Maintenance Manual

7900
Continuous Ink Jet
Printer

MAINTENANCE
MANUAL

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 Amendment record
Each page of this publication bears the date of initial issue. Subsequent amendments to this
publication will bear the amendment number and its date of issue.
Amendments should be incorporated in strict numerical order so that the technical integrity
and accuracy of the publication are retained.
Incorporation of amendments should be recorded on the Amendment Record below.

Amdt Incorporated by Date of Amdt Incorporated by Date of

No. (name) incorporation No. (name) incorporation

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Copyright
No part of this publication may be reproduced, transmitted, transcribed, stored in a
retrieval system, or translated into any human or computer language by any means or in
any form, without the express prior written permission of Linx Printing Technologies Ltd.
Neither whole nor part of the product described in this manual may be adapted or
reproduced in any material form without the express prior written permission of Linx
Printing Technologies Ltd.
Contravention of copyright may also reduce the ability of Linx Printing Technologies Ltd to
provide effective support for its equipment.
This First edition published 2013
© Linx Printing Technologies Ltd 2013
LINX, SureFill, and Easi-Change are registered trademarks of Linx Printing Technologies
Ltd.
Microsoft and Windows are registered trademarks of Microsoft Corporation.

Manual content
The content of this manual is provided for information only. Nothing in the content of this
manual represents, or should be construed as, any contractual or other commitment on the
part of Linx Printing Technologies Ltd.
Linx products are subject to continual development and improvement, and updates to the
content of this manual will be made accordingly in the form of amendments.
Linx reserves the right to make changes without notice to both this publication and to the
products described herein.
All possible care has been taken in the preparation of this manual, and information of a
technical nature and particulars of the product and its use are given by Linx in good faith.
However, Linx makes no guarantees regarding the accuracy or completeness of this
publication.

Safety recommendation
Before attempting to use either the printer or its accessories, the information contained in
the ‘Safety’ chapter should be read. It is essential that safe operating procedures are
followed at all times, and that the equipment is maintained according to the directions
contained herein and as recommended by Linx or its authorized Distributors. It is strongly
recommended that maintenance tasks described in this manual are performed only by Linx
maintenance technicians or Linx-trained personnel.

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About this manual
The purpose of this manual is to provide maintenance technicians with sufficient
information to safely and effectively carry out maintenance tasks on the Linx 7900
Continuous Ink Jet Printer.
The information contained in this manual is applicable to Version 5.2 System Software
unless otherwise stated.
Linx will be pleased to receive any correspondence relating to this manual and the
information contained herein; please write to us at the address below.
For further information or help with Linx products, please contact:
Linx Printing Technologies Ltd
Burrel Road
St Ives
Cambridgeshire
PE27 3LA
UK
Tel: + 44 (0) 1480 302100
Fax: + 44 (0) 1480 302116
E-mail: sales@linx.co.uk
or visit our website at www.linxglobal.com

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 Contents
Amendment record ..................................................................................................iii
Copyright ............................................................................................................ v
Manual content ................................................................................................... v
Safety recommendation...................................................................................... v
About this manual .............................................................................................. vi
Contents ............................................................................................................vii
List of figures .............................................................................................. xv
List of tables ...............................................................................................xxi
Document conventions ................................................................................... xxiii
Text conventions ...................................................................................... xxiii
Other conventions ....................................................................................xxiv
Additional publications....................................................................................xxiv

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

1.1 Introduction............................................................................................. 1—1
1.2 Safety warnings and cautions................................................................. 1—1
1.2.1 Warnings ....................................................................................... 1—1
1.2.2 Cautions ........................................................................................ 1—1
1.2.3 Warning symbols ........................................................................... 1—2
1.3 Lethal voltages ....................................................................................... 1—3
1.4 Inks and solvents.................................................................................... 1—4
1.5 Heavy equipment hazard........................................................................ 1—5
1.6 First aid................................................................................................... 1—5
1.6.1 Procedures .................................................................................... 1—5
1.7 Test printing............................................................................................ 1—6

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

2.1 Introduction............................................................................................. 2—1
2.2 Technical data ........................................................................................ 2—1
2.2.1 Printer configurations..................................................................... 2—1
2.2.2 Environmental................................................................................ 2—2
2.2.3 Electrical ........................................................................................ 2—2
2.2.4 Cabinet .......................................................................................... 2—2
2.2.5 Low voltage power supply unit ...................................................... 2—3
2.2.6 EHT power supply unit .................................................................. 2—3
2.2.7 Ink system ..................................................................................... 2—3
2.2.8 Printhead ....................................................................................... 2—5
2.2.9 Printing performance ..................................................................... 2—6
2.2.10 Memory capacity ......................................................................... 2—8
2.2.11 Regulatory approvals................................................................... 2—8
2.3 Abbreviations and glossary .................................................................... 2—9

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

3.1 Introduction............................................................................................. 3—1
3.2 Cabinet ................................................................................................... 3—1
3.2.1 Introduction.................................................................................... 3—1
3.2.2 Top cover....................................................................................... 3—1

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 3.2.3 Base unit ........................................................................................3—2
3.2.4 Ink system ......................................................................................3—2
3.2.5 Cooling and air filter .......................................................................3—2
3.3 User interface ..........................................................................................3—4
3.3.1 Keyboard and display.....................................................................3—4
3.3.2 Control panel LEDs ........................................................................3—4
3.4 Printhead components ............................................................................3—6
3.4.1 Gun chamber and nozzle assembly ...............................................3—7
3.4.2 Charge electrode............................................................................3—7
3.4.3 Strobe LED.....................................................................................3—7
3.4.4 Deflector plates ..............................................................................3—7
3.4.5 Phase and TOF sensors ................................................................3—7
3.4.6 Printhead cover sensor ..................................................................3—8
3.4.7 Printhead temperature sensor........................................................3—8
3.4.8 Printhead feed and purge valves ...................................................3—9
3.4.9 In-line feed filter..............................................................................3—9
3.4.10 Standard gutter restrictor ...........................................................3—10
3.4.11 In-line gutter check valve ...........................................................3—10
3.4.12 Electrical and fluid connections ..................................................3—10
3.4.13 Dynamic flow control ..................................................................3—11
3.5 Printhead theory of operation ................................................................3—12
3.5.1 Summary ......................................................................................3—12
3.5.2 Printhead types ............................................................................3—12
3.5.3 Modulation....................................................................................3—13
3.5.4 Drop charge .................................................................................3—15
3.5.5 Historic correction ........................................................................3—15
3.5.6 Drop deflection .............................................................................3—16
3.5.7 Guard drops .................................................................................3—16
3.5.8 Phasing ........................................................................................3—17
3.5.9 Time of flight (TOF) ......................................................................3—18
3.5.10 Phase/TOF during a stalled print ...............................................3—18
3.5.11 Viscosity control .........................................................................3—19
3.5.12 Starting up and shutting down....................................................3—19
3.5.13 Jet/nozzle alignment ..................................................................3—20
3.5.14 Print quality ................................................................................3—20
3.5.15 Printhead/nozzle replacement....................................................3—21
3.6 Ink system .............................................................................................3—22
3.6.1 General description ......................................................................3—22
3.6.2 Venturi manifold assembly ...........................................................3—25
3.6.3 Valves ..........................................................................................3—28
3.6.4 Main ink filter ................................................................................3—28
3.6.5 Damper ........................................................................................3—29
3.6.6 Ink system connections ................................................................3—30
3.6.7 Ink and solvent flows ....................................................................3—31
3.6.8 Ink type dependent parameters ...................................................3—37
3.7 Electrical components ...........................................................................3—41
3.7.1 Summary ......................................................................................3—41
3.7.2 Mains electrical supply cable .......................................................3—41
3.7.3 Mains electrical supply switch ......................................................3—41
3.7.4 Power on switch ...........................................................................3—41
3.7.5 Mains electrical supply filter .........................................................3—42
3.7.6 Mains electrical supply fuses .......................................................3—42

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 3.7.7 Low voltage power supply unit (LVPSU) ..................................... 3—42
3.7.8 EHT power supply unit (EHTPSU) .............................................. 3—43
3.7.9 Ink system pump ......................................................................... 3—44
3.7.10 Ink system valves and cableform assembly .............................. 3—44
3.7.11 Cooling fan ................................................................................ 3—45
3.7.12 Printhead positive air pump ....................................................... 3—45
3.8 Electronics and software ...................................................................... 3—46
3.8.1 Summary ..................................................................................... 3—46
3.8.2 System diagram........................................................................... 3—46
3.8.3 IPM PCB...................................................................................... 3—46
3.8.4 Display PCB ................................................................................ 3—55
3.8.5 Auxiliary PCB............................................................................... 3—55
3.8.6 System Software ......................................................................... 3—56
3.9 External signals .................................................................................... 3—56
3.9.1 Primary trigger ............................................................................. 3—56
3.9.2 Secondary trigger ........................................................................ 3—58
3.9.3 Shaft encoders ............................................................................ 3—59
3.9.4 Alarm output ................................................................................ 3—61
3.9.5 Dual alarm ................................................................................... 3—63
3.9.6 Multi-stage alarms ....................................................................... 3—64
3.9.7 Serial interface............................................................................. 3—65
3.9.8 Parallel I/O interface .................................................................... 3—66
3.9.9 Ethernet interface ........................................................................ 3—68
3.9.10 USB facility ................................................................................ 3—68
3.9.11 Alarm and interface upgrade combinations ............................... 3—68
3.9.12 D-type connector assembly ....................................................... 3—69

CHAPTER 4: SYSTEM OPTIONS ................................................. 4—1

4.1 Introduction............................................................................................. 4—1
4.2 Print Monitor ........................................................................................... 4—1
4.2.1 How to select and change options................................................. 4—2
4.2.2 Total system options...................................................................... 4—3
4.2.3 Password access........................................................................... 4—3
4.2.4 Option availability .......................................................................... 4—5
4.3 Line Setup page ..................................................................................... 4—7
4.3.1 Power Down .................................................................................. 4—7
4.4 Menu page.............................................................................................. 4—9
4.4.1 Event Log .................................................................................... 4—10
4.4.2 Maintenance ................................................................................ 4—15
4.4.3 Setup ........................................................................................... 4—16
4.4.4 Change User Level...................................................................... 4—26

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

5.1 Introduction............................................................................................. 5—1
5.2 Maintenance options .............................................................................. 5—1
5.2.1 How to select and change options................................................. 5—1
5.2.2 Total Maintenance options ............................................................ 5—2
5.2.3 Security access levels ................................................................... 5—2
5.2.4 Option availability .......................................................................... 5—3
5.3 Maintenance page .................................................................................. 5—5
5.3.1 Jet Functions ................................................................................. 5—5

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 5.3.2 Monitor Jet .....................................................................................5—8
5.3.3 Maintenance Times ......................................................................5—16
5.3.4 Charge Calibration .......................................................................5—20
5.3.5 Jet Sequences .............................................................................5—21
5.3.6 Valves ..........................................................................................5—25
5.3.7 Test Message...............................................................................5—26
5.3.8 System Flush ...............................................................................5—27
5.3.9 Print and Consumables History....................................................5—29
5.3.10 Software Upgrade ......................................................................5—30
5.4 Maintenance instructions.......................................................................5—33
5.4.1 Double pole/neutral fusing ...........................................................5—33
5.4.2 Introduction ..................................................................................5—33
5.4.3 Maintenance terminology .............................................................5—33
5.4.4 Antistatic precautions ...................................................................5—34
5.4.5 Recommended procedures ..........................................................5—34
5.4.6 7900 CE approval checklist..........................................................5—35
5.4.7 Scheduled Maintenance Checklist ...............................................5—36
5.4.8 Maintenance instruction documents.............................................5—36
Scheduled Maintenance...............................................................5—37
Printhead Cleaning for Pigmented Inks........................................5—47
Draining the Ink System ...............................................................5—51
Spectrum Ink Tank Removal........................................................5—57
Ink Tank Pick-up Tube Replacement ...........................................5—61
3-Way Fluid Connector Filter Replacement .................................5—65
Main Ink Filter Replacement ........................................................5—69
Main Ink Filter Purge ....................................................................5—75
Charge Amplifier Calibration ........................................................5—77
Pressure Transducer Calibration .................................................5—81
Printhead Valves Tests ................................................................5—83
Ink System Feed Valve Test ........................................................5—87
Purge and Gutter Valves Tests ....................................................5—89
Solvent Flush Valve Tests............................................................5—95
Solvent Add Valve Tests ..............................................................5—99
Jet Alignment and Nozzle Cleaning ...........................................5—103
Modulation Range Checks .........................................................5—113
Blocked Gutter Clearance ..........................................................5—117
System Flush .............................................................................5—123
Ink Conversion Calibration (Offset Calibration)..........................5—135
Calibrated Nozzle Replacement (Offset Calibration) .................5—139
Positive Air Pump Installation.....................................................5—145
Printhead Feed Valve Replacement ..........................................5—151
Printhead Feed Valve Filter Replacement .................................5—155
Printer Installation ......................................................................5—159
Correct Installation of Mk7 Printheads .......................................5—161
Changing the Orientation of Mk7 Right-Angled P/HDs ..............5—167
Auto Mains Power-Off Bypass Kit Installation............................5—171
MidiEC Printhead Cleaning ........................................................5—177
Dynamic Flow Control Module Replacement .............................5—183
Printhead Replacement (Printer with DFC)................................5—187
Software Upgrade Using the 7900 Boot PROM.........................5—191
24 Volts Alarm Beacon Installation (Printer Mounted) ...............5—195
Mains (VFC) External Alarm Conversion ...................................5—199

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 Dual Alarm Installation .............................................................. 5—207
Multi-Stage Alarm (24 V) Conversion........................................ 5—217
Multi-Stage Alarm (VFC) Conversion ........................................ 5—223
Parallel I/O Interface Installation ............................................... 5—231
Linx Sync (Service Tool) v4.0 Procedures ................................ 5—235

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

6.1 Introduction............................................................................................. 6—1
6.2 System event identifications ................................................................... 6—2
6.2.1 System Failures............................................................................. 6—2
6.2.2 Print Failures ................................................................................. 6—2
6.2.3 System Warnings .......................................................................... 6—2
6.2.4 Information events ......................................................................... 6—2
6.3 Summary of system events .................................................................... 6—3
6.4 System Failures...................................................................................... 6—4
6.4.1 “1.00 Internal Failure” .................................................................... 6—5
6.4.2 “1.01 Stack Overflow” .................................................................... 6—5
6.4.3 “1.02 Corrupt Program Data”......................................................... 6—5
6.4.4 “1.03 Internal Software Failure” ..................................................... 6—5
6.5 Print Failures .......................................................................................... 6—6
6.5.1 Restart sequence .......................................................................... 6—6
6.5.2 “2.00 Printhead Over Temperature” .............................................. 6—7
6.5.3 “2.01 EHT Trip”.............................................................................. 6—7
6.5.4 “2.02 Phase Failure” ...................................................................... 6—8
6.5.5 “2.03 Time Of Flight Failure”.......................................................... 6—9
6.5.6 “2.04 300V Power Supply”............................................................. 6—9
6.5.7 “2.05 Ink Tank Empty” ................................................................... 6—9
6.5.8 “2.06 Solvent Tank Empty” ............................................................ 6—9
6.5.9 “2.07 Internal Spillage” ................................................................ 6—10
6.5.10 “2.08 Printer Over Temperature” ............................................... 6—10
6.5.11 “2.09 Misaligned Ink Jet” ........................................................... 6—10
6.5.12 “2.11 Pressure Limit Reached”.................................................. 6—11
6.5.13 “2.12 Viscosity” .......................................................................... 6—11
6.5.14 “2.13 Hardware Safety Trip” ...................................................... 6—12
6.5.15 “2.14 Pressure O/ride Circuit Tripped”....................................... 6—12
6.5.16 “2.15 Scheduled Maintenance is overdue by 3 months–Please contact
your local Linx Service Centre immediately” ........................................ 6—12
6.5.17 “2.16 System Configuration Not Recognised” ........................... 6—12
6.6 System Warnings ................................................................................. 6—13
6.6.1 “3.00 Shutdown Incomplete”........................................................ 6—13
6.6.2 “3.01 Shutdown Incomplete (Failure)” ......................................... 6—13
6.6.3 “3.02 Memory Corrupt” ................................................................ 6—13
6.6.4 “3.03 Ink Low”.............................................................................. 6—13
6.6.5 “3.04 Solvent Low”....................................................................... 6—14
6.6.6 “3.05 Over Speed (Print Trigger)”................................................ 6—14
6.6.7 “3.06 Over Speed (Synchronous Data)” ...................................... 6—14
6.6.8 “3.07 Over Speed (Asynchronous Data)” .................................... 6—15
6.6.9 “3.08 Over Speed (Line Speed)” ................................................. 6—15
6.6.10 “3.09 Over Speed (Compensation)” .......................................... 6—15
6.6.11 “3.10 Under Speed (Line Speed)” ............................................. 6—15
6.6.12 “3.11 Printer Requires Scheduled Maintenance”....................... 6—16

