shutdown 5—7
Generate Test Pattern 5—19
Monitor Jet 5—8
Modln (Modulation) 5—9
Phase 5—9
Pressure 5—8
Read Press (Pressure) 5—10
Ref Modln (Modulation) 5—10
Ref TOF 5—10
Solv Add 5—10
TOF 5—8
Nozzle Flush 5—7
Phase 5—13
Phase Fault 5—17
Phase Offset 5—14
Phase Period 5—17
Quick Start Jet 5—4
Ref Pressures 5—14
Maximum Run 5—16
Print Head Ref 5—15
Solvent Add 5—15
Save Cal Value 5—19
Set Pressure 5—14
Start Jet 5—3
Start Print 5—5
Stop Jet 5—4
Quick Stop 5—4
Stop Print 5—5

Amdt 03 MP65209–1
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System Config 5—12

Data PROMs 5—13
Enabled Options 5—13
Head Type 5—12
PCB Issue 5—12
Raster Type 5—12
SW Links 5—12
SW Version 5—12
System Flush (prior to v1.1 software) 5—20
System Flush (v1.1 software) 5—20
System Times 5—11
Filter Change 5—11
Jet Running 5—11
Power On 5—11
Service 5—11
Test Print 5—5
TOF Correction 5—18
TOF Warm Up 5—18
Valve Test 5—21
Dimensions 1—1
Display PCB 3—65
Test Points 3—65
Divide Ratio 4—10
Draining the Ink System 5—39
Drawing List 3—75
Drop Charge 3—9
Drop Deflection 3—9

E
EHT Power Supply Unit 1—2, 3—19
Electrical Components 3—18
Cooling Fan 3—19
EHT Power Supply Unit 3—19
Ink System Pump 3—19
Low Voltage Power Supply Unit 3—18
Mains Filter 3—18
Mains Input Fuses 3—18
Positive Air Pump 3—19
Electromagnetic Compatibility 1—4
Electronics System 3—62
Circuit Diagrams 3—62
Display PCB 3—65
Test Points 3—65
Drawing List 3—75
IPM PCB 3—62
Links 3—64
Test Points 3—62
IPM PCB Calibration 3—64
Photocell PCB 3—65
Links 3—65
Test Points 3—65
Test Points and Links 3—62
Electronics System Faults 7—40
EMC Standards 1—4
Enabled Options 5—13
Environmental Specification 1—2
Error and Fault Messages 6—1
Error Info. 6—4
Error List 6—4

MP65209–1 Amdt 03
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Error Messages 6—1. See also System Warnings

Error Reporting Configuration 6—3
European EMC Standards 1—4
European Safety Standards 1—4
External Signals 3—70
Alarm Output 3—73
Auxiliary Photocell 3—71
D-type Connector Assembly 3—75
Primary Photocell 3—70
Print Ready Signal 3—73
RS–232 and RS–485 Cable Connections 3—74
RS–232 and RS–485 Interfaces 3—74
Shaft Encoders 3—72

F
Fail LED 3—17
Fault Codes
FC1 High Viscosity 7—10
FC10 Deflector Voltage Faults 7—21
FC12 Pressure Loss 7—22
FC13 Leaking Feed Valve 7—23
FC14 Inactive Feed Valve 7—23
FC15 Inactive Purge Valve 7—24
FC16 Leaking Purge Valve or Gutter Valve 7—24
FC17 Leaking Gutter Valve 7—24
FC18 Leaking Solvent Top-Up Valve 7—25
FC19 Solvent Contamination 7—25
FC2 Low Viscosity 7—11
FC20 New Pump Requiring Priming 7—25
FC21 Solvent Pick-up Pipes Clogged with Dust 7—25
FC22 Pressure Loss 7—26
FC23 Ink Low Warning 7—26
FC24 Solvent Low Warning 7—26
FC25 Inoperative Feed Valve 7—27
FC26 Incorrect Valve Operation 7—27
FC27 Incorrect Viscosity Control 7—28
FC28 Modulation Problems 7—29
FC29 Charge Problems 7—30
FC3 Modulation Problems 7—12
FC30 No Strobe LED 7—31
FC31 No Drop Deflection 7—31
FC32 Jet Alignment Problems 7—32
FC33 Modulation Problems 7—34
FC34 Charge Problems 7—35
FC35 Gutter Problems 7—35
FC36 Vibration Problems 7—36
FC37 Poor Print 7—40
FC38 Power Failures 7—40
FC4 Phasing Errors 7—14
FC5 Gutter Clipping 7—16
FC6 Printhead Cover Catch 7—17
FC7 Charge Faults 7—19
FC8 Character Generation Faults 7—20
FC9 Shaft Encoder Faults 7—20
Fault Diagnosis 7—1
Fault Info. 6—6
Fault Messages 6—1. See also System Failures and Print Failures
Fault Reporting Configuration 6—3
Fault Shutdown Sequence 3—58