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 6.6.13 “3.12 Printhead Cover Off” .........................................................6—16
6.6.14 “3.13 Cover Override Link Fitted” ...............................................6—16
6.6.15 “3.14 Power Off Override Active” ...............................................6—17
6.6.16 “3.15 Safety Override Active” .....................................................6—17
6.6.17 “3.16 Gutter Override Active” .....................................................6—17
6.6.18 “3.17 Gate Array Test Mode Active”...........................................6—18
6.6.19 “3.18 Low Pressure” ...................................................................6—18
6.6.20 “3.19 Valid UNIC Chip Not Found” .............................................6—18
6.6.21 “3.20 No Time Of Flight”.............................................................6—18
6.6.22 “3.21 Ink Low Prevented Mix” ....................................................6—19
6.6.23 “3.22 Fault Prevented Mix” .........................................................6—19
6.6.24 “3.23 Power Off Occurred During Mixing” ..................................6—19
6.6.25 “3.24 Restart In Progress” ..........................................................6—19
6.6.26 “3.25 Ink Unmixed For 4 Weeks”................................................6—19
6.6.27 “3.26 User Data Corrupt–Please contact your local Linx Service
Centre” ..................................................................................................6—19
6.6.28 “3.27 Mix Disabled” ....................................................................6—19
6.6.29 “3.28 Printhead requires cleaning at shutdown”.........................6—19
6.6.30 “3.29 Over Speed (No Remote Data)”........................................6—20
6.6.31 “3.30 Remote Error” ...................................................................6—20
6.6.32 “3.31 Restarted Print Delay”.......................................................6—20
6.6.33 “3.35 Printer Requires Scheduled Maintenance Within One Month”...
6—21

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

7.1 Introduction..............................................................................................7—1
7.2 How to use the flow charts ......................................................................7—1
7.3 First steps................................................................................................7—3
7.4 Fault recording ........................................................................................7—3
7.5 When flow charts seem inappropriate .....................................................7—3
7.6 Miscellaneous faults ................................................................................7—3
7.7 List of flow charts.....................................................................................7—5
FC001 Troubleshooting Start ..................................................................7—6
FC002 Jet................................................................................................7—7
FC003 Modulation ...................................................................................7—8
FC004 Charge.........................................................................................7—9
FC005 Phase ........................................................................................7—10
FC006 Low Pressure ............................................................................7—11
FC007 Ink Quality .................................................................................7—12
FC008 Low Viscosity Ink .......................................................................7—13
FC009 High Viscosity Ink ......................................................................7—14
FC010 EHT Deflection ..........................................................................7—15
FC011 Print ...........................................................................................7—16
FC012 Print Quality ...............................................................................7—17
FC200 2.00 Printhead Over Temperature.............................................7—18
FC201 2.01 EHT Trip ............................................................................7—19
FC202 2.02 Phase Failure ....................................................................7—20
FC203 2.03 Time Of Flight Failure ........................................................7—21
FC204 2.04 300V Power Supply ...........................................................7—22
FC205 2.05 Ink Tank Empty .................................................................7—23
FC206 2.06 Solvent Tank Empty ..........................................................7—24

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 FC207 2.07 Internal Spillage ................................................................ 7—25
FC208 2.08 Printer Over Temperature................................................. 7—26
FC209 2.09 Misaligned Ink Jet ............................................................. 7—27
FC211 2.11 Pressure Limit Reached ................................................... 7—28
FC212 2.12 Viscosity............................................................................ 7—29
FC213 2.13 Hardware Safety Trip........................................................ 7—30
FC999 Final Test .................................................................................. 7—31

CHAPTER 8: TRAINING COURSE GUIDES................................. 8—1

Course One: Printer Operation (Level C & Level A) ..................................... 8—1
Level C: Module 01 – Introduction................................................................ 8—3
Level C: Module 02 – Continuous ink jet printing ......................................... 8—4
Level C: Module 03 – Getting started and printing messages ...................... 8—5
Level C: Module 04 – Navigating the 7900................................................... 8—6
Level C: Module 05 – Creating and editing messages ................................. 8—7
Level C: Module 06 – Stopping print and shutting down .............................. 8—8
Level C: Module 07 – Looking after your printer........................................... 8—9
Level C: Module 08 – Routine maintenance............................................... 8—10
Level C: Module 09 – Line installation........................................................ 8—11
Level C: Module 10 – Review ..................................................................... 8—12
Level A: Module 01 – Introduction .............................................................. 8—13
Level A: Module 02 – Continuous ink jet printing ....................................... 8—14
Level A: Module 03 – Getting started and printing messages .................... 8—15
Level A: Module 06 – Stopping print and shutting down ............................ 8—16
Level A: Module 07 – Looking after your printer ......................................... 8—17
Level A: Module 09 – Line installation ........................................................ 8—18
Level A: Module 10 – Review ..................................................................... 8—19

APPENDIX A: 7900 FOOD GRADE PRINTER..............................A—1

A.1 Introduction ............................................................................................ A—1
A.2 Summary of differences ......................................................................... A—1
A.2.1 Hardware....................................................................................... A—1
A.2.2 Configuration................................................................................. A—1
A.2.3 Software ........................................................................................ A—2
A.2.4 User interface................................................................................ A—2
A.3 Technical Description............................................................................. A—2
A.3.1 Printhead components .................................................................. A—2
A.3.2 Printhead theory of operation........................................................ A—2
A.3.3 Ink system ..................................................................................... A—5
A.3.4 Electrical components ................................................................. A—16
A.3.5 Electronics and software ............................................................. A—17
A.4 System Options.................................................................................... A—18
A.4.1 Option availability ........................................................................ A—18
A.4.2 Line Setup page .......................................................................... A—18
A.4.3 Installation page .......................................................................... A—19
A.5 Maintenance......................................................................................... A—21
A.5.1 Jet Functions............................................................................... A—21
A.5.2 Monitor Jet .................................................................................. A—22
A.5.3 Maintenance Times..................................................................... A—22
A.5.4 Maintenance instructions ............................................................ A—22
A.6 System Events ..................................................................................... A—23

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 A.6.1 Print Failures............................................................................... A—23
A.6.2 System Warnings........................................................................ A—23
A.7 Troubleshooting ................................................................................... A—23
A.7.1 First steps ................................................................................... A—23
FC001 Troubleshooting Start ............................................................... A—24
A.8 Training Course Guides ....................................................................... A—25
A.8.1 Course One: Printer Operation (Level C & Level A) ................... A—25
A.9 Illustrated parts list ............................................................................... A—25
A.9.1 Introduction ................................................................................. A—25
A.10 On-farm egg coding ........................................................................... A—26
A.10.1 Introduction ............................................................................... A—26
A.10.2 Configuration code.................................................................... A—26
A.10.3 Warm-up delay ......................................................................... A—26
A.10.4 Maintenance Times .................................................................. A—26

APPENDIX B: 7900 SPECTRUM PRINTER..................................B—1

B.1 Introduction ............................................................................................ B—1
B.2 B.2 Summary of differences................................................................... B—1
B.2.1 Hardware ...................................................................................... B—1
B.2.2 Configuration ................................................................................ B—1
B.2.3 Software........................................................................................ B—1
B.3 Technical Description............................................................................. B—2
B.3.1 Ink system..................................................................................... B—2
B.3.2 Electrical components................................................................. B—17
B.4 System Options.................................................................................... B—19
B.4.1 Installation page.......................................................................... B—19
B.5 Maintenance ........................................................................................ B—21
B.5.1 Maintenance Times .................................................................... B—21
B.5.2 Valves ......................................................................................... B—21
B.6 System Events ..................................................................................... B—22

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

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 List of figures
Figure Page

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

Figure 1-1. Test printing into a non-metallic container..................................................................1—6

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

Figure 3-1. 7900 (IP65 version) printer base unit and main components.....................................3—3
Figure 3-2. 7900 European user interface ....................................................................................3—5
Figure 3-3. Mk7 Midi printhead main components........................................................................3—6
Figure 3-4. 3-way fluid connector containing the in-line feed filter................................................3—9
Figure 3-5. In-line gutter check valve..........................................................................................3—10
Figure 3-6. Dynamic flow control assembly ................................................................................3—11
Figure 3-7. Modulation of the ink jet by a piezoelectric crystal ...................................................3—13
Figure 3-8. Correct drop break-off in the charge electrode.........................................................3—14
Figure 3-9. Guard drops .............................................................................................................3—16
Figure 3-10. Phase control process............................................................................................3—17
Figure 3-11. Static ink system—standard 7900 printer...............................................................3—24
Figure 3-12. Mk5 venturi manifold assembly ..............................................................................3—25
Figure 3-13. Section view of the venturi .....................................................................................3—26
Figure 3-14. Mk4 venturi.............................................................................................................3—27
Figure 3-15. Ink system 3-way valve ..........................................................................................3—28
Figure 3-16. Main ink filter ..........................................................................................................3—28
Figure 3-17. Damper...................................................................................................................3—29
Figure 3-18. Ink system pipe connections—standard 7900 printer ............................................3—30
Figure 3-19. Primary circuit—standard 7900 printer...................................................................3—32
Figure 3-20. Secondary circuit (normal running after a start purge—standard 7900 printer ......3—33
Figure 3-21. Solvent addition—standard 7900 printer ................................................................3—35
Figure 3-22. Ink system after a successful normal shutdown—standard 7900 printer ...............3—36
Figure 3-23. Ink system pump and motor assembly—standard 7900 printer .............................3—44
Figure 3-24. IPM PCB test points and links locations.................................................................3—54
Figure 3-25. Primary trigger—NPN configuration .......................................................................3—57
Figure 3-26. Primary trigger—PNP configuration .......................................................................3—57
Figure 3-27. Secondary trigger—NPN configuration ..................................................................3—58
Figure 3-28. Secondary trigger—PNP configuration ..................................................................3—58
Figure 3-29. 5 V single-ended shaft encoder connections .........................................................3—60
Figure 3-30. 24 V single-ended shaft encoder connections .......................................................3—60
Figure 3-31. 5 V quadrature shaft encoder connections.............................................................3—60
Figure 3-32. 24 V quadrature shaft encoder connections...........................................................3—61
Figure 3-33. RS-232 interface cable pin connections.................................................................3—65
Figure 3-34. Parallel I/O PCB links .............................................................................................3—67
Figure 3-35. Correct assembly of the IP67 D-type connector.....................................................3—69

CHAPTER 4: SYSTEM OPTIONS .................................................................... 4—1

Figure 4-1. Print Monitor page ......................................................................................................4—1
Figure 4-2. Soft keys and related options .....................................................................................4—2
Figure 4-3. Total Menu page options............................................................................................4—3
Figure 4-4. Change User Level page............................................................................................4—4
Figure 4-5. Line Setup page .........................................................................................................4—7
Figure 4-6. Power Down page ......................................................................................................4—8
Figure 4-7. Menu page .................................................................................................................4—9
Figure 4-8. Current Events page ................................................................................................4—10
Figure 4-9. Event History page ...................................................................................................4—10
Figure 4-10. Track New Events option .......................................................................................4—11
Figure 4-11. Event Filtering page ...............................................................................................4—12
Figure 4-12. Clear Event History page .......................................................................................4—13
Figure 4-13. Event Setup page...................................................................................................4—13
Figure 4-14. Always Log option ..................................................................................................4—14

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Figure 4-15. Never Log option ................................................................................................... 4—14
Figure 4-16. Edit Interval page................................................................................................... 4—15
Figure 4-17. Setup page ............................................................................................................ 4—16
Figure 4-18. Installation page..................................................................................................... 4—16
Figure 4-19. Date & Time page.................................................................................................. 4—17
Figure 4-20. Printhead page ...................................................................................................... 4—18
Figure 4-21. Printhead conduit label .......................................................................................... 4—19
Figure 4-22. ID page .................................................................................................................. 4—20
Figure 4-23. Ink/Solvent page .................................................................................................... 4—22
Figure 4-24. Locale page ........................................................................................................... 4—23
Figure 4-25. Photocells page ..................................................................................................... 4—25
Figure 4-26. Change User Level page ....................................................................................... 4—26

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

Figure 5-1. Soft keys and related options .................................................................................... 5—1
Figure 5-2. Total Maintenance options......................................................................................... 5—2
Figure 5-3. Maintenance page ..................................................................................................... 5—5
Figure 5-4. Jet Functions page .................................................................................................... 5—5
Figure 5-5. Monitor Jet page ........................................................................................................ 5—8
Figure 5-6. Edit Pressure page .................................................................................................... 5—9
Figure 5-7. Edit Modulation page ............................................................................................... 5—12
Figure 5-8. TOF Mode page....................................................................................................... 5—14
Figure 5-9. Maintenance Times page ........................................................................................ 5—16
Figure 5-10. Enter Easi-Change Code page.............................................................................. 5—19
Figure 5-11. Charge Calibration page........................................................................................ 5—20
Figure 5-12. Jet Sequences page .............................................................................................. 5—21
Figure 5-13. Valves page ........................................................................................................... 5—25
Figure 5-14. Test Message page ............................................................................................... 5—26
Figure 5-15. Test Message—Save As page .............................................................................. 5—27
Figure 5-16. System Flush—first preparation page ................................................................... 5—28
Figure 5-17. System Flush—options page................................................................................. 5—28
Figure 5-18. Print and Consumables History page .................................................................... 5—29
Figure 5-19. Software Upgrade verification page....................................................................... 5—31

Scheduled Maintenance .......................................................................................................... 5—37

Figure 1. Removing the 7900 (IP65 version) air filter................................................................. 5—42
Figure 2. Removing the 7900 (IP55 version) air filter................................................................. 5—42

Printhead Cleaning for Pigmented Inks ................................................................................. 5—47

Figure 1. Correct area of the printhead to wash with solvent..................................................... 5—48
Figure 2. Correct area of the printhead to clean with the brush ................................................. 5—49
Figure 3. Washing the printhead cover tube with solvent .......................................................... 5—50

Draining the Ink System .......................................................................................................... 5—51

Figure 1. System Flush—first page............................................................................................ 5—52
Figure 2. Damper orientation and drain tube—standard 7900................................................... 5—53
Figure 3. Damper orientation and drain tube—7900 Food Grade and 7900 Spectrum ............. 5—53
Figure 4. System Flush options page......................................................................................... 5—54
Figure 5. Empty Tank sequence in progress ............................................................................. 5—55

Spectrum Ink Tank Removal ................................................................................................... 5—57

Figure 1. 7900 Spectrum ink tank .............................................................................................. 5—58

Ink Tank Pick-up Tube Replacement...................................................................................... 5—61

Figure 1. Ink tank pick-up tube and filter assembly.................................................................... 5—61
Figure 2. Correct assembly of the ink pick-up tube fluid connection.......................................... 5—62

3-Way Fluid Connector Filter Replacement........................................................................... 5—65

Figure 1. 3-way fluid connector disassembled ........................................................................... 5—66

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Main Ink Filter Replacement ....................................................................................................5—69
Figure 1. Correct assembly of the main ink filter fluid connections.............................................5—70
Figure 2. One end of the main ink filter enclosed in a protective glove ......................................5—71
Figure 3. Both ends of the main ink filter enclosed in protective gloves .....................................5—72

Charge Amplifier Calibration ...................................................................................................5—77

Figure 1. Calibration Mode page ................................................................................................5—78

Printhead Valves Tests ............................................................................................................5—83

Figure 1. Entering a Set Pressure of 4.49 bar on the Edit Pressure page..................................5—83
Figure 2. Feed Valve open on the Valves page..........................................................................5—84
Figure 3. Jet Test – Start option on the Jet Functions page .......................................................5—85

Ink System Feed Valve Test.....................................................................................................5—87

Figure 1. Entering a Set Pressure of 4.49 bar on the Edit Pressure page..................................5—87
Figure 2. Printhead Feed valve open on the Valves page..........................................................5—88

Purge and Gutter Valves Tests................................................................................................5—89

Figure 1. Jet Test – Start option on the Jet Functions page .......................................................5—90
Figure 2. Purge/Gutter Test fluid connector fitted in the 3-way fluid connector ..........................5—91
Figure 3. Testing for a leaking Purge or Gutter valve (closed) ...................................................5—92
Figure 4. Nozzle Clear option on the Jet Sequences page ........................................................5—93

Solvent Flush Valve Tests .......................................................................................................5—95

Figure 1. Jet Test – Start option on the Jet Functions page .......................................................5—96
Figure 2. Solvent Flush valve open on the Valves page.............................................................5—96
Figure 3. Nozzle Clear option on the Jet Sequences page ........................................................5—97
Figure 4. Creating bubbles to test the Solvent Flush valve for leaks..........................................5—97

Solvent Add Valve Tests ..........................................................................................................5—99

Figure 1. Creating bubbles to test the Solvent Add valve for leaks ..........................................5—100
Figure 2. Entering a Set Pressure of 4.49 bar on the Edit Pressure page................................5—100
Figure 3. Solvent Add valve open on the Valves page .............................................................5—101

Jet Alignment and Nozzle Cleaning ......................................................................................5—103

Figure 1. Jet Test – Start option on the Jet Functions page .....................................................5—104
Figure 2. Correct alignment of the jet into the gutter ................................................................5—104
Figure 3. Correct alignment of the jet from the nozzle..............................................................5—105
Figure 4. Nozzle Clear option on the Jet Sequences page ......................................................5—105
Figure 5. Nozzle Clear sequence—applying solvent to the nozzle face ...................................5—106
Figure 6. Suspending the nozzle in a beaker of solvent ...........................................................5—107
Figure 7. Feed and Printhead Feed valves open on the Valves page......................................5—110

Modulation Range Checks.....................................................................................................5—113

Figure 1. Creating a test message on the Test Message page ................................................5—113
Figure 2. Jet Test – Start and Start Print options on the Jet Functions page ...........................5—114
Figure 3. Reference Modulation value on the Monitor Jet page ...............................................5—114
Figure 4. Changing the Actual Modulation value on the Edit Modulation page ........................5—115
Figure 5. Under modulation—expected deterioration when Reference Mod is < Vm1.............5—115
Figure 6. Over modulation—expected deterioration when Reference Mod is > Vm2...............5—115

Blocked Gutter Clearance......................................................................................................5—117

Figure 1. Gutter Clear fluid connector fitted in the 3-way fluid connector .................................5—119
Figure 2. Removal of the DFC pipe connections ......................................................................5—119
Figure 3. Gutter line connection................................................................................................5—120
Figure 4. Entering a Set Pressure of 4.49 bar on the Edit Pressure page................................5—120
Figure 5. Feed Valve open on the Valves page........................................................................5—121

System Flush ..........................................................................................................................5—123

Figure 1. System Flush—first page ..........................................................................................5—128
Figure 2. Damper orientation and drain tube—standard 7900 .................................................5—129

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Figure 3. Damper orientation and drain tube—7900 Food Grade and 7900 Spectrum ........... 5—130
Figure 4. System Flush options page....................................................................................... 5—130
Figure 5. Empty Tank sequence in progress ........................................................................... 5—131
Figure 6. System Flush options page—Empty Tank sequence count of 1 .............................. 5—132
Figure 7. System Flush options page—Flush Cycle sequence count of 1............................... 5—133
Figure 8. Entering a Set Pressure of 4.49 bar on the Edit Pressure page ............................... 5—134

Ink Conversion Calibration (Offset Calibration).................................................................. 5—135

Figure 1. Reference Pressure value on the Printhead Code page .......................................... 5—136
Figure 2. Reference Modulation value on the Printhead Code page ....................................... 5—137
Figure 3. Correct fitting of the printhead calibration label on the conduit ................................. 5—138

Calibrated Nozzle Replacement (Offset Calibration) .......................................................... 5—139

Figure 1. Reference Pressure value on the Printhead Code page .......................................... 5—141
Figure 2. Reference Modulation value on the Printhead Code page ....................................... 5—142
Figure 3. Jet Test – Start option on the Jet Functions page .................................................... 5—142
Figure 4. Correct alignment of the jet into the gutter................................................................ 5—143
Figure 5. Correct fitting of the printhead calibration label on the conduit ................................. 5—144

Positive Air Pump Installation .............................................................................................. 5—145

Figure 1. Connecting and fitting the printhead positive air pump—IP65 printer....................... 5—146
Figure 2. Printhead positive air pipe outlet............................................................................... 5—147
Figure 3. Connecting and fitting the printhead positive air pump—IP55 printer....................... 5—148

Printhead Feed Valve Replacement ..................................................................................... 5—151

Figure 1. Printhead upper cover and securing screw(s) .......................................................... 5—152
Figure 2. Printhead Feed valve assembly................................................................................ 5—152
Figure 3. Printhead Feed valve component parts .................................................................... 5—153

Printhead Feed Valve Filter Replacement............................................................................ 5—155

Figure 1. Printhead upper cover and securing screw(s) .......................................................... 5—155
Figure 2. Printhead Feed valve assembly................................................................................ 5—156
Figure 3. Printhead Feed valve component parts .................................................................... 5—156

Changing the Orientation of Mk7 Right-Angled P/HDs ...................................................... 5—167

Figure 1. Removing the right-angle adaptor top section .......................................................... 5—167
Figure 2. Changing the orientation of the right-angle adaptor bottom section ......................... 5—168

Auto Mains Power-Off Bypass Kit Installation .................................................................... 5—171

Figure 1. Location of the auto power on/off connector PL20 on the IPM PCB......................... 5—172
Figure 2. Printer rear view showing the auto power on/off cableform connections.................. 5—172
Figure 3. Printer front view showing the auto power on/off cableform connections ................. 5—173
Figure 4. Auto mains power-off bypass kit ............................................................................... 5—174

MidiEC Printhead Cleaning ................................................................................................... 5—177

Figure 1. Area of the printhead to wash with solvent ............................................................... 5—178
Figure 2. Printhead components to clean with the swabs........................................................ 5—179
Figure 3. Identification of the printhead components ............................................................... 5—180
Figure 4. Washing the printhead cover tube with solvent ........................................................ 5—181

Dynamic Flow Control Module Replacement ...................................................................... 5—183

Figure 1. DFC module removal ................................................................................................ 5—184
Figure 2. DFC module cableform and connectors ................................................................... 5—184
Figure 3. DFC module cableform routing ................................................................................. 5—185

Printhead Replacement (Printer with DFC).......................................................................... 5—187

Figure 1. Printhead removal..................................................................................................... 5—188
Figure 2. Printhead fitting ......................................................................................................... 5—189
Figure 3. DFC module cableform—location of position 15 on PL6 .......................................... 5—189
Figure 4. DFC module cableform—control signal connector ‘A’ .............................................. 5—190

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Software Upgrade Using the 7900 Boot PROM....................................................................5—191
Figure 1. “Verifying USB Firmware” message ..........................................................................5—192
Figure 2. “Insert USB” instruction .............................................................................................5—192
Figure 3. Download progress....................................................................................................5—193
Figure 4. “Reprogramming Complete ...” instruction.................................................................5—193

24 Volts Alarm Beacon Installation (Printer Mounted)........................................................5—195

Figure 1. Alarm beacon mounting bracket fitted to the stalk assembly ....................................5—195
Figure 2. Fitting the alarm beacon to the rear of the printer .....................................................5—196
Figure 3. Alarm Setup page — “3.12 Printhead Cover Off” set to Constant .............................5—197

Mains (VFC) External Alarm Conversion..............................................................................5—199

Figure 1. Alarm Setup page — “3.12 Printhead Cover Off” set to Constant .............................5—201
Figure 2. Alarm Setup page — “3.12 Printhead Cover Off” set to Constant .............................5—202
Figure 3. Assembly of the Mains (VFC) External Alarm external connector.............................5—205
Figure 4. Mains (VFC) External Alarm connector details..........................................................5—206

Dual Alarm Installation...........................................................................................................5—207

Figure 1. Front view of the 7900 Dual Alarm option plate.........................................................5—209
Figure 2. Alarm Setup page — “3.12 Printhead Cover Off” set to Constant .............................5—211
Figure 3. Alarm Setup page — “3.12 Printhead Cover Off” set to Constant .............................5—212
Figure 4. Assembly of the Mains (VFC) External Alarm external connector.............................5—214
Figure 5. Mains (VFC) External Alarm connector details..........................................................5—215

Multi-Stage Alarm (24 V) Conversion....................................................................................5—217

Figure 1. Alarm (24 V), Ethernet and Parallel I/O option plate .................................................5—219
Figure 2. Multi-Stage Alarm PCB details ..................................................................................5—219
Figure 3. Multi-Stage Alarm (24 V) connector details ...............................................................5—221

Multi-Stage Alarm (VFC) Conversion....................................................................................5—223

Figure 1. Alarm (VFC), Ethernet and Parallel I/O option plate..................................................5—225
Figure 2. Multi-Stage Alarm PCB details ..................................................................................5—226
Figure 3. Assembly of the Multi-Stage Alarm (VFC) external connector ..................................5—229
Figure 4. Multi-Stage Alarm (VFC) connector details ...............................................................5—229

Parallel I/O Interface Installation ...........................................................................................5—231

Figure 1. Front view of the 7900 Alarm, Ethernet and Parallel I/O option plate........................5—233

Linx Sync (Service Tool) v4.0 Procedures ...........................................................................5—235

Figure 1. Connected printers in the Linx Sync window.............................................................5—237
Figure 2. Dragging and dropping the system software file .......................................................5—238
Figure 3. Copying and pasting the system software file ...........................................................5—238
Figure 4. Downloading the system software file using the Download menu command ............5—239
Figure 5. “Maintain the store during download?” message dialog box .....................................5—239
Figure 6. Download progress dialog box ..................................................................................5—240
Figure 7. “Maintain the store backed up last time?” message dialog box.................................5—242
Figure 8. Changing the base directory of the backup files........................................................5—243
Figure 9. Selecting a printer to back up ....................................................................................5—244
Figure 10. Named backup file in the printer’s backup directory................................................5—244
Figure 11. Selecting a backup file to restore to a printer ..........................................................5—245
Figure 12. Transferring data items from a printer .....................................................................5—246
Figure 13. Transferring data types from a printer to a backup..................................................5—246
Figure 14. Transferring data items from a backup....................................................................5—247
Figure 15. Transferring data types from a backup....................................................................5—247
Figure 16. Transferring data items from a PC ..........................................................................5—248

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

Figure 6-1. System Event page ....................................................................................................6—1

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CHAPTER 7: TROUBLESHOOTING ................................................................7—1
Figure 7-1. Simple flow chart example......................................................................................... 7—1
Figure 7-2. How to use a flow chart ............................................................................................. 7—2
Figure 7-3. FC001 Troubleshooting Start..................................................................................... 7—6
Figure 7-4. FC002 Jet .................................................................................................................. 7—7
Figure 7-5. FC003 Modulation ..................................................................................................... 7—8
Figure 7-6. FC004 Charge ........................................................................................................... 7—9
Figure 7-7. FC005 Phase........................................................................................................... 7—10
Figure 7-8. FC006 Low Pressure ............................................................................................... 7—11
Figure 7-9. FC007 Ink Quality .................................................................................................... 7—12
Figure 7-10. FC008 Low Viscosity Ink ....................................................................................... 7—13
Figure 7-11. FC009 High Viscosity Ink....................................................................................... 7—14
Figure 7-12. FC010 EHT Deflection........................................................................................... 7—15
Figure 7-13. FC011 Print............................................................................................................ 7—16
Figure 7-14. FC012 Print Quality ............................................................................................... 7—17
Figure 7-15. FC200 2.00 Printhead Over Temperature ............................................................. 7—18
Figure 7-16. FC201 2.01 EHT Trip............................................................................................. 7—19
Figure 7-17. FC202 2.02 Phase Failure..................................................................................... 7—20
Figure 7-18. FC203 2.03 Time Of Flight Failure ........................................................................ 7—21
Figure 7-19. FC204 2.04 300V Power Supply ........................................................................... 7—22
Figure 7-20. FC205 2.05 Ink Tank Empty .................................................................................. 7—23
Figure 7-21. FC206 2.06 Solvent Tank Empty........................................................................... 7—24
Figure 7-22. FC207 2.07 Internal Spillage ................................................................................. 7—25
Figure 7-23. FC208 2.08 Printer Over Temperature .................................................................. 7—26
Figure 7-24. FC209 2.09 Misaligned Ink Jet .............................................................................. 7—27
Figure 7-25. FC211 2.11 Pressure Limit Reached..................................................................... 7—28
Figure 7-26. FC212 2.12 Viscosity............................................................................................. 7—29
Figure 7-27. FC213 2.13 Hardware Safety Trip ......................................................................... 7—30
Figure 7-28. FC999 Final Test ................................................................................................... 7—31

APPENDIX A: 7900 FOOD GRADE PRINTER ................................................ A—1

Figure A-1. Static ink system—7900 Food Grade printer ............................................................ A—7
Figure A-2. Damper...................................................................................................................... A—8
Figure A-3. Ink system pipe connections—7900 Food Grade printer .......................................... A—9
Figure A-4. Primary circuit—7900 Food Grade printer............................................................... A—11
Figure A-5. Secondary circuit (normal running after a start purge)—7900 Food Grade printer . A—12
Figure A-6. Solvent addition—7900 Food Grade printer............................................................ A—14
Figure A-7. Ink system after a successful normal shutdown—7900 Food Grade printer........... A—15
Figure A-8. Dual-circuit pump ink flows...................................................................................... A—16
Figure A-9. Power Down page ................................................................................................... A—18
Figure A-10. Printhead page ...................................................................................................... A—19
Figure A-11. Ink/Solvent page.................................................................................................... A—20
Figure A-12. Advisory message for minimum run time override ................................................ A—21
Figure A-13. FC001 7900 Food Grade printer Troubleshooting Start........................................ A—24

APPENDIX B: 7900 SPECTRUM PRINTER .................................................... B—1

Figure B-1. Static ink system—7900 Spectrum printer ................................................................ B—4
Figure B-2. Mk1 venturi manifold assembly and valves—7900 Spectrum printer........................ B—5
Figure B-3. Damper...................................................................................................................... B—6
Figure B-4. Ink system pipe connections—7900 Spectrum printer .............................................. B—7
Figure B-5. Primary circuit—7900 Spectrum printer .................................................................... B—9
Figure B-6. Secondary circuit (normal running after a start purge—7900 Spectrum printer ...... B—10
Figure B-7. Solvent addition—7900 Spectrum printer................................................................ B—12
Figure B-8. Ink mixing—7900 Spectrum printer ......................................................................... B—15
Figure B-9. Ink system after a successful normal shutdown—7900 Spectrum printer............... B—16
Figure B-10. Ink system pump and motor assembly—7900 Spectrum printer........................... B—17
Figure B-11. Ink/Solvent page.................................................................................................... B—19
Figure B-12. Valves page........................................................................................................... B—21

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 List of tables
Table Page

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

Table 2-1. Printer types ................................................................................................................2—1
Table 2-2. Printer configurations...................................................................................................2—1

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

Table 3-1. Ink type dependent parameters table (Ultima printhead) ..........................................3—37
Table 3-2. Ink type dependent parameters table (Midi printhead) ..............................................3—37
Table 3-3. Ink type dependent parameters table (Ultima A printhead) .......................................3—38
Table 3-4. Ink type dependent parameters table (Midi A printhead)...........................................3—38
Table 3-5. Ink type dependent parameters table (MidiEC printhead) .........................................3—38
Table 3-6. Ink type dependent parameters table (Mini printhead) ..............................................3—39
Table 3-7. Ink type dependent parameters table (Micro printhead) ............................................3—39
Table 3-8. Ink type dependent parameters table (Ultima plus printhead)...................................3—40
Table 3-9. Ink type dependent parameters table (Midi plus printhead) ......................................3—40
Table 3-10. LVPSU input details.................................................................................................3—42
Table 3-11. LVPSU output details ..............................................................................................3—43
Table 3-12. EHTPSU input/output details...................................................................................3—43
Table 3-13. Valve cableform connections...................................................................................3—45
Table 3-14. IPM PCB link default positions ................................................................................3—53
Table 3-15. Fault conditions and actions ....................................................................................3—55
Table 3-16. 24 volts external alarm pin connections ..................................................................3—61
Table 3-17. Mains (VFC) external alarm pin connections...........................................................3—62
Table 3-18. Multi-stage alarm (24 V) pin connections ................................................................3—64
Table 3-19. Multi-stage alarm (VFC) pin connections ................................................................3—64
Table 3-20. Parallel I/O interface pin connections ......................................................................3—67
Table 3-21. Alarm and interface upgrade combinations .............................................................3—68

CHAPTER 4: SYSTEM OPTIONS .................................................................... 4—1

Table 4-1. System options availability table..................................................................................4—5
Table 4-2. Gregorian calendars ..................................................................................................4—24

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

Table 5-1. Maintenance options availability table .........................................................................5—3
Table 5-2. Pressure conversion table .........................................................................................5—11
Table 5-3. Basic scheduled maintenance intervals ....................................................................5—18

Main Ink Filter Replacement ....................................................................................................5—69

Table 1. Main ink filter inlet and outlet pipe lengths....................................................................5—70

Ink Conversion Calibration (Offset Calibration) ..................................................................5—135

Table 1. Example of a Reference Pressure and Reference Modulation offset table ................5—136

Calibrated Nozzle Replacement (Offset Calibration)...........................................................5—139

Table 1. Example of a Reference Pressure and Reference Modulation offset table ................5—141

Mains (VFC) External Alarm Conversion..............................................................................5—199

Table 1. Mains (VFC) External Alarm ratings specification ......................................................5—204
Table 2. External connector cable specification .......................................................................5—204

Dual Alarm Installation...........................................................................................................5—207

Table 1. Mains (VFC) External Alarm ratings specification ......................................................5—213
Table 2. External connector cable specification .......................................................................5—213

Multi-Stage Alarm (VFC) Conversion....................................................................................5—223

Table 1. Multi-Stage Alarm (VFC) ratings specification ............................................................5—228

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Table 2. External connector cable specification....................................................................... 5—228

Linx Sync (Service Tool) v4.0 Procedures........................................................................... 5—235

Table 1. Linx Sync compatibility issues.................................................................................... 5—235

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

Table 6-1. System events summary table.................................................................................... 6—3

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

Table 7-1. Miscellaneous faults.................................................................................................... 7—3
Table 7-2. Flow chart record sheet .............................................................................................. 7—4
Table 7-3. List of troubleshooting flow charts............................................................................... 7—5

APPENDIX A: 7900 FOOD GRADE PRINTER ................................................ A—1

Table A-1. 7900 Food Grade printer parts ................................................................................. A—25

APPENDIX B: 7900 SPECTRUM PRINTER .................................................... B—1

Table B-1. Ink Mixing sequence timings .................................................................................... B—13
Table B-2. Valve cableform connections.................................................................................... B—18

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Document conventions
Text conventions
The following text conventions are used throughout this maintenance manual for
identification and emphasis.