Amdt 03 MP65209–1
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Feed Valve Test 5—67

Filter Change 5—11
Filter Purge 5—16
First Aid 2—4
Eye Contact 2—4
Ingestion 2—4
Inhalation 2—4
Skin Contact 2—4
Flow Control 4—20
Fluid, 3-Way Connector Filter Replacement 5—51, 5—52, 5—53, 5—54
Flush Shutdown 5—7
Flush Shutdown Sequence 3—41
Fuses 3—18

G
Generate Test Pattern 5—19
Glossary 1—5
Good Practice 5—24
Guard Drops 3—12
Gutter Alignment 5—93
Gutter Clipping 7—16
Gutter Problems 7—35

H
Hazards. See Safety
Head Height 4—12
Head Type 5—12
High Flow Gutter Restrictor 3—25
High Frequency Vibration 7—38
High Viscosity 7—10
Historic Correction 3—9

I
Identifying Faults by Print Sample 7—2
Identifying Faults by Symptom 7—5
In-Line Gutter Check Valve 3—26
Inactive Feed Valve 7—23
Inactive Purge Valve 7—24
Incorrect Valve Operation 7—27
Incorrect Viscosity Control 7—28
Ink and Solvent Flows 3—26
Ink Conversion Calibration 5—117
Ink Jet 3—7
Ink Low 1—2, 6—18
Ink Low Warning 7—26
Ink Selection 4—14
Ink System 1—2, 3—20
Capacity 1—2
Clear Nozzle (Diagnostics Menu) 3—59
Clear Nozzle and Restart Sequence 3—39
Fault Shutdown Sequence 3—58
Flush Shutdown Sequence 3—41
High Flow Gutter Restrictor 3—25
In-Line Gutter Check Valve 3—26
Ink and Solvent Flows 3—26
Level Control 1—2
Manifold Assembly 3—22
Manifold Connections 3—24

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Non-Flush Shutdown Sequence 3—53

Normal Startup Sequence 3—33
Nozzle Flush (Diagnostics Menu) 3—60
Pressure 1—2
Pressure Transducer 3—23
Primary Circuit 3—26
Quick Start Sequence 3—38
Quick Stop Sequence 3—59
Secondary Circuit 3—26
Solvent Addition 3—29
Standard Gutter Restrictor 3—25
Startup and Shutdown Routines 3—31
Vacuum Venturi 3—23
Valves 3—23
Ink System Cableform Assembly—Solvent Damage 5—23
Ink System Electrical Faults 7—26
Ink System Mechanical Faults 7—22
Ink System Pump 3—19
Ink Tank Dip Tube Replacement 5—43, 5—44, 5—45, 5—46
Ink Tank Empty 6—16
Ink Type Dependent Parameters 3—61
Inks and Solvents (Safety) 2—3
Inoperative Feed Valve 7—27
Internal Failure 6—7
Internal Spillage 6—16
Invalid Failure 6—12
IPM PCB 3—62
Calibration 5—63
Links 3—64
Replacement and Calibration 3—64
Test Points 3—62

J
Jet Alignment and Nozzle Cleaning 5—87
Jet Alignment Problems 7—32
Jet Running 5—11
Jet Shut Down Incomplete 6—18
Jet/Nozzle Alignment 3—6
Jewel size 3—7
Julian Date Format 4—9

K
Keyboard and Display 3—16

L
Language Version 6—10
Last Chance Filter 3—5
Leaking Feed Valve 7—23
Leaking Gutter Valve 7—24
Leaking Purge Valve or Gutter Valve 7—24
Leaking Solvent Top-Up Valve 7—25
LEDs 3—17
Lethal Voltages 2—3
Links. See individual PCBs
Logo Version 6—11
Low Pressure 6—21
Low Viscosity 7—11
Low Voltage Power Supply Unit 1—1, 3—18