Display elements
Bold text is used to identify the following:
 Page names, options and items. For example, the Print Monitor page; the Service page;
the Monitor Jet option on the Service page; the Modulation item on the Monitor Jet
page.
 Operator input in procedures. For example:
“In the Enter password for required level text box, type: ADMIN”

Control panel and keyboard keys

The word ‘key’ in this manual describes any of the keys physically located on the printer
control panel and the keyboard. Keys are always ‘pressed’ to achieve an effect.
Reference to a key on the control panel or keyboard is made as follows:
… press the [stop] key to …
… press the [alt] key to …
This identifies the key labelled ‘stop’ on the control panel and the key labelled ‘alt’ on the
keyboard.

Cross-references
Where a cross-reference is made to another chapter, section or subsection within this
manual (an internal cross-reference), the reference is shown as follows:
… refer to ‘Password Access’ in Chapter 4: ‘System Options’ …
Alternatively, where a cross-reference is made to a specific page element, a route reference
is used, for example:
… refer to Chapter 5: Maintenance Page > Charge Calibration > Calibration
Mode …
This method is also used to show the location of an item in the menu structure of the
printer, for example:
… select the Jet Test – Start option (Print Monitor > Menu > Maintenance > Jet
Functions > Jet Test – Start) …
Refer to the ‘Contents’ and ‘Index’ pages to locate the references quickly.
Where a cross-reference is made to another publication (an external cross-reference), the
reference is shown in italics, as follows:
… refer to the Linx Remote Communications Interface Reference Manual …

Amended content
Changes to text and illustrations on amendment pages are indicated by a vertical line in the
left margin.

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Linx 7900 Maintenance Manual (xxiii) Oct 2013
 Printer models
There are four 7900 printer models: 7900 (IP55 version), 7900 (IP65 version), 7900 Spectrum,
and 7900 Food Grade. Where a single model is referred to in this manual, the printer name is
shown in italics (as shown in the previous sentence). Where information is applicable only
to the 7900 (IP55 version) and the 7900 (IP65 version) printers (that is, not a Food Grade or
Spectrum printer), the printer is referred to as ‘standard 7900’ in plain text. Information that
is common to all printer models is referred to generically as ‘7900’ in plain text.

Other conventions
The following types of annotation are used in this manual to identify and to draw the
reader’s attention to particular types of information.

Important Note symbol

The pointing hand symbol is shown beside an IMPORTANT Note to indicate that the
information given is essential to the completion of a task.

Notes
Notes are used to provide additional information that may apply in special cases, such as
memory limitations, printer configuration, or details that apply to specific versions of
system software.

Additional publications
Additional information about the Linx 7900 Continuous Ink Jet Printer is provided in the
following publications. These publications are available from Linx or from your Linx
Distributor, or can be downloaded from ExtraLinx:
1. Linx 5900 & 7900 Quick Start Guide (part number FA69315).
This document provides instructions on the basic operator functions of the printer, and
how to carry out routine maintenance.
 Linx 5900 & 7900 How To ... guides.
These documents provide details of how to use the more complex functions of the
printer.
 Printer Care Card, English (part number FA68022).
The card contains basic routine maintenance and safety information, and is designed to
be printed and positioned near the printer.
 Linx Remote Communications Interface Reference Manual (available on CD only—part
number FA76014).
This manual describes the RS-232 communications protocol for Linx printers. It also
includes information on printer setup and hardware connections.
 For information about spare parts, refer to ExtraLinx or the Linx 7900 Service Information
CD provided with this manual.

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Oct 2013 (xxiv) Linx 7900 Maintenance Manual
 CHAPTER 1: SAFETY
1.1 Introduction

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

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

1.2 Safety warnings and cautions

Warning and Caution statements are provided within the text of this manual. These
statements advise the reader of potential hazards, how to prevent them and how to safely
use a product. A Warning statement always includes a related warning symbol.
The definitions of Warning and Caution statements are given below, with the text
conventions used in this manual.

1.2.1 Warnings
A Warning advises the reader of a hazard that can cause loss of life, injury or illness. The
statement is printed in bold capital letters and includes a warning symbol that identifies the
type of hazard.

1.2.2 Cautions
A Caution advises the reader of actions that can damage equipment or the environment,
but are not a direct danger to personnel. The statement is printed in bold lower-case letters
and does not include a symbol.

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 1.2.3 Warning symbols
The following subsections describe the different types of warning symbols.

Eye protection

The mandatory Eye Protection warning symbol indicates that safety eye glasses must be
worn when any work is done that includes contact with inks or solvents. The safety eye
glasses must be an approved type according to European and international safety
standards.

Hand protection

The mandatory Hand Protection warning symbol indicates that solvent-resistant protective
gloves must be worn when any work is done that includes hand contact with inks or
solvents.

Irritant substance hazard

The Irritant Warning symbol indicates that a substance can cause irritation to the eyes and
the respiratory system if the correct safety precautions are not taken.

Electric shock hazard

The Lethal Voltage warning symbol indicates that there is a risk of electric shock from
possible lethal voltages if the correct safety precautions are not taken.

Fire hazard

The Highly Flammable warning symbol indicates that there is a risk of fire from a highly
flammable type of material if the correct safety precautions are not taken.

Hot surface hazard

The Hot Surface Warning symbol indicates that there is a risk of skin burns from contact
with a hot surface if the correct safety precautions are not taken.

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 General hazard

The General warning symbol is shown with a Warning statement that does not have a
special symbol to indicate the hazard. The Warning advises the reader of other activities
that can be harmful or lethal.

1.3 Lethal voltages

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

EQUIPMENT IS PROTECTED BY DOUBLE-POLE FUSING. THAT IS, FUSES ARE FITTED IN THE
LIVE AND NEUTRAL CONDUCTORS OF THE MAINS ELECTRICAL SUPPLY. IF THE NEUTRAL
FUSE OPERATES, PARTS OF THE EQUIPMENT THAT REMAIN ENERGIZED CAN BE AN
ELECTRICAL HAZARD DURING MAINTENANCE WORK.
TURN OFF AND DISCONNECT THE PRINTER FROM THE MAINS ELECTRICAL SUPPLY
BEFORE THE COVER IS REMOVED.

THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS SAFETY

WARNING IS IGNORED.

WARNING: LETHAL VOLTAGE HAZARD. DANGEROUS VOLTAGES EXIST IN THIS

EQUIPMENT WHEN ELECTRICAL POWER IS APPLIED.
MAXIMUM CARE MUST BE TAKEN WHEN ANY WORK IS DONE ON THE PRINTER WHILE
ELECTRICAL POWER IS APPLIED AND THE COVER IS REMOVED. THE CORRECT,
STANDARD ELECTRICAL SAFETY PRECAUTIONS MUST BE TAKEN.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS SAFETY
WARNING IS IGNORED.
When the printer cabinet cover is removed, the mains electrical supply and the 300 volts DC
supply can be accessed.
To protect against the danger of electric shock, printing is stopped when the printhead
cover tube is removed. Also, the charge electrode voltage is decreased to less than 10 volts
instead of the normal 300 volts, and the +8 kV supply to the deflector plates is turned off.

WARNING: THIS PRINTER MUST BE EARTHED.

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1.4 Inks and solvents

WARNING: HAZARDOUS SUBSTANCES. THIS PRINTER USES SOLVENT AND

SOLVENT-BASED INKS THAT CAN BE HAZARDOUS. THESE INKS AND SOLVENTS ARE
HIGHLY FLAMMABLE, AND THE LIQUID, VAPOUR OR SPRAY CAN CAUSE IRRITATION TO
THE EYES AND SKIN.
WEAR SAFETY EYE GLASSES AND SOLVENT-RESISTANT PROTECTIVE GLOVES WHEN
THERE IS DIRECT CONTACT WITH THE INKS AND SOLVENTS, WHEN WORK IS DONE ON THE
PRINTER, AND WHEN THE PRINTER IS CLEANED.
THERE IS A RISK OF SEVERE IRRITATION AND TEMPORARY (REVERSIBLE) DAMAGE TO
THE EYES, AND IRRITATION OF THE SKIN IF THIS SAFETY WARNING IS IGNORED.
Solvents and inks can be harmful. When inks and solvents are used, the following necessary
precautions must be taken:
 Before work is started on the printer, read the applicable ink and solvent Material
Safety Data Sheets. If you do not completely understand the information, or are not
sure, contact Linx for instruction.
If the Material Safety Data Sheets have not been supplied or are not available, contact
Linx for copies. Always refer to the Material Safety Data Sheets before inks and solvents
are used.
 Do not smoke or use open flames near the printer, or ink and solvent storage areas and
containers.
 Make sure that the printing area has good ventilation when the printer is in operation,
when work is done on the printer, and when inks and solvents are used.
 Wear safety eyeglasses when inks and solvents are used, or when the printer is
examined or repaired. The safety eyeglasses must be an approved type according to
European and international safety standards. The Eye Protection Warning symbol is
shown in this manual, where applicable, to indicate the mandatory requirement to
wear safety eyeglasses.
 Wear solvent-resistant gloves when inks and solvents are used, when the printer is
examined or repaired, or at any time that hand contact with inks or solvents is possible.
The Hand Protection Warning symbol is shown in this manual, where applicable, to
indicate the mandatory requirement to wear safety gloves.
 Barrier creams can help to protect areas of bare skin, but they do not give the same level
of protection as safety gloves. Barrier creams must not be applied after exposure to ink
or solvent has occurred.
 Never use cleaning fluids or solvents to remove ink from the skin; use an approved skin
cleanser.
 Never look into the end of the printhead or point the printhead at any person while the
printer is turned on.
 Do not overfill the ink and solvent tanks of the printer. Refer to the Linx 5900 & 7900
Quick Start Guide for information on how to correctly refill the ink system.
 Remove all ink and solvent spillage immediately from the interior and exterior of the
printer, and from the area around the printer. Use the correct solvent type for the
related ink type to remove ink spillage.
 Remove any increased ink deposits from the interior of the printer with the correct
solvent type for the related ink type.

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  Store all inks and solvents in their original containers, which must be tightly closed.
Store the containers in a cabinet with good air circulation or in a recommended
flameproof storage container. Inks and solvents must be kept away from any source of
heat or ignition.
 All waste ink and solvent must be discarded correctly, according to local regulations
and must not be allowed to enter the water drainage system.

1.5 Heavy equipment hazard

WARNING: HEAVY EQUIPMENT HAZARD. THE WEIGHT OF THE 7900 CIJ PRINTER IS
APPROXIMATELY 25.0 KG WHEN THE INK AND SOLVENT TANKS ARE FULL.
CARE MUST BE TAKEN WHEN THE PRINTER IS MOVED.
THERE IS A RISK OF PERSONAL INJURY IF THE CORRECT GUIDELINES FOR THE SAFE
MANUAL HANDLING OF HEAVY OBJECTS ARE NOT FOLLOWED.

1.6 First aid

Ideally, all maintenance personnel should be trained in first aid and know the possible
effects from the use of flammable and toxic materials.
All maintenance personnel must have access to the ink and solvent Material Safety Data
Sheets, which describe the hazards and the actions to be taken if first aid is necessary.
Maintenance personnel must make sure that the first aid information is easily available if
ink and solvent ingestion, inhalation, or contact with the eyes or skin occurs.

1.6.1 Procedures
The following paragraphs contain first aid procedures for inks and solvents from the
Material Safety Data Sheets. For complete and up to date information, always refer to the
Material Safety Data Sheet for the related ink or solvent.

Eye contact with inks or solvents

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

Skin contact with inks or solvents

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

Ingestion of inks or solvents

If accidentally swallowed, DO NOT INDUCE VOMITING. Obtain immediate medical
attention. Rise the mouth thoroughly with water and give large amounts of water to drink if
the person is conscious. Keep at rest, and provide warmth and fresh air.

Inhalation of solvent fumes

Remove the affected person to fresh air immediately. If the person stops breathing, give
artificial respiration and get medical attention immediately. Make sure that the person does
not move and keep the person warm.

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1.7 Test printing

Printing drops hold a charge, which is not discharged until the drops contact the substrate.
If test printing is performed into a container, a charge can build in the collected ink. This
charge can eventually, suddenly discharge to earth and cause the ink to ignite.
To prevent this risk of fire, it is extremely important to make sure that the ink is earthed so
that the charge does not occur. If a metal container is used, connect the container to an earth
point. If a non-metallic container is used (for example, glass or plastic), put one end of a
length of wire directly into the ink, and connect the other end to an earth point (see
Figure 1-1). The knurled securing screw for the printhead cover tube can be used as an earth
point.
IMPORTANT: To make sure that the printer operates correctly, this safety procedure is the
only time that the cover tube securing screw is to be used as an earth point.

68001

MIDI

Figure 1-1. Test printing into a non-metallic container

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 CHAPTER 2: GENERAL AND
COMPLIANCE INFORMATION
2.1 Introduction
The Linx 7900 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. The following table shows the different printer types and
their names, and the printheads available with each.

Printer type Non-pigmented ink printers Pigmented ink printer Food Grade ink printer
Printer name 7900 (IP55 version) 7900 (IP65 version) 7900 Spectrum 7900 Food Grade
IP rating IP55 IP65 IP65 IP55
Printheads: Ultima plus (75 µm) Ultima plus (75 µm) Ultima plus (75 µm) MidiEC (62 µm)
Midi plus (75 µm) Midi plus (75 µm) Midi plus (75 µm)
Ultima (62 µm) Ultima (62 µm)
Midi (62 µm) Midi (62 µm)
Ultima A (62 µm) Ultima A (62 µm)
Midi A (62 µm) Midi A (62 µm)
Mini (50 µm) Mini (50 µm)
Micro (40 µm) Micro (40 µm)

Table 2-1. Printer types

2.2 Technical data

2.2.1 Printer configurations
Speed Standard Speed (SS) High Performance (HP)
Lines of print 2 3 4 2 3 4
Printheads: Ultima plus   —   —
Midi plus    — — —
Ultima and Ultima A   —   —
Midi and Midi A      

MidiEC   —   —
Mini  — —  — —
Micro      

Table 2-2. Printer configurations

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 2.2.2 Environmental
Operating temperature:
Operating altitude:
Humidity range:
Acoustic emission:
Protection rating (dust & water):7900 (IP55 version) and 7900 Food Grade protected to IP55
+5 °C to +45 °C ambient (all printers except 7900 Food
Grade)
0 °C to +40 °C ambient (7900 Food Grade)
+5 °C to +35 °C ambient (7900 Food Grade when using Blue
Food Grade ink 6220 (EU-type))
maximum 2000 m
maximum of 90% relative humidity, non–condensing
less than 70 dBA
7900 (IP65 version) protected to IP65
7900 Spectrum protected to IP65

2.2.3 Electrical
Mains electrical supply: single phase, 100 V (3 A) to 230 V (1 A) AC, 50/60 Hz
Power rating: 200 W
Power consumption: 60 W typical when printing
This equipment is a Class 1 earthed appliance as defined by EN 60950. Electrical
connections at the rear of the cabinet comply with the extra low voltage safety requirements
as defined by EN 60950.

WARNING: THIS PRINTER MUST BE EARTHED/GROUNDED.

The integrity of the insulation resistance between the live conductors and earth has been
tested in accordance with the test defined in EN 60950.
The integrity of the protective earthing conductors has been tested in accordance with the
test defined in EN 60950.

2.2.4 Cabinet
Construction

7900 (IP55 version), 7900 (IP65 version), 7900 Spectrum and 7900 Food Grade
Base tray unit: stainless steel
Top cover: stainless steel

Dimensions

7900 (IP55 version), 7900 (IP65 version), 7900 Spectrum and 7900 Food Grade
External height: 240 mm (including filler caps)
External width: 490 mm
External depth: 600 mm

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 Weight
Excluding ink, solvent, accessories and packaging.
7900 (IP55 version): 20.0 kg
7900 (IP65 version): 21.5 kg
7900 Spectrum: 22.5 kg
7900 Food Grade: 22.0 kg

2.2.5 Low voltage power supply unit

Input: 85 V AC to 264 V AC, 50/60 Hz
Outputs (100 W total): +5.1 V DC ±5%, 2.5 A
+12 V DC ±5%, 0.9 A
–16 V DC ±5%, 0.4 A
+24 V DC ±5%, 2.5 A

2.2.6 EHT power supply unit

Inputs: +24 V DC ±5%, 1.2 A (power input)
0 V to +10 V DC (EHT output level control)
Outputs: 0 V to +10 kV DC ±5%, 10 µA
+300 V DC ±5%, 10 mA to 46 mA max.

2.2.7 Ink system

IMPORTANT: Linx 7900 Continuous Ink Jet Printer cannot be used in some environments.
For example, on offshore oil and gas installations, in petro-chemical plants,
mines, inappropriate areas in flour mills, and other areas where a
potentially explosive atmosphere may be present.

Construction

7900 (IP55 version), 7900 (IP65 version) and 7900 Food Grade
Ink system enclosure: stainless steel
Ink tank: natural colour polyethylene
Solvent tank: natural colour polyethylene

7900 Spectrum
Ink system enclosure: stainless steel
Ink tank: stainless steel
Solvent tank: natural colour polyethylene

Environmental
Protection rating: Protected to a minimum of IP65 with respect to the
electrical compartment of the printer cabinet when the
printer top cover is fitted.

Electrical connections
Construction:  double insulated
 in accordance with the requirements for equipment
operating in Zone 2

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 Maximum surface temperature
Valves solenoids: 107 °C under fault conditions

Pressure

7900 (IP55 version) and 7900 (IP65 version)

Pressure range: up to 4.49 bar (65.00 p.s.i.) normal operating pressure
Maximum pressure: 6.21 bar (90.00 p.s.i.) under fault conditions

7900 Spectrum and 7900 Food Grade

Pressure range: up to 4.49 bar (65.00 p.s.i.) normal operating pressure
Maximum pressure: 5.8 bar (84.00 p.s.i.) under fault conditions
NOTE: To convert bar to p.s.i. multiply by 14.503.

Capacity

7900 (IP55 version), 7900 (IP65 version) and 7900 Food Grade
Ink and solvent tanks: 1600 ml maximum; 1440 ml usable

7900 Spectrum
Ink tank: 1400 ml approximately
Solvent tank: 1600 ml maximum; 1440 ml usable

Fluid level control

7900 (IP55 version), 7900 (IP65 version) and 7900 Food Grade
Ink & solvent tanks sense low: warning reported at approximately 740 ml, leaving 690 ml
of usable ink or solvent

7900 Spectrum
Ink tank sense low: warning reported at less than 450 ml
Solvent tank sense low: warning reported at approximately 740 ml, leaving 690 ml
of usable solvent

Performance
Solvent consumption: Please contact Linx for information on solvent
consumption, as this changes with the ink type, the printer
configuration, and the environment in which the printer
operates.

Inks

7900 (IP55 version) and 7900 (IP65 version)

Ink capability: Refer to the ‘Ink Type Dependent Parameters’ tables at the
end of the ‘Ink System’ description in ‘Chapter 3: Technical
Description’.

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 7900 Spectrum
Ink capability: Black Pigmented ink 1009
Yellow Pigmented ink 1039
Opaque Blue ink 1043
White Pigmented ink 1059 and 1069
Brilliant White ink 1305 and 1306
High-Opacity Grey ink 1310 and 1311

7900 Food Grade

Ink capability: Red Food Grade ink 6100
Blue Food Grade ink 6120
Blue Food Grade ink 6220

2.2.8 Printhead
Types
Ultima plus: Mk7 (75 µm nozzle jewel diameter)
Midi plus: Mk7 (75 µm nozzle jewel diameter)
Ultima and Ultima A: Mk7 (62 µm nozzle jewel diameter)
Midi and Midi A: Mk7 (62 µm nozzle jewel diameter)
MidiEC: Mk7 (62 µm nozzle jewel diameter)
Mini: Mk7 (50 µm nozzle jewel diameter)
Micro: Mk7 (40 µm nozzle jewel diameter)

Construction
Printhead: thermoplastic polyester body
Cover tube: stainless steel
Conduit adaptor: stainless steel

Dimensions

Straight and right-angled printheads

Printhead body length:
Printhead body diameter:
Conduit length:
Conduit diameter:
Conduit minimum bend radius: 75 mm (static applications)
straight printhead 225 mm, excluding conduit fitting (see
also conduit minimum bend radius below for clearance)
right-angled printhead 261 mm, including conduit fitting
Midi short reach right angle (SRRA) printhead 143 mm,
excluding conduit fitting
42 mm
2 m or 4 m
16.5 mm
150 mm (dynamic applications)

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 2.2.9 Printing performance
Further information can be found in the Linx CIJ print performance data pamphlet for the
Mk7 printhead types, or in the Linx 5900 & 7900 Quick Start Guide.

Ultima plus (75 µm)

Lines of print: up to three lines of 7 High characters
No. of message types (rasters): 20
Maximum speed: 7.28 m/s—one line of 5 High characters using message
type 5 Linear Wide
Minimum character height: 2.1 mm nominal at default EHT using message types:
5 Linear Quality
5 Linear Speed
Maximum character height: 9.5 mm nominal at default EHT using message type
25 Linear Quality

Midi plus (75 µm)

Lines of print: up to four lines of 7 High characters
No. of message types (rasters): 7
Maximum speed: 2.10 m/s—one line of 5 High characters using message
type 5 Linear Quality
Minimum character height: 2.1 mm nominal at default EHT using message type
5 Linear Quality
Maximum character height: 13.8 mm nominal at default EHT using message type
34 Linear Quality

Ultima and Ultima A (62 µm)

Lines of print: up to three lines of 7 High characters
No. of message types (rasters): 34
Maximum speed: 6.25 m/s—one line of 5 High characters using message
type 5 Linear Wide
Minimum character height: 1.8 mm nominal at default EHT using message types:
5 Linear Quality
5 Linear Speed
Maximum character height: 7.8 mm nominal at default EHT using message type
25 Linear Speed

Midi and Midi A (62 µm)

Lines of print: up to four lines of 7 High characters
No. of message types (rasters): 30
Maximum speed: 6.28 m/s—one line of 5 High characters using message
type 5 Linear Wide
Minimum character height: 1.8 mm nominal at default EHT using message type
5 Linear Quality
Maximum character height: 12.0 mm nominal at default EHT using message types:
34 Linear Quality
4×7 Stitched Quality

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 MidiEC (62 µm)
Lines of print: up to three lines of 7 High characters
No. of message types (rasters): 28
Maximum speed: 6.28 m/s—one line of 5 High characters using message
type 5 Linear Wide
Minimum character height: 1.8 mm nominal at default EHT using message type
5 Linear Quality
Maximum character height: 10.5 mm nominal at default EHT using message type
3×7 Stitched Wide

Mini (50 µm)

Lines of print:
No. of message types (rasters): 52
Maximum speed:
Minimum character height:
Maximum character height:
up to two lines of 7 High characters
6.83 m/s—one line of 5 High characters using message types:
4T 1×5 WIDE 6.83m/s
8T 1×5 WIDE 6.83m/s
1.43 mm nominal at default EHT using message types:
4T 1×5 Quality 2.27m/s
4T 1×5 Speed 2.73m/s
4T 1×5 Speed 4.55m/s
8T 1×5 Quality 1.82m/s
8T 1×5 Speed 2.73m/s
6.70 mm nominal at default EHT using message types:
12T 2×7 WIDE 1.95m/s
12T 2×7 WIDE 2.27m/s

Micro (40 µm)

Lines of print: up to four lines of 7 High characters
No. of message types (rasters): 28
Maximum speed: 8.41 m/s—one line of 7 High characters using message
type 1×7 WIDE 8.41m/s
Minimum character height: 1.1 mm nominal at default EHT using message type
1×5 Quality 1.82m/s
Maximum character height: 8.0 mm nominal at default EHT using message type
1×32 Quality 0.19m/s

Printhead to substrate distance (recommended)

Ultima plus*; Midi plus: 12 mm
Ultima; Midi**; MidiEC**: 12 mm
Ultima A; Midi A**; MidiEC**: 12 mm
Mini: 4 mm, 8 mm or 12 mm, depending on message type. For
more information, refer to the Linx 5900 & 7900 Quick Start
Guide
Micro: 4 mm
* The recommended printhead to substrate distance for the 21 Linear Speed message type is
6 mm.
** The recommended printhead to substrate distance for the 25 Linear Speed message type is
6 mm.

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 2.2.10 Memory capacity
Storage capacity in RAM:
Up to a maximum of approximately 2 MB for storage of
messages, datasets, downloaded fonts, logos and
passwords. More information can be found on the
Software page (Print Monitor > Menu > System
Information > Software).

2.2.11 Regulatory approvals

Safety
Approved in accordance with TÜV/GS requirements.

Low Voltage Directive

2006/95/EC

Applicable European safety standards

IEC 60950-1:2005+A1:2009 Information technology equipment. Safety. General
requirements

Environmental

RoHS Directive
2011/65/EC Restriction of the use of certain hazardous substances in
electrical and electronic equipment.

Electromagnetic compatibility (EMC)

EMC Directive
2004/108/EC

Applicable European EMC standards

EN 61000-3-2:2006 Electromagnetic compatibility (EMC). Limits. Limits for
harmonic current emissions (equipment input current 
16 A per phase).
EN 61000-3-3:2008 Electromagnetic compatibility (EMC). Limits. Limitation
of voltage changes, voltage fluctuations and flicker in
public low-voltage supply systems, for equipment with
rated current  16 A per phase and not subject to
conditional connection.
EN 61000-6-2:2005 Electromagnetic compatibility (EMC). Generic standards.
EN 61000-6-4:2007+A1:2011 Electromagnetic compatibility (EMC). Generic standards.
Emission standard for industrial environments.

Applicable USA EMC standards

FCC CFR 47, Part 15,
subpart B:2007 Class A devices.

Enclosure protection
BS EN 60529:1992 Specification for degrees of protection provided by
enclosures (IP code).

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2.3 Abbreviations and glossary
AC alternating current
ADC analogue to digital converter
CIJ continuous ink jet
CPU central processing unit
DAC digital to analogue converter
DC direct current
DFC dynamic flow control
DPP deflector and phase plate
DVM digital voltmeter
EHT extra high tension (voltage)
EHTPSU extra high tension power supply unit
EMC electromagnetic compatibility
EPROM erasable programmable read-only memory
FC fault code
Flash memory A high density, non-volatile, read/write memory IC,
which holds the system software program
FPGA field-programmable gate array
IC integrated circuit
IP ingress protection, or internet protocol
IPM PCB integrated processor module printed circuit board
LCD liquid crystal display
LK link
LVPSU low voltage power supply unit
MEK methyl ethyl ketone
Mk Mark (followed by a number indicating a particular
design, model, version, as in Mk7 Printhead)
N/A not available or not applicable
NiMH nickel metal hydride
NMI non-maskable interrupt
NVR non-volatile RAM

p.s.i. pounds per square inch (lb/in2); (imperial unit of

pressure)
PCB printed circuit board
PIO parallel input/output
Pixel The smallest size of spot on the screen that makes up the
displayed message
PL plug (connector with male pins/contacts)
PLC programmable logic controller
PLCC plastic leadless chip carrier
PLD programmable logic device

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Linx 7900 Maintenance Manual 2—9 Oct 2013
 Print Go An internal logic signal that initiates print, normally
preceded by a print trigger
Print registration The horizontal position of a printed message on a substrate
Print trigger A logic signal generated by a product sensor, which
initiates printing of a single message
PSU power supply unit
r.f. radio frequency
RAM random-access memory
raster A variable line of drops printed at 90 degrees to the
direction of production line travel, which create characters
that are made up of one or more rasters
RCI remote communications interface
RoHS restriction of hazardous substances
S/W software
SK socket (connector with female pins/contacts)
SRAM static random-access memory; a low density, volatile,
reprogrammable memory
SRRA (printhead) short reach right angle
Substrate surface (product) on which printing is done
t.b.a. to be announced
TFT thin-film transistor
TOF time of flight
TP test point
UNIC unique number identification chip
USB universal serial bus
VFC volt-free contact (relay)
VGA video graphics array

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Oct 2013 2—10 Linx 7900 Maintenance Manual
 CHAPTER 3: TECHNICAL
DESCRIPTION
3.1 Introduction
This chapter provides a technical description of the function of the sub-systems, modules
and components that constitute the Linx 7900 Continuous Ink Jet Printer. The following
topics are described in this chapter:
3.2 Cabinet
3.3 User interface
3.4 Printhead components
3.5 Printhead theory of operation
3.6 Ink system
3.7 Electrical components
3.8 Electronics and software
3.9 External signals
NOTE: This chapter provides technical information about the standard 7900 (IP55 version)
and 7900 (IP65 version) printers. Where the 7900 Food Grade printer is different from
the standard 7900 printer described in this chapter, the alternative information is
provided in Appendix A. Where the 7900 Spectrum printer is different from the
standard 7900 printer described in this chapter, the alternative information is
provided in Appendix B.

3.2 Cabinet
3.2.1 Introduction
The purpose of the cabinet is to house and support the modules and components of the
printer, and to protect them from contamination. The printer cabinet is designed to meet an
ingress protection (IP) rating in respect of water and dust ingress. There are four printer
models: the 7900 (IP55 version) and 7900 Food Grade which are sealed to IP55, and the 7900
(IP65 version) and 7900 Spectrum which are sealed to IP65.
The cabinet is a two-piece structure consisting of a top cover and a base tray unit.

3.2.2 Top cover

The stainless steel top cover for all models is attached at the front and the rear to the
stainless steel base unit.
A handle block with a hinge blade at each end is fitted to the rear of the top cover. The
hinge blades fit into the two hinge blocks fitted on the rear of the base unit. When the top
cover is lowered to the closed position, the rear hinge assembly locks and fastens the rear of
the cover. In the closed position the top cover is attached at the front by a latch. The latch is
locked by rotating it through 90 degrees with a special tool, which is available to
maintenance technicians.
The top cover can be completely removed from the hinge blocks when the cover is in the
vertically open position.
The top cover houses the keyboard, LCD screen, and the Display PCB, which form the
interface between the operator and the printer. The keyboard is an integral part of the top
cover. The LCD screen is fitted directly onto the underside of the top cover with the Display
PCB fitted on stand-off pillars above it.

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 3.2.3 Base unit
The base unit houses the following main components:
 Ink system enclosure.
 Electronics system (IPM PCB and optional Auxiliary PCBs).
 Mains electrical supply and power on switches.
 Mains electrical supply filter and fuses.
 Low voltage power supply unit (LVPSU).
 EHT power supply unit (EHTPSU).
 Cooling fan and air filter.
 Optional printhead positive air pump.
The rear panel of the base unit allows entry of the printhead conduit and the
non-operator-removable mains electrical supply cable. The mains electrical supply cable
enters the rear of the printer below the mains electrical supply switch. External connectors
for product sensors, shaft encoders, RS-232, Ethernet and the alarm output are also
provided on the rear panel. A USB connector is provided on the front face of the base unit.
All the connectors have a minimum rating of IP65.
The Ethernet and 24 volts alarm connectors are supplied as standard and are fitted to a
removable options plate. This plate can be replaced with different option plates that
provide combinations of a mains (VFC) external alarm, multi-stage alarm, dual alarm, and
parallel input/output (PIO). Refer to ‘External signals’ on page 3—56 for more information.
The cabinet also provides fixing points on the rear face for the alarm beacon.

3.2.4 Ink system

The ink system is further protected by, and housed within, a self-contained stainless steel
enclosure that is part of the base unit of the printer. The lid of the ink system is formed by
the top cover and a gasket when closed. When the top cover is fitted correctly, the ink
system enclosure is sealed to a minimum IP54 rating with respect to the electronics
enclosure.
Protective caps for the ink and solvent filler tubes are on the upper, rear surface of the top
cover.

3.2.5 Cooling and air filter

The air intake for the cooling fan is on the underside of the base unit. A cabinet air filter is
included, located beneath the fan in its own housing. The cooling air flows in through the
air filter, over the IPM PCB and PSUs, and out through vents in the bottom of the base unit
at each side.
The air filter can be removed for cleaning or replacement depending on its type. On the
7900 (IP65 version) the filter element is designed to be disposable, that is, it should be
replaced when necessary rather than cleaned and refitted. Replacement is achieved by
removing the protective plate on the right-hand side of the base unit, and pulling the loop
attached to the filter to remove it from its housing.
On the 7900 (IP55 version) there is no protective plate; the filter is simply removed by
pulling the tab attached to the filter. This filter should be cleaned using compressed air
blown through in the reverse direction to the normal air flow, or replaced if it is severely
blocked or damaged.
There is a natural air vent for the ink system on the rear panel of the base unit.
The following illustration is a view of the 7900 (IP65 version) printer base unit showing the
locations of the main components.

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Oct 2013 3—2 Linx 7900 Maintenance Manual
 External alarm output
and Ethernet connectors
(on rear panel plate)
79052
Location of auxiliary PCB Mains electrical supply

FA69398–1
filter (hidden) fitted below
the mains electrical
Ink system enclosure
supply switch

Mains electrical supply

Ink system valves x5 fuses x2 (accessed under
the protection box for the
Pressure transducer mains electrical supply
cable connector)

Linx 7900 Maintenance Manual

IPM PCB

Cooling fan

Protection box

3—3
for the mains
electrical supply
cable connector

Mains electrical
supply switch
USB (on/off switch is
connector LVPSU on the rear panel)
(with sealing cap)

Positive air pump Ink system pump/motor assembly

(optional)
Top cover
securing latch Air filter (behind protective plate)

Power on switch EHTPSU

Figure 3-1. 7900 (IP65 version) printer base unit and main components

Oct 2013
3.3 User interface
The user interface consists of a keyboard and a display, with associated controls and
indicators.

3.3.1 Keyboard and display

Keyboard
The keyboard includes 47 character keys (QWERTY layout) and 15 standard control keys on
a tactile membrane keypad, which are used to input and edit messages.

Display
The display is positioned above the keyboard and is a 256-colour LCD screen with cold
cathode back-lighting and automatic contrast control.
There are six soft keys associated with the display, and four navigating arrow keys to the
right of the display. A [start] key and a [stop] key are also provided to the left of the display.