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M
Main Ink Filter Replacement 5—55
Mains Filter 3—18
Mains Input Fuses 3—18
Mains Power Requirements 1—1
Maintenance Instructions 5—22
1400 Hour Scheduled Maintenance 5—27
Alarm Beacon Fitting (Gantry Mounted) 5—133
Alarm Beacon Fitting (Printer Mounted) 5—129, 5—130, 5—131, 5—132
Blocked Gutter Clearance Procedure 5—83
Calibrated Nozzle Replacement 5—101, 5—102, 5—103, 5—104
Draining the Ink System 5—39
Feed Valve Test 5—67
Fluid, 3-Way Connector Filter Replacement 5—51, 5—52, 5—53, 5—54
Ink Conversion Calibration 5—117
Ink Tank Dip Tube Replacement 5—43, 5—44, 5—45, 5—46
IPM PCB Calibration 5—63
Jet Alignment and Nozzle Cleaning 5—87
Main Ink Filter Replacement 5—55
Modulation Range Checks 5—95
Nozzle O-ring Replacement 5—97
Positive Air Pump Fitting Instructions 5—125, 5—126, 5—127, 5—128
Printhead Cleaning for Pigmented Inks 5—35
Pump Motor Brush Assembly Replacement 5—135
Purge and Gutter Valves Tests 5—69
Solvent Bottle Adaptor Fitting Instructions 5—141
Solvent Flush Valve Tests 5—75
Solvent Tank Dip Tube Replacement 5—47
Solvent Top-up Valve Tests 5—79
System Flush Procedure 5—105
Maintenance Terminology 5—22
Manifold Assembly 3—22
Manifold Connections 3—24
Maximum Characters/Second 1—4
Maximum Run 5—16
Maximum Speed 1—3
Memory Capacity 1—2
Memory Corrupt 6—22
Memory Failure 6—22
Menu Options
Selecting and Changing 4—4
Message Count 6—3
Message Delimiters 4—20
Minimum Delay default values 4—7
Modln (Modulation) (Monitor Jet screen) 5—9
Modulation 3—7, 6—21
Modulation Problems 7—12, 7—29, 7—34
Modulation Range Checks 5—95
Monitor Jet 5—8
Modln (Modulation) 5—9
Phase 5—9
Pressure 5—8
Read Press (Pressure) 5—10
Ref Modln (Modulation) 5—10
Ref TOF 5—10
Solv Add 5—10
TOF 5—8

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N
New Print Head Fitted 6—20
New Pump Requiring Priming 7—25
No Char Sets 6—10
No Drop Deflection 7—31
No Language 6—9
No Message Stored In Memory 6—23
No Rasters 6—10
No Strobe LED 7—31
No TOF Adjustments 6—17
Non-Flush Shutdown Sequence 3—53
Normal Startup Sequence 3—33
Normalise Height 4—5
Nozzle Cleaning 5—87
Nozzle Flush 5—7
Nozzle Flush (Diagnostics Menu) 3—60
Nozzle O-ring Replacement 5—97
Nozzle Realignment 5—87, 5—93, 7—32

O
Option Version 6—11
Over Speed (Print Go) 6—18
Over Speed (Variable Data) 6—22

P
Password 4—4
Password Access 4—1, 5—1
Passwords 4—25
PCB Issue 5—12
Phase (Diagnostics Menu) 5—13
Phase (Monitor Jet screen) 5—9
Phase Fault 5—17
Phase Offset 5—14
Phase Period 5—17
Phase Sensor 3—4
Phasing 3—9
Phasing Errors 7—14
Photocell 3—70, 3—71, 4—9
Photocell PCB 3—65
Links 3—65
Test Points 3—65
Piezo Crystal 3—3, 3—7
Pixel RAM 6—11
Poor Print 7—40
Positive Air Pump 3—19
Positive Air Pump Fitting Instructions 5—125, 5—126, 5—127, 5—128
Power Failures 7—40
Power LED 3—17
Power On 5—11
Power Supply, 300V 6—16
Precautions (Safety) 2—4
Press (Pressure) (Monitor Jet screen) 5—8
Pressure Loss 7—22, 7—26
Pressure Transducer 3—23
Pressure Transducer Calibration 5—63
Primary Photocell 3—70
Print Control 4—21
Print Count 4—7
Print Delay 4—7