Messages
Before printing can take place, a message or messages must be created. A message is a
structure describing the text or pattern to be printed. Each message consists of one or more
fields, which can be of a number of types. For example, a text field is simply fixed text that
does not change from one print to the next; a time field displays the actual time (or the time
offset by a specific amount) and changes accordingly from one print to the next. Refer to the
Linx 5900 & 7900 Quick Start Guide for details about creating and editing messages.

3.3.2 Control panel LEDs

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

Warning
The software controlled red Warning LED illuminates when there is one or more active
System Warnings on the printer. These warnings can be viewed (and cleared) via the Event
Log option (Print Monitor > Menu > Event Log). When the last remaining warning is
cleared, the LED is not illuminated.

Ready
The software controlled green Ready LED illuminates when the printer is ready to print,
that is, when the jet is running, a message is loaded, and the [start] key is pressed.

Power
The green Power LED remains illuminated while the printer is powered up. It is not under
software control.
The following illustration shows the 7900 standard European user interface.

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Oct 2013 3—4 Linx 7900 Maintenance Manual
 79040
7900

FA69398–1
Fail

Warning

Ready

Power

Linx 7900 Maintenance Manual

start

stop

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Figure 3-2. 7900 European user interface

Oct 2013
3.4 Printhead components
This section identifies the main components of the printhead and describes their basic
functions together with various other aspects of the printhead. The illustration below shows
the location of the main printhead components.

68153

Printhead conduit from

control system and ink system

Printhead conduit strain relief

Printhead Feed and Purge

valves (inside the cover)

Cover tube
securing screw

MIDI

Nozzle cover

Nozzle Charge electrode

Strobe LED (bottom

of charge electrode slot)
0 V deflector plate (incorporating
+8 kV deflector plate Phase and TOF sensors)

Gutter

Figure 3-3. Mk7 Midi printhead main components

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 3.4.1 Gun chamber and nozzle assembly
The printhead operation requires ink to be supplied under pressure from the ink system to
the ink gun chamber and then out of the nozzle.
The gun chamber is located underneath the printhead component mounting board, directly
below the nozzle assembly. On the Micro and Mini printheads it is fitted above the
component mounting board. Inside the chamber, the ink is pulsed (modulated) by the effect
of a piezoelectric crystal causing the ink jet to break up into drops.
The modulated jet is forced from the nozzle assembly through a precisely machined hole in
a small jewel (located in the nozzle cap) of either 40 µm, 50 µm, 62 µm or 75 µm, depending
on the type of printhead.

3.4.2 Charge electrode

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

3.4.3 Strobe LED

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

3.4.4 Deflector plates

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

3.4.5 Phase and TOF sensors

There are two sensors incorporated in the 0 volt deflector plate and this assembly is called
the deflector and phase plate (DPP). These sensors are used to monitor the jet to make sure that
the printer is operating correctly. The first sensor (nearest the nozzle) is called the phase
sensor; the second sensor (nearest the gutter) is called the time of flight (TOF) sensor.
During startup, and at intervals between printing patterns, the printer monitors the jet
performance. Signals are detected by the two sensors from the passing drops and these
signals are used by the printer for two functions. The first is to make sure that the drops are
receiving 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 is called the time of flight
measurement.
The phase and TOF readings are checked routinely during printing, between patterns, to
maximize print quality.

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 3.4.6 Printhead cover sensor
This sensor is a Hall-effect switch that is used to detect the presence of the printhead cover
tube, and is situated within the printhead body. A small magnet inside the cover tube
activates the Hall-effect switch when the cover tube is fitted to the printhead. Activation of
the Hall-effect switch enables the print process by switching on the deflector plate EHT
circuit. When the cover tube magnet is moved away from the Hall-effect switch by
approximately 3 mm (which is insufficient to allow access to the potentially dangerous
deflector plates), the switch is deactivated. This disables the EHT circuit and printing is
suspended. Printing is resumed a few seconds after the printhead cover tube is refitted.

3.4.7 Printhead temperature sensor

The printhead is also fitted with a thermistor, which has two functions.

Over temperature
Firstly, the thermistor acts as a safety sensor so that if a local printhead temperature in
excess of 60 °C is detected, the printer is immediately shut down in a controlled way. In
addition, the Print Failure message “2.00 Printhead Over Temperature” is displayed to
indicate that an 'over temperature' condition has been detected at the printhead.

Ink density
Secondly, the temperature monitored by the sensor is used to compensate for variations in
ink density at the extremes of the printer’s operating temperature range.
Under normal operating conditions the Set Pressure is varied as the ink viscosity changes,
to maintain a constant TOF. For example, as the ink viscosity increases due to solvent
evaporation, the Set Pressure is increased to maintain a constant TOF (at the Reference TOF)
with the thicker ink. If the Set Pressure reaches the predetermined Solvent Add Pressure,
solvent is added to the ink to decrease the viscosity and thus maintain the Actual TOF at
Reference TOF. Refer to ‘Solvent addition (Figure 3-21 on page 3—35)’ in the section, ‘Ink
system’ later in this chapter.
Whilst the pressure required to achieve the correct TOF is viscosity dependent, it is also
affected by temperature and, more importantly, by ink density. For example, at lower
temperatures when the ink is more dense, it is necessary to drive the jet at a greater
pressure to maintain the correct TOF. Therefore, the printhead temperature is monitored
and the Set Pressure is adjusted accordingly to compensate for the greater ink density.
The Solvent Add Pressure is offset by an amount determined by the printhead temperature.
This prevents the printer from adding solvent too early to thin the ink at low temperatures,
when the ink is at a higher density but is at the ideal viscosity.
The above principle applies, but in reverse, when there is a high printhead temperature and
the ink density is low.
This pressure compensation explains why the Solvent Add Pressure may be seen to change
at extreme operating temperatures on the Monitor Jet page (Print Monitor > Menu >
Maintenance > Monitor Jet).
See also: ‘Viscosity control’ in the section ‘Printhead theory of operation’ later in this
chapter.
‘Solvent addition (Figure 3-21 on page 3—35)’ in the section ‘Ink system’ later in
this chapter.

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 3.4.8 Printhead feed and purge valves
During the time that the printer is turned off, small amounts of residual ink-stained solvent
can form into ‘slugs’ in the pipes between the printhead nozzle and the Ink System Feed
and Purge valves.
Printhead Feed and Purge valves are incorporated in the Mk7 printhead, which prevent the
slugs from reaching the gun. During the normal shutdown sequence solvent is flushed
through the system to clear the printhead gun, and the feed and purge lines of ink. The
solvent is fed directly to the Printhead Feed valve and out to the gun chamber. Towards the
end of the shutdown sequence the gun–to–Printhead Feed valve pipe is cleared of solvent.
The Printhead Feed valve is then closed and the gun–to–Printhead Purge valve pipe is
cleared of solvent.
At the end of the shutdown sequence the Printhead Feed and Purge valves are in the closed
position, which seals the ink system from the printhead nozzle. Therefore, any slugs of
ink-stained solvent that form in the feed and purge lines are contained, keeping the nozzle
clean in preparation for the next startup.

Feed valve
The Printhead Feed valve is a 24-volt, electrically-operated, solenoid valve. It is fitted with
an integral 35 µm filter on Ultima plus and Midi plus printheads, and a 15 µm filter on
Ultima, Midi, Mini, and Micro printheads.
NOTE: All specified filter sizes are nominal ratings.

Purge valve
The Printhead Purge valve is a ball-and-spring type of non-return valve (NRV), which is
designed to open at a positive pressure difference of approximately 0.14 bar (2.04 p.s.i.).

3.4.9 In-line feed filter

This component is a stainless steel in-line filter fitted in the feed line within the printhead
3-way fluid connector. The purpose of the filter is to provide increased protection for the
printhead from foreign particles in the ink, which can cause a blockage in the nozzle. The
filter size is 35 µm for Ultima plus and Midi plus printheads, and 15 µm for Ultima, Midi,
Mini, and Micro printheads.
NOTE: All specified filter sizes are nominal ratings.
The filter is also colour-coded—white for Ultima plus and Midi plus printheads; black for
Ultima, Midi, Mini, and Micro printheads. It is most important when replacing an in-line
feed filter that a white filter (35 µm) is fitted to a white 3-way fluid connector female part
(printhead side); and a black filter (15 µm) is fitted to a black 3-way fluid connector female
part (printhead side).
68053

Female part

O-ring gasket

Male part

Feed line Locating lug

Filter

Locating recess

Assembly screw

Figure 3-4. 3-way fluid connector containing the in-line feed filter

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 3.4.10 Standard gutter restrictor
During normal running conditions, air is drawn into the gutter with the ink that is
returning to the ink tank. This volume of air flowing with the ink in the gutter return line
causes the solvent in the ink to evaporate, which in turn causes an increase in solvent
consumption.
A restrictor is fitted in the printhead gutter return line to control the airflow. This reduces
solvent consumption and, consequently, the volume of vented solvent fumes.
The gutter restrictor is currently fitted as standard inside the gutter return line of the Mk7
Ultima, Midi, Mini, and Micro printheads (2-metre conduits only), and as such is part of the
printhead assembly. The restrictor is held in place with a clip and is located on the
printhead side of the 3-way fluid connector, within the printer cabinet.

3.4.11 In-line gutter check valve

Where the application of a printer requires that the printhead is installed below the level of
the printer, there is a small risk that ink can siphon from the ink tank when the printer is not
in use. To eliminate the possibility of this occurring, a check valve can be fitted in the gutter
return line of all Mk7 printheads.

48007

FLOW

Figure 3-5. In-line gutter check valve

This check valve is available as a spare part only; it is not fitted to Mk7 printheads as
standard.

3.4.12 Electrical and fluid connections

The printhead is connected to the printer by a number of electrical cables and fluid lines.
The various electrical connections are either labelled with letter identifications, or are
polarized sockets and plugs.
A 3-way fluid connector connects the three fluid lines to the printer, which are colour-coded
as follows: feed line—red stripe; purge line—blue stripe; gutter line—no stripe. The
printhead part of the connector is also colour-coded: white for Ultima plus and Midi plus
printheads; black for Ultima, Midi, Mini, and Micro printheads.

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 3.4.13 Dynamic flow control
The Dynamic Flow Control (DFC) option is a factory-fit module that reduces solvent
consumption by up to 40% at 20 °C. The solvent reduction is achieved by a controlled
restriction of the airflow down the printhead gutter of approximately 40%. When the DFC
option is used, the Print and Consumables Data page shows the extended hours per solvent
bottle. A 7900 printer that has the DFC option fitted is called a Linx 7900 Solver printer. The
DFC option cannot be retrofitted, because a configuration code is required to enable the
DFC software control, which is entered into the printer during manufacturing.
The DFC module is an 80 mm x 60 mm x 30 mm box with an inlet pipe and 20 µm (absolute)
disc filter, an outlet pipe, an electrical cable, and a twin-colour LED (red and green). The
electrical cable has four connectors, two of which interrupt the 24 volts fan supply from the
LVPSU to supply the DFC. The third connector carries the control signal for the DFC
module, and the fourth connector is an earth blade connector.
The module is installed in the ink system enclosure and replaces the function of the
standard gutter restrictor in the printhead gutter line (see ‘Standard gutter restrictor’ on
page 3—10).
The DFC option is only compatible with 2-metre printhead conduits and Mk7 Ultima, Midi,
Midi SRRA, Mini, and Micro printheads (not Ultima plus or Midi plus printheads), and so is
not compatible with the 7900 Spectrum printer. It is also not approved for inks 1405, 2030,
2035 and 2250.
The disc filter is replaced at every scheduled maintenance.
The DFC module operates in two states:
 Active (green LED illuminated)—the gutter has controlled airflow restriction.
 Inactive (red LED illuminated)— the gutter has unrestricted airflow.
NOTE: The green and red LEDs are a single component.
The module is ‘active’ between Reference Pressure and Solvent Add Pressure +1 bit, and
‘inactive’ outside this pressure range.
The module is switched to ‘inactive’ before a ‘Solvent Add’ and then reactivated, providing
that the Set Pressure is between Reference Pressure and Solvent Add Pressure + 1 bit.
The module is switched to ‘inactive’ during the ‘Jet Starting’ and ‘Jet Stopping’ states, but is
switched to ‘active’ in the ‘Idle’ state to prevent drying out of the solenoid valve.
Refer to the ‘Dynamic Flow Control Module Replacement’ maintenance instruction in
Chapter 5: ‘Maintenance’ for the replacement procedure.

73079

Figure 3-6. Dynamic flow control assembly

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3.5 Printhead theory of operation
3.5.1 Summary
The following is a short summary of the basic theory of operation of the ink jet printhead.
This summary is followed by a full description of each part of the process.
A character is created on the substrate from ink drops discharged from the printhead. The
structure of the character depends on drops being printed or discarded. The drops are
discharged from the printhead in lines called rasters, and each raster has a preset number of
drops that controls the potential height of a character. The characters are created from
rasters printed one after the other as the substrate moves past the printhead.
Inside the printhead, electrically-conductive ink is fed under pressure through an
accurately-cut hole in an industrial jewel in the printhead nozzle cap to create the ink jet.
Before the jet leaves the nozzle, the ink is pulsed (modulated) to generate a continuous jet of
modulated ink. This modulated jet passes along the length of the printhead and between
the charge electrode plates where the jet divides into separate ink drops. The jet continues to a
gutter, which collects the non-printing drops and returns these drops under vacuum to the
ink tank.
Ink drops that are to be printed receive an electrostatic charge. This process occurs between
the charge electrode plates, which is at the point in the jet flight path where the jet naturally
separates into drops. The electrostatic charge causes a flow of electrons onto each drop as it
is created. The printing drop now has a negative electric charge.
This electrically charged drop moves with the main jet of drops until it enters the area
between two deflector plates. The electrostatic field generated between the plates applies a
force to the drop, which deflects the drop from its original straight path and draws it
towards the positive potential plate. The drop is deflected by an amount that is
proportional to the charge on the drop and the potential across the two deflector plates.
To make sure that the printing drops are correctly charged, a regular test of the charging
function is performed, which measures the drop charge at the phase sensor.
A measurement of jet speed is also performed. Both the phase sensor and the time of flight
sensor are used to measure the time taken for drops to move the known distance between
the two sensors. This time period provides an accurate evaluation of jet speed, which is
used by the printer to adjust the pressure at which the ink is ejected from the nozzle. Jet
speed is also used with the pressure to monitor ink viscosity at the printhead.

3.5.2 Printhead types

Linx 7900 printers currently use six types of Mk7 printheads. The basic design of these is
similar but with two important differences. Firstly, the six types of printheads use four
different nozzle orifice sizes (measured in micrometres), as follows:
 Ultima plus: 75 µm
 Midi plus: 75 µm
 Ultima: 62 µm
 Midi: 62 µm
 Mini: 50 µm
 Micro: 40 µm
Secondly, the Ultima plus, Ultima and Mini 2-line printheads, and the 4-line Micro
printhead have shorter flight paths than the corresponding Midi plus and Midi printheads.
This provides better print quality and/or faster print speed, depending on the message
type.

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 The Ultima plus and Ultima printheads are for 2-line printing (or reduced height 3-line
printing), or a single line of up to 25 High characters. The Midi plus and Midi printheads are
for printing up to four lines, or a single line of up to 34 High characters. The Mini printhead
is for 2-line printing, or a single line of up to 16 High characters. The Micro printhead is for
printing up to four lines, or a single line of up to 32 High characters.
Refer to the Linx 5900 & 7900 Quick Start Guide for more information about the different
message types (rasters) that are available for each printhead and printer configuration
combination, and for related speed and quality data.

3.5.3 Modulation
The jet of ink from the nozzle is broken into drops of equal size and spacing by a process
called modulation.
A jet of fluid naturally breaks into approximately equal size drops because of the effects of
aerodynamic drag and noise. The jet break-up (drop break-off) can be accurately controlled
by the introduction of a disturbance or excitation into the fluid. This excitation is done in
the Linx printheads by the oscillation of a piezoelectric crystal that is in contact with the ink.

Ink delivered under pressure

from the ink system
through the ink feed line

Piezoelectric crystal pulsed

by the modulation signal 6245

Gun chamber
Modulation signal

Ink drop break-off (jet break-up)

occurs in the charge electrode Nozzle
caused by excitation from
the piezoelectric crystal

Charge electrode
NOTE: charge electrode shown
rotated through 90 degrees
for ease of representation
Figure 3-7. Modulation of the ink jet by a piezoelectric crystal
If a voltage is applied to a piezoelectric crystal, it bends, and the amount that the crystal
bends depends on the amplitude of the applied voltage. Two opposite-polarity, bimorph
piezoelectric crystals are used in the printhead gun chamber, joined together so that the
crystals bend in sympathy with a fixed-frequency sine wave. This process gives a direct and
very controlled modulation to the ink. Because the edges are fixed, the crystal deflects and
moves a small volume of ink. This movement is transmitted through the ink and causes
disturbance in the jet, which then separates into equal size drops.

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 The frequency of the sine wave (modulation frequency) applied to the piezoelectric crystal
controls the rate of drop production. This drop production rate is a fixed value for each type
of printhead:
 Ultima plus and Midi plus: 64 kHz
 Ultima and Midi: 80 kHz
 Mini: 96 kHz
 Micro: 120 kHz
The amplitude of the sine wave (modulation voltage) applied to the piezoelectric crystal
controls exactly where the ink jet forms into drops, and depends on:
 The type of printhead.
 The different characteristics of each separate printhead.
 The type of ink that is used.
This modulation voltage is a value calibrated at Linx between 0 and 255 volts AC, and is
unique to every printhead. The value is referred to as the Reference Modulation and is part of
the printhead code, and is also printed on each printhead conduit label.
As described earlier, the modulation amplitude controls the point at which the ink jet
separates into drops. This point changes and depends on the viscosity of the ink—if the ink
is thicker, the drop break-off occurs at a later point than for thinner ink. The correct point of
drop break-off is within the charge electrode plates where printing drops are required to be
charged.

6246

Printhead nozzle

Ink jet pulsed by the

piezoelectric crystal

Drop break-off
begins to occur Charge electrode

Strobe LED

Point of drop break-off (jet break-up).

This must occur within the central
area of the charge electrode for the
drops to receive the correct charge Charged drops

Figure 3-8. Correct drop break-off in the charge electrode

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 3.5.4 Drop charge
To build a pattern, each drop has to be directed to an exact position on the substrate. To get
this accuracy, each drop is charged and deflected separately by a defined amount.
Each drop to be printed receives an electric charge, so that the drop can be deflected by the
electrostatic field between the deflector plates. The amount that the drop is charged is
controlled by the planned position of the drop on the substrate. The further the drop has to
be deflected, the greater the electric charge on it.
To charge a drop, a positive voltage of between 0 volts and +255 volts is applied to the
charge electrode for the time (1/modulation frequency) required to create one complete
drop. The drop now has a negative charge. This charge is created by capacitive coupling, by
which a flow of electrons is induced from the nozzle (which is at earth potential), through
the electrically conductive ink onto the ink drop as it takes shape. When the drop separates
from the ink jet, the charging voltage is removed from the charge electrode and the drop
holds the given charge.
The charge timing is such that the exact point of drop break-off occurs at the end of the
charge pulse. Timing the end of the charge pulse to occur at the exact drop break-off point is
very important. Accurate timing makes sure that the drop has been given the full charge,
which increases the accuracy of the printed position of the drop on the substrate.
If the following drop is to be printed, the voltage on the charge electrode is set to the
applicable level for the time period of the drop production. If the next drop is not for
printing (and is, therefore, passed straight to the gutter), a small correction voltage of 12.5%
of the previous charge voltage is applied. This action is called historic correction, which is
described later in this section (refer to ‘Historic correction’ on page 3—15).

Strobe LED
A red light-emitting diode (LED) is fitted at the bottom of the charge electrode slot, so that
the light is behind the jet break-up point when looked at from the front of the printhead.
The LED is pulsed at the same frequency as the modulation signal. The stroboscopic effect
of the light causes the ink jet to appear stationary in the charge electrode slot when looked
at with a magnifying eyeglass. This feature allows the jet break-up to be examined, which
can be useful for fault diagnosis purposes. When the ink jet break-up is examined with an
eyeglass of x10 or x20 magnification, the example shown in Figure 3-8 is seen.
The LED electrical supply is enabled when the printhead cover tube is removed, and so can
also be used as an indication that the Hall-effect switch circuit is operating correctly.
However, for safety reasons, make sure that the deflector plates and the charge electrode
have been made safe before these components are touched or work is done on the
printhead. Refer to ‘Printhead cover sensor’ on page 3—8 for more information. Refer also
to the descriptions of the Safety Override link LK19 and the Cover Off Override link LK21
in the section, ‘Electronics and software’ on page 3—46.

3.5.5 Historic correction

Historic correction is used to remove the positive charge induced in a non-printing drop
from a printing drop. The historic correction voltage ensures that non-printing drops have
zero charge when they leave the charge electrode, and therefore pass straight to the gutter.
A non-printing drop following a charged drop is susceptible to capacitive coupling from
the charged drop. This would place a small but significant positive charge on the
non-printing drop. To remove this unwanted charge, an historic correction voltage of 12.5%
of the previous charge voltage is applied to the charge electrode for all non-printing drops.
For example, a printing drop has 100 volts applied to the charge electrode for the time
period 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 induced in the non-printing drop
from the preceding printing drop, 12.5 volts is applied to the charge electrode for the period
of the non-printing drop’s production, to stabilize its charge at zero.

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 3.5.6 Drop deflection
When drops have been charged to the correct level, the drops continue along the flight path
and pass between the deflector (EHT) plates. These plates have a fixed high voltage applied
across them of +8 kV maximum, which creates an electrostatic field. The drops that have a
negative charge (printing drops) are deflected in this field towards the positive plate. The
drops are deflected by an amount that is proportional to the field strength and the amount
of charge on each drop.
The printing drops then exit through the slot in the printhead cover tube and are applied to
the substrate in rasters to create the characters. The combination of the speed of the drops
through the field and the charge given to the drops is accurately measured to make sure
that each drop is put in the correct position on the substrate.
Non-printing drops are given zero charge, which causes zero deflection, so the drops
continue along a straight flight path and enter the gutter. A vacuum on the gutter draws the
ink drops back through the system to the ink tank to be used again.
IMPORTANT: The deflector plates and mountings must always remain clean and without
ink deposits, otherwise a decrease in print quality can occur. The mounting
for the 0 volts deflector plate is black in colour, and so ink deposits are not
always easily seen. The +8 kV deflector plate is made from stainless steel
and the mounting pillars are made from white plastic.

3.5.7 Guard drops

Because all printing drops have a negative charge, each drop tries to repel adjacent drops in
the flight path, which can cause a decrease in print quality. The most deflected drops in a
raster carry a higher negative charge and therefore have a greater repulsion effect on
adjacent drops. This effect is greater in large characters, which causes a greater decrease in
print quality. Because of this effect, it would not normally be possible to have drops that
touch on the substrate, which would ideally give a higher-quality print.
However, where high-quality print is required (with printed drops that touch on the
substrate), the drops in the flight path must be separated to remove the drop repulsion
effect. To get this separation, guard drops are inserted.
Guard drops are low-charge, non-printing drops that are inserted into each raster between
printing drops to separate the drops in flight, which decreases their interactive effect. When
large characters are printed, more guard drops are inserted between the most deflected
(higher charged) drops to decrease their greater interactive effect.

6248

No guard drops, therefore,

much greater repulsion

Low charge, non-printing

guard drops inserted
to reduce repulsion

Gutter Gutter

Figure 3-9. Guard drops

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

40006

Jet break-up
Instant of drop break-off

Modulation signal

Phasing signal Phase sensor

(½ width pulses) output

Step 1

Step 2
(moved right by one phase position)

Step 3
(moved right by one phase position)

Phase found

Charging pulses

Figure 3-10. Phase control process

The process performs a continuous sequence of phase cycles if the printer is in the 'Jet
Running' state. If the printer is printing, a single phase cycle is performed at the end of each
message.

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 3.5.9 Time of flight (TOF)
During printer operation, solvent naturally evaporates from the ink. This evaporation
causes the ink to become thicker, that is, the viscosity of the ink increases. If the evaporation
is not controlled, a decrease in jet speed occurs. This in turn would cause 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 the jet speed and adjusts the pressure to
compensate for any changes.
This monitoring of the jet speed is known as time of flight (TOF) and is achieved initially in
the same way as the phase operation. That is, a number of TOF drops are charged by
applying 10 volts to the charge electrode. This packet of drops travels past the phase sensor
(situated in the DPP) where it induces a current in the sensor, which starts a counter. The
count increments until the same packet of TOF drops passes the TOF sensor (also situated
in the DPP). As the TOF packet passes the TOF sensor it induces a current, known as the
TOF signal, in the sensor, which stops the counter. The counter value is the Actual TOF.
This Actual TOF value is compared with a Reference TOF, an evaluation of jet speed is made,
and the system pressure is increased or decreased as necessary to maintain a constant jet
speed, as follows:
 If Actual TOF is equal to Reference TOF (±0.3%), system pressure is left unchanged.
 If Actual TOF is greater than Reference TOF (+0.3%), system pressure is increased.
 If Actual TOF is less than Reference TOF (–0.3%), 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 processes the received signal.

3.5.10 Phase/TOF during a stalled print

Stalled print is when a production line stops and the shaft encoder stops turning.
On older printers the printer waited until the print had completed before a phase/TOF
sequence was started. Because production lines are sometimes stopped for extended
periods, the phase position can drift during this time, which causes bad print quality when
the line is restarted. If the line was stopped for more than 40 minutes, the printer would
shut down with a “2.03 Time Of Flight Failure” Print Failure.
The ‘Phase/TOF during a Stalled Print’ feature on 7900 printers allows phase and TOF
sequences to begin again after the print has been stalled for 30 seconds. If the line restarts,
the printer completes the current print and restarts at the raster immediately after the last
printed raster.
There is a limitation with this feature: if the line restarts during a phase/TOF sequence,
printing will not continue until the phase/TOF sequence has completed. This delay can be
approximately 7 ms, which causes a small space between the previous and next printed
rasters. However, it is unlikely that production lines increase speed that quickly, therefore
the space will be negligible.
When phase/TOF sequences begin again during a stalled print, they repeat at the same rate
as inter-print phase/TOF sequences.

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 3.5.11 Viscosity control
As previously stated, the viscosity of the ink changes during printer operation. The
viscosity of the ink at the printhead is determined by the control system from the Set
Pressure required to maintain the actual TOF at the Reference TOF value. The Set Pressure
is varied in line with viscosity changes to maintain a constant TOF. When 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
Pressure. Solvent Add Pressure is derived from a Reference Pressure, which is a calibrated
value unique to each printhead (and which forms part of the printhead code).
See also: ‘Printhead temperature sensor’ on page 3—8.
For each of the printhead types, the Solvent Add Pressure is calculated as follows:
Solvent Add Pressure = Reference Pressure + 0.07 bar (1.02 p.s.i.).
Solvent is added to the ink when all of the following five conditions apply:
 Pressure check is OK (that is, the pressure generation circuits functioned correctly at jet
startup and there is no System Warning “3.18 Low Pressure”).
 Set Pressure is greater than Solvent Add Pressure.
 Actual TOF is within ±0.3% of Reference TOF.
 Warm-up time has expired (that is, the jet has been running for 45 minutes).
 Solvent level is OK (that is, the printer solvent level is above the minimum required and
there is no System Warning “3.04 Solvent Low”).
When solvent is added to the ink, the viscosity of the ink is lowered. Within 20 minutes (the
Viscosity Settle Time) this thinner ink arrives at the printhead, causing the Set Pressure to
decrease as the thinner ink flows from the nozzle. If, after 20 minutes, the Set Pressure value
is still above the Solvent Add Pressure value, more solvent is added to the ink tank.
To ensure that too much solvent is not inadvertently added to the ink, the printer allows
only 8 (MEK and pigmented inks), 12 (mixed base inks) or 25 (ethanol inks) 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 fails with Print
Failure “2.12 Viscosity”.

3.5.12 Starting up and shutting down

The principle of continuous ink jet printing has proved to be the most effective means of
printing with an ink that is required to dry almost instantly (within a second) on virtually
any surface. If ink is required to dry quickly on the product, it also has a tendency to dry in
the printhead, causing it to become blocked.
The continuous ink jet printer overcomes this problem by continuously circulating the ink
through the printhead and the ink system. Although the solvent in the ink is evaporating
quickly during this process, the nozzle does not become blocked because there is a
continuous replacement of ink in the nozzle.
A problem occurs at shutdown when ink is left in the printhead nozzle; because it is fast
drying, it will soon cause a blockage in the nozzle. To overcome this, special functions to
clear the nozzle are necessary.
On shutdown, the ink is removed from the nozzle and the gun by suction through the feed
and purge lines. Just before final shutdown, solvent is introduced into the ink gun and is
circulated through the nozzle and gutter, which clears ink from these vital components.
This automatic procedure makes it unnecessary to manually clean the printhead after
shutdown.

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 During startup, the following series of actions occurs automatically:
 The electronic circuitry is checked.
 The Ink System Feed valve, and the Printhead Feed and Purge valves are opened to
allow the ink to circulate through the printhead.
 The Purge valve is closed, causing the ink jet to be established.
 Pressure is increased to normal operating pressure and the ink jet is pulsed by the
modulation process to cause drop break-off.
 The TOF is adjusted to be close to the reference TOF, that is, drop velocity is corrected.
Only when these systems are operating correctly will the printer go to the ‘Printing’
state.
 The phasing and modulation are checked automatically for optimum positioning.
 On receiving a signal from the ‘print go’ sensor (for example, a photocell), the printer
prints the message previously entered, which is automatically updated for items such
as dates and sequential numbers.
All these actions should operate automatically and it should not, under normal operating
conditions, be necessary to remove the printhead cover tube and perform any maintenance
during startup or shutdown. However, under certain conditions it may be necessary to
remove the printhead cover tube and clean the printhead manually with solvent at regular
intervals.
IMPORTANT: When the printhead is cleaned with solvent, the solvent used must be the
correct type for the ink that is used in the printer.

3.5.13 Jet/nozzle alignment

The alignment of the jet is critical to the performance of the printhead. There are two
requirements:
 The jet must pass centrally through the charge electrode slot to ensure correct charging.
 The undeflected drops must enter the gutter cleanly, that is, without clipping the edges.
It is not possible to adjust the position of the charge electrode, the DPP or the gutter. It is
possible to achieve a small amount of movement of the nozzle to correct jet misalignment.

3.5.14 Print quality

During manufacturing, each printer undergoes a series of performance and quality tests to
establish the individual characteristics of each printhead. These characteristics are related to
the printhead type and variant (for example, type 62 µm; variant Ultima) and are:
 Reference Pressure
 Reference Modulation voltage
 Charge Calibration Factor
These parameters are established to give consistent print quality. The parameters are then
grouped together to form the printhead code for the particular printhead. These parameters
are also identified on the printhead conduit label, which is located near to the conduit
attachment point to the printer.
Refer to Printhead > Printhead Code in Chapter 4: ‘System Options’ for information about
how the code is created.

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 3.5.15 Printhead/nozzle replacement
Whenever a printhead is replaced, the printhead type and the code for the new printhead
must be entered through the options on the Printhead page (Print Monitor > Menu > Setup
> Installation > Printhead > Printhead Type and Printhead Code). Also, whenever a
printhead or a nozzle is replaced, the new offset values, for all ink types except 3103, must
be used from the supplied Reference Pressure and Reference Modulation Offset Table. For the
calibration procedure, refer to Chapter 5: Maintenance > Maintenance Instructions >
‘Calibrated Nozzle Replacement (Offset Calibration)’ maintenance instruction.
Prior to removing the printhead for replacement, the printer must be allowed to complete a
full normal shutdown. This removes any residual ink in the nozzle, and the feed, purge and
gutter lines.

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3.6 Ink system
3.6.1 General description
NOTE: All specified filter sizes are nominal ratings.
The ink system is contained in a stainless steel enclosure, which is part of the base unit of
the cabinet. The cabinet top cover has two openings through which the ink and solvent
tanks are filled, by internal filler tubes. The filler tubes are sealed by removable protective
caps. Both the filler tubes and protective caps are colour coded—black for ink and white for
solvent. Adhesive identification labels for the ink and solvent types are supplied with the
printer, which can be attached to the protective caps.
The ink system contains the following main components (refer to Figure 3-11 on
page 3—24, ‘Static ink system—standard 7900 printer’):
 Ink tank
 Ink pick-up tube that includes a 40 µm stainless steel in-line filter
 Pump and motor assembly
 10 µm (nominal) polypropylene disposable main ink filter
 Small ink manifold assembly, which includes the pressure transducer and venturi
 Damper
 Solvent tank
 Solvent pick-up tube that includes a 20 µm stainless steel in-line filter
 Five solenoid-operated valves
 Interconnecting pipes
NOTE: The symbol ‘µm’ stands for micrometre, which is the SI unit of length and formerly
known as the micron.
Standard 7900 printers have polyethylene ink and solvent tanks with nominal capacities of
1440 ml. Both tanks are fitted with fluid level sensors (float switches) to detect when the
level of ink or solvent is below a set point. If either sensor detects a low fluid level, a System
Warning message is displayed (“3.03 Ink Low” or “3.04 Solvent Low”).
If, during a print run, the low ink condition is allowed to continue, the system reports the
Print Failure “2.05 Ink Tank Empty” after 8 hours for Ultima, Midi, Mini, and Micro
printheads, and 6 hours for Ultima plus and Midi plus printheads. If, during a print run, the
low solvent condition is allowed to continue, the system reports the Print Failure “2.06
Solvent Tank Empty” after 12 hours (for all printheads). This response prevents the ink or
solvent from running out completely.
The ink system pump used in the standard 7900 printer has an internal pressure relief valve
(PRV). The pump and motor assembly is controlled by a 0 volts to +5 volts drive signal
(which depends on the requested pressure) supplied by the IPM PCB.
The pump draws ink from the tank through the ink pick-up tube, which includes a 40 µm
in-line filter. The ink then flows through the pump to the 10 µm main ink filter, which
provides the primary filtration within the ink system. The filter removes any remaining
particles before the ink reaches the venturi manifold and the printhead. From the main ink
filter, the ink is fed through the venturi manifold, damper, and open Feed valve, and then
through a Y-piece connector out to the printhead.The damper minimizes any ink pressure
fluctuations within the primary circuit, and isolates the printhead from pressure
fluctuations.