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Print Failures 6—13

2.00 Print Head Temperature 6—13
2.01 Deflector Voltage 6—14
2.02 Charge 6—14
2.03 Time Of Flight 6—15
2.04 300V Power Supply 6—16
2.05 Temperature/Deflector 6—16
2.06 Ink Tank Empty 6—16
2.16 Internal Spillage 6—16
Print Go/Remote Data 6—19
Print Head Code 4—13
Print Head Cover Off 6—19
Print Head Not Fitted 6—20
Print Head Ref 5—15
Print Head Temperature 6—13
Print Height 4—4
Print Mode 4—22
Print Ready Signal 3—73
Print Samples 7—9
Print Status Screen 6—3
Error Info. 6—4
Error List 6—4
Fault Info. 6—6
Print Width 4—6
Calculating 4—10
Example Calculation 4—11
Printer Address (RS–485) 4—24
Printhead 1—3
Printhead Cleaning for Pigmented Inks 5—35
Printhead Connections 3—5
Printhead Cover Catch 7—17
Printhead Cover Sensor 3—4
Printhead Electrical Faults 7—29
Printhead Mechanical Faults 7—32
Printhead Principles of Operation 3—6
Drop Charge 3—9
Drop Deflection 3—9
Guard Drops 3—12
Historic Correction 3—9
Ink Jet 3—7
Modulation 3—7
Phasing 3—9
Reference TOF 3—11
Set Pressure 3—11
Shutting Down 3—13
Solvent Add Reference Pressure 3—11
Starting Up 3—13
Time Of Flight 3—11
Viscosity Control 3—11
Printhead Quality 3—5
Printhead Replacement 3—5
Printhead Types 3—3
Printing Performance 1—3
Problem Solving 7—9
Electronics System Faults 7—40
Ink System Electrical Faults 7—26
Ink System Mechanical Faults 7—22
Print Samples 7—9
Printhead Electrical Faults 7—29
Printhead Mechanical Faults 7—32

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Product Vibration/Tilting 7—36

Prog PROM Checksum 6—9
Pump Motor Brush Assembly Replacement 5—135
Purge and Gutter Valves Tests 5—69

Q
Quick Start Jet 5—4
Quick Start Sequence 3—38
Quick Stop 5—4
Quick Stop Sequence 3—59

R
Raster Data 6—10
Raster Information 1—3
Raster Type 5—12
Raster Version 6—10
Read Press (Pressure) 5—10
Read Pressure 3—7
Ready LED 3—17
Ref Modln (Modulation) 5—10
Ref Modulation 4—14
Ref Pressures 5—14
Maximum Run 5—16
Print Head Ref 5—15
Solvent Add 5—15
Ref TOF 5—10
Reference TOF 3—11
Regulatory Approvals 1—4
Relative Viscosity (evaluating) 5—96
Remote Setup Menu (RS–232) 4—18. See also Setup Menu
Flow Control 4—20
Message Delimiters 4—20
Print Control 4—21
Print Mode 4—22
Serial Parameters 4—19
Transfer Parameters 4—18
Remote Setup Menu (RS–485) 4—24
Transfer Parameters 4—24
Printer Address 4—24
Reverse Message 4—8
RS–232 and RS–485 Cable Connections 3—74
RS–232 and RS–485 Interfaces 3—74

S
Safety 2—1
First Aid 2—4
Inks and Solvents 2—3
Lethal Voltages 2—3
Precautions 2—4
Test Printing 2—5
Warnings and Cautions 2—1
Safety Override Detected 6—21
Safety Sensors 3—4
Safety Standards 1—4
Save Cal Value 5—19
Scheduled Maintenance (1400 Hour) 5—27
Scheduled Maintenance Checklist (1400 Hour) 5—25
Serial Parameters 4—19

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Service 5—11
Service Time 6—19
Set Date 4—8
Set Pressure 3—7, 3—11, 5—14
Set Time 4—8
Setup Menu 4—1
Alarm 4—16
Bold Ratio 4—8
Calculating the Print Width 4—10
Calibrate Print Head 4—15
Change Language 4—17
Change Password 4—17
Conduit Length 4—12
Current Message Screen 4—1
Diagnostics 4—24. See also Diagnostics Menu
Head Height 4—12
Ink Selection 4—14
Julian Date Format 4—9
Normalise Height 4—5
Option Availability 4—3
Options 4—2
Password 4—4
Password Access 4—1
Photocell 4—9
Print Count 4—7
Print Delay 4—7
Print Head Code 4—13
Print Height 4—4
Print Width 4—6
Ref Modulation 4—14
Remote Setup Menu (RS–232) 4—18
Flow Control 4—20
Message Delimiters 4—20
Print Control 4—21
Print Mode 4—22
Serial Parameters 4—19
Transfer Parameters 4—18
Remote Setup Menu (RS–485) 4—24
Transfer Parameters 4—24
Reverse Message 4—8
Set Date 4—8
Set Time 4—8
Shaft Encoder 4—10
Shaft Encoder Divide Ratio (Print Width) 4—10
Solv Add Time 4—24
Shaft Encoder 4—10
Shaft Encoder Divide Ratio (Print Width) 4—10
Shaft Encoder Faults 7—20
Shaft Encoder Modes 4—12
Shaft Encoders 3—72
Shutting Down 3—13
Software 3—66
Configuration Software Sets 3—67
Software Options 3—68
Standard Software Sets 3—66
Software Options 3—68
Solv Add (Monitor Jet screen) 5—10
Solv Add Time 4—24
Solvent Add 5—15

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Solvent Add Reference Pressure 3—11

Solvent Addition 3—29
Solvent Bottle Adaptor Fitting Instructions 5—141
Solvent Contamination 7—25
Solvent Flush Valve Tests 5—75
Solvent Low 1—2, 6—19
Solvent Low Warning 7—26
Solvent Pick-up Pipes Clogged with Dust 7—25
Solvent Tank Dip Tube Replacement 5—47
Solvent Top-up Valve Tests 5—79
Spare Parts List 8—1
Stack Overflow 6—8
Standard Gutter Restrictor 3—25
Standard Software Sets 3—66
Standards 1—4
Start Jet 5—3
Start Print 5—5
Starting Up 3—13
Startup and Shutdown Routines 3—31
Status 6—3
Stop Jet 5—4
Quick Stop 5—4
Stop Print 5—5
SW Links 5—12
SW Version 5—12
System Config 5—12
Data PROMs 5—13
Enabled Options 5—13
Head Type 5—12
PCB Issue 5—12
Raster Type 5—12
SW Links 5—12
SW Version 5—12
System Failures 6—7
1.01 Internal Failure 6—7
1.02 Unexpected NMI 6—8
1.03 Unexpected Interrupt 6—8
1.04 Unexpected RST 6—8
1.05 Stack Overflow 6—8
1.06 Prog PROM Checksum 6—9
1.07 System RAM 6—9
1.09 Data PROM Not Fitted 6—9
1.10 Data PROM Checksum 6—9
1.11 No Language 6—9
1.12 Language Version 6—10
1.13 No Rasters 6—10
1.14 Raster Version 6—10
1.15 Raster Data 6—10
1.16 No Char Sets 6—10
1.17 Char Set Version 6—11
1.20 Logo Version 6—11
1.21 Pixel RAM 6—11
1.22 Date Format Version 6—11
1.23 Option Version 6—11
1.34 Configuration 6—12
1.99 Invalid Failure 6—12
System Flush (prior to v1.1 software) 5—20
System Flush (v1.1 software) 5—20
System Flush Procedure 5—105

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System RAM 6—9

System Times 5—11
Filter Change 5—11
Jet Running 5—11
Power On 5—11
Service 5—11
System Warnings 6—17
3.00 No TOF Adjustments 6—17
3.01 Jet Shut Down Incomplete 6—18
3.02 Over Speed (Print Go) 6—18
3.03 Ink Low 6—18
3.04 Solvent Low 6—19
3.05 Print Go/Remote Data 6—19
3.06 Service Time 6—19
3.07 Print Head Cover Off 6—19
3.08 Print Head Not Fitted 6—20
3.09 New Print Head Fitted 6—20
3.10 Charge Calibration Range 6—20
3.11 Safety Override Detected 6—21
3.12 Low Pressure 6—21
3.13 Modulation 6—21
3.14 Over Speed (Variable Data) 6—22
3.15 Default Language 6—22
3.16 Memory Failure 6—22
3.17 Memory Corrupt 6—22
3.18 No Message Stored In Memory 6—23

T
Technical Data 1—1
Temperature Sensor 3—4
Temperature/Deflector 6—16
Test Points. See individual PCBs
Test Print 5—5
Test Printing (Safety) 2—5
Throw Distance 1—3
Time Of Flight 3—11, 6—15
TOF (Monitor Jet screen) 5—8
TOF Correction 5—18
TOF Sensor 3—4
TOF Warm Up 5—18
Transfer Parameters (RS–232) 4—18
Transfer Parameters (RS–485) 4—24

U
Unexpected Interrupt 6—8
Unexpected NMI 6—8
Unexpected RST 6—8
User Interface 3—16

V
Vacuum Venturi 3—23
Valve Test 5—21
Valves 3—23
Venturi 3—23
Vibration Problems 7—36
Viscosity Control 3—11

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W
Warning LED 3—17
Warnings (Safety) 2—1
Weight (printer) 1—1
Width Adjuster Unit 4—12

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