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 Ink is fed to and from the printhead through the feed, purge and gutter lines, and a 3-way
fluid connector, which connects the printhead to the ink system. This connector is within
the ink system enclosure and contains a 35 µm filter in the feed line on Ultima plus and Midi
plus printheads, and a 15 µm filter on Ultima, Midi, Mini, and Micro printheads. The ink
system and printhead interconnecting pipes are colour-coded: red stripe for the feed line,
blue stripe for the purge line, and no stripe for the gutter line.
The ink pick-up tube and filter (all ink types), main ink filter (all ink types), 3-way fluid
connector filter (pigmented inks only), and damper are replaced at every scheduled
maintenance. All of these items must be replaced according to the ‘Scheduled Maintenance’
procedure provided in Chapter 5: ‘Maintenance’.
The venturi in the manifold provides suction to return surplus ink from the printhead
gutter to the ink tank through the Gutter valve. This suction also draws solvent from the
solvent tank as required.
During solvent addition, solvent is drawn from the tank through the solvent pick-up tube,
which includes a 20 µm in-line filter. The solvent is then drawn through the de-energized
Solvent Flush valve, energized Solvent Add (Solvent Top-up) valve and the venturi to the
ink tank.
During a solvent flush, solvent is drawn from the tank through the solvent pick-up tube.
The solvent is then drawn through the de-energized Solvent Add (Solvent Top-up) valve,
energized Solvent Flush valve, Y-piece connector, and out to the printhead along the feed
line.

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 Gun Printhead Printhead Feed valve and filter assembly
chamber Purge valve (35 µm filter—Ultima plus and Midi plus 75 µm printheads;
15 µm filter—Ultima and Midi 62 µm, Mini 50 µm and Micro 40 µm printheads)
Purge line

Oct 2013
Printhead OFF Feed line Gutter restrictor
(2-metre printhead conduits only—Ultima and Midi 62 µm,
Gutter line Mini 50 µm, and Micro 40 µm printheads)

Restrictor

10 µm Main ink 3-way fluid connector and in-line feed filter assembly
filter (35 µm filter—Ultima plus and Midi plus 75 µm printheads;
15 µm filter—Ultima and Midi 62 µm, Mini 50 µm
Damper and Micro 40 µm printheads)
7 25 1 21 79088_01_Stat

19 20
Venturi
24

14 OFF 15 OFF 16 OFF 17 OFF 18 OFF

8
Pressure
transducer
9 3 10 4 11 5 12 6 13

3—24
Feed Purge Gutter Solvent Solvent
valve valve valve Add Flush
A valve valve
C

Vent
Pump
22
Vent
PIPE FLUID KEY
40 µm in-line
Ink filter fitted in
Ink with air bubbles ink pick-up tube 20 µm in-line
filter fitted in
Solvent
INK SOLVENT solvent
pick-up tube
This drawing provides details for all Mk7 printheads regardless
of which model of printer they can be fitted to.

Figure 3-11. Static ink system—standard 7900 printer

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 3.6.2 Venturi manifold assembly
The central part of the ink system is the manifold assembly, which manages the ink and
solvent distribution in the system. Three components are used to perform these
processes—the manifold block, vacuum venturi, and pressure transducer, all of which are
part of the complete manifold assembly.
The main component is the manifold block, which has moulded internal interconnecting
bores. These bores enter and exit the manifold block at ports to which are fitted the vacuum
venturi, pressure transducer, and interconnecting ink and solvent pipes.
The manifold assembly is fitted through the front wall of the ink system enclosure to the
right of the ink system valves. The fluid connections of the manifold are on the inside of the
enclosure, and the electrical connections of the pressure transducer are on the outside. This
arrangement isolates the electrical and fluid connections from each other.
The standard 7900 printer and the 7900 Food Grade printer are fitted with the Mk4 venturi
manifold and the Mk4 venturi. The following illustration shows the manifold assembly, ink
system valves, and the cableform for the valves and pressure transducer.
Mk4 venturi
manifold block
Solvent Flush
valve (5)
Pressure
transducer

Gutter Solvent Add

valve (3) valve (4)
73075

Feed Purge
valve (1) valve (2)

Venturi
Violet
Blu

Gr
e

ee Festo
n
Yello fitting
w
Red

Connector SK1

Ink system cableform

Figure 3-12. Mk5 venturi manifold assembly

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 Vacuum venturi
When the ink flows through the venturi, a vacuum is created, which is applied in the ink
system for different functions. During normal operation, the vacuum draws surplus ink
back into the system from the printhead gutter.
The vacuum is also used to draw solvent from the solvent buffer tank into the system for
ink viscosity control, and to flush the printhead and ink lines. Other uses for the vacuum
are to purge the ink lines, and to clear blockages and obstructions in the printhead.

Venturi vacuum suction

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

48004

Small bore drilling

Groove around the circumference of

the venturi to allow equalization of
vacuum at both tappings
Suction connected through
the manifold to the
Solvent Add valve Suction connected
through the manifold
to the Gutter valve

Area of low pressure around

the ink flow caused by turbulence
Venturi housing

Large bore drilling

Ink and air returned

to the ink tank
Figure 3-13. Section view of the venturi

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 Mk4 venturi
The Mk4 venturi is fitted to all 7900 printers and provides improved gutter suction
compared to the standard Mk3 version. The venturi is the same shape and size as the Mk3
but is made of stainless steel. A hole is provided in the end of the venturi to allow easy
removal from the manifold with a screw. Each spare part Mk4 venturi is supplied with a
screw.

Hole to allow 73078

easy removal

Figure 3-14. Mk4 venturi

Mk3 high flow rate venturi

The Mk3 high flow-rate venturi was introduced as a special type of venturi to correct gutter
overflow issues in some applications.
This special venturi is white and has a larger bore diameter to increase the ink flow. This
increased ink flow gives a 15% improvement in gutter suction compared to the standard
Mk3 and the Mk4 venturis.
The venturi can be used in difficult applications where there is a problem with gutter
suction. For example:
 For Ultima plus or Midi plus printheads fitted with a 4-metre conduit.
 In very cold environments.
 Where the printhead is installed below the printer.
NOTES:
1. When the high flow-rate venturi is fitted, solvent consumption increases by
approximately 15%. Linx recommends that the high flow-rate venturi is not fitted
unless the Mk4 venturi does not provide enough suction.
2. Linx recommends that the high flow-rate venturi is not used with Linx Black Ultra
Fast-Drying ink 1405.

Pressure transducer
The pressure transducer monitors the current ink pressure (Actual Pressure) in the ink
system and provides a feedback signal for pressure control.
Every pressure transducer has a calibration value that is printed on a label attached to the
pressure transducer.
IMPORTANT: Calibration of the pressure transducer is required only when the IPM PCB
or pressure transducer is replaced. The pressure transducer must not be
calibrated when a new printer is commissioned or during scheduled
maintenance. Refer to the ‘Pressure Transducer Calibration’ maintenance
instruction in Chapter 5: ‘Maintenance’.

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 3.6.3 Valves
There are five valves in the ink system enclosure of the standard 7900 printer and the 7900
Food Grade printer. These solenoid-operated valves control the flow of ink and solvent
through the system. The valves are sealed and cannot be disassembled.
The following gives the type of valve and its function:
 2-way Feed valve
 3-way Purge valve
 3-way Gutter valve
 3-way Solvent Add (Solvent Top-up) valve
 3-way Solvent Flush valve
The five valves are fitted through the front wall of the ink system enclosure. The fluid
connections are on the inside of the enclosure and the electrical connections are on the
outside. This arrangement isolates the electrical and fluid connections from each other.

Electrical connector

79094
Valve solenoid

Inlet/outlet ports

Valve body
Figure 3-15. Ink system 3-way valve

3.6.4 Main ink filter

All 7900 printers use the same 10 µm (nominal) polypropylene, disposable main ink filter,
which provides the primary filtration within the ink system.

79071

Figure 3-16. Main ink filter

FA69398–1
Oct 2013 3—28 Linx 7900 Maintenance Manual
 3.6.5 Damper
The standard 7900 printer is fitted with the type of damper shown in Figure 3-17. The
damper minimizes any ink pressure fluctuations within the primary circuit, and isolates the
printhead from pressure fluctuations. A restrictor is fitted in the inlet pipe to the damper
(between the venturi manifold and the damper). This restrictor must be fitted, otherwise the
damper will not operate correctly.
A drain fitted to the bottom of the damper allows the ink system to be easily emptied.
The damper is attached to a hook on the right inside wall of the ink system enclosure.

79073

Restrictor

Figure 3-17. Damper

When a scheduled maintenance is completed and the Maintenance Finished key is
pressed, the printer requests an Easi-Change® code. This 12-character Easi-Change® code
is printed on a label attached to the damper assembly and on the damper packaging.
The new scheduled maintenance intervals (maintenance times) cannot be applied until a
valid code is entered into the printer.
Refer to ‘Easi-Change code’ in the ‘Maintenance Times’ section of Chapter 5: ‘Maintenance’
for more information about the Easi-Change® code and how the code is entered into the
printer.
The 7900 Spectrum and 7900 Food Grade printers do not have the Easi-Change® facility.

FA69398–1
Linx 7900 Maintenance Manual 3—29 Oct 2013
 3.6.6 Ink system connections
The pipe connections to the venturi manifold are made with barb or Festo fittings. The
barbs are sealed by interference-fit to the manifold and cannot be removed, and so cannot
be replaced.
The following illustration shows the Mk4 venturi manifold assembly and ink system valves
used in the standard 7900 printer, and provides information about the ink system pipe
connections. Refer to the static ink system diagram (Figure 3-11) with the following
illustration.
22

21

20 19

Venturi manifold Mk4

18 17 16 15 14
1

25

8 7

6 5 4 3 2
13 12 11 10 9
B
C Solvent Flush Solvent Add Gutter Purge Feed
(5) (4) (3) (2) (1)
A
24 73027
STANDARD 7300, 7900 AND 5900 PRINTER—INK SYSTEM PIPE CONNECTIONS
From To Pipe lengths
Port 1 (venturi) Damper inlet (bleed cap end) 400 mm natural pipe (1/8 in. o.d.)
Port 2 not used — —
Port 3 (Purge valve) 3-way fluid connector (purge) 360 mm blue stripe pipe (1/8 in. o.d.)
Port 4 (Gutter valve) Port 8 (venturi) 160 mm natural pipe (1/8 in. o.d.)
Port 5 (Solvent Add valve) Port 6 (Solvent Flush valve) 160 mm natural pipe (1/8 in. o.d.)
Port 9 (Feed valve) Port A (new Y-piece connector) 120 mm red stripe pipe (1/8 in. o.d.)
Port 10 (Purge valve) Ink tank 360 mm natural pipe (1/8 in. o.d.)
Port 12 (Solvent Add valve) Port 7 (venturi) 160 mm yellow stripe pipe (1/8 in. o.d.)
Port 13 (Solvent Flush valve) Port B (new Y-piece connector) 120 mm red stripe pipe (1/8 in. o.d.)
Port 15 (Purge valve) Port 11 (Gutter valve) 160 mm natural pipe (1/8 in. o.d.)
Port 16 (Gutter valve) 3-way fluid connector (gutter) 360 mm natural pipe (1/8 in. o.d.)
Port 17 (Solvent Add valve) 19 (Y-piece connector) 90 mm natural pipe (1/8 in. o.d.)
Port 18 (Solvent Flush valve) 20 (Y-piece connector) 90 mm natural pipe (1/8 in. o.d.)
Port 21 (Y-piece connector) 22 (solvent tank pick-up tube) 260 mm natural pipe (1/8 in. o.d.)
Port 24 (venturi) Ink tank (ink return line) 500 mm natural pipe (6 mm o.d.)
Port C (new Y-piece connector) 3-way fluid connector (feed) 300 mm red stripe pipe (1/8 in. o.d.)
Damper outlet Port 14 (Feed valve) 360 mm red stripe pipe (1/8 in. o.d.)
Main ink filter outlet Port 25 (venturi & pressure transducer) 185 mm natural pipe (6 mm o.d.)
Ink pick-up tube Pump inlet 330 mm natural pipe (6 mm o.d.)
Pump outlet Main ink filter inlet 120 mm natural pipe (6 mm o.d.)
Ink tank Solvent tank (vent) 300 mm natural pipe (3/16 in. o.d.)
Solvent tank Ink tray (vent) 480 mm natural pipe (3/16 in. o.d.)

Figure 3-18. Ink system pipe connections—standard 7900 printer

FA69398–1
Oct 2013 3—30 Linx 7900 Maintenance Manual
 3.6.7 Ink and solvent flows
Read the following ink and solvent flow descriptions with the ink and solvent flow
diagrams on the following pages.
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 3-19 on page 3—32)

The ink flow in the primary circuit is from the ink tank through the ink pick-up tube and
in-line filter to the pump. The ink is then fed under pressure from the pump through the
main ink filter to the venturi manifold. The pressurized ink within the manifold passes the
pressure transducer, which sends an electrical feedback signal to the electronics system.
This signal is an indication of the Actual Pressure at which the pump is operating, and is
used to control the pump speed to set the required pressure. After the pressure transducer,
the ink flows through the venturi, where the vacuum is generated, and then returns to the
ink tank.

Secondary circuit (Figure 3-20 on page 3—33)

The secondary ink flow circuit operates when the Ink System Feed valve and the Printhead
Feed valve are opened. A fluid connection within the manifold feeds the ink from the
primary circuit at the venturi out to the damper and the open Feed valve. This valve allows
the pressurized ink to be fed along the feed line, through a Y-piece connector and the in-line
feed filter in the 3-way fluid connector. The ink continues along the feed line to the
printhead, and then passes through the open Printhead Feed valve to the printhead nozzle,
which creates the jet.
Drops of ink that are not used for printing enter the gutter. The venturi vacuum action on
the gutter draws the surplus ink back into the system through the 3-way fluid connector
and the de-energized Gutter valve. The ink is then returned to the ink tank through the
venturi.

FA69398–1
Linx 7900 Maintenance Manual 3—31 Oct 2013
 Gun Printhead Printhead Feed valve and filter assembly
chamber Purge valve (35 µm filter—Ultima plus and Midi plus 75 µm printheads;
15 µm filter—Ultima and Midi 62 µm, Mini 50 µm and Micro 40 µm printheads)
Purge line

Oct 2013
Printhead OFF Feed line Gutter restrictor
(2-metre printhead conduits only—Ultima and Midi 62 µm,
Gutter line Mini 50 µm, and 40 Micro µm printheads)

Restrictor

10 µm Main ink 3-way fluid connector and in-line feed filter assembly
filter (35 µm filter—Ultima plus and Midi plus 75 µm printheads;
15 µm filter—Ultima and Midi 62 µm, Mini 50 µm
Damper and Micro 40 µm printheads)
7 25 1 21 79088_02_Pri

19 20
Venturi
24

14 OFF 15 OFF 16 OFF 17 OFF 18 OFF

8
Pressure
transducer
9 3 10 4 11 5 12 6 13

3—32
Feed Purge Gutter Solvent Solvent
valve valve valve Add Flush
A valve valve
C

Vent
Pump
22
Vent
PIPE FLUID KEY
40 µm in-line
Ink filter fitted in
Ink with air bubbles ink pick-up tube 20 µm in-line
filter fitted in
Solvent
INK SOLVENT solvent
pick-up tube
This drawing provides details for all Mk7 printheads regardless
of which model of printer they can be fitted to.

Figure 3-19. Primary circuit—standard 7900 printer

FA69398–1
Linx 7900 Maintenance Manual
 Gun Printhead Printhead Feed valve and filter assembly
chamber Purge valve (35 µm filter—Ultima plus and Midi plus 75 µm printheads;
15 µm filter—Ultima and Midi 62 µm, Mini 50 µm and Micro 40 µm printheads)
Purge line

Printhead ON Feed line Gutter restrictor

FA69398–1
(2-metre printhead conduits only—Ultima and Midi 62 µm,
Gutter line Mini 50 µm, and Micro 40 µm printheads)

Restrictor

10 µm Main ink 3-way fluid connector and in-line feed filter assembly
filter (35 µm filter—Ultima plus and Midi plus 75 µm printheads;
15 µm filter—Ultima and Midi 62 µm, Mini 50 µm
Damper and Micro 40 µm printheads)
7 25 1 21 79088_03_Sec

19 20

Linx 7900 Maintenance Manual

Venturi
24

14 ON 15 OFF 16 OFF 17 OFF 18 OFF

8
Pressure
transducer
9 3 10 4 11 5 12 6 13

3—33
Feed Purge Gutter Solvent Solvent
valve valve valve Add Flush
A valve valve
C

Vent
Pump
22
Vent
PIPE FLUID KEY
40 µm in-line
Ink filter fitted in
Ink with air bubbles ink pick-up tube 20 µm in-line
filter fitted in
Discoloured solvent
INK SOLVENT solvent
pick-up tube
This drawing provides details for all Mk7 printheads regardless
of which model of printer they can be fitted to.

Figure 3-20. Secondary circuit (normal running after a start purge—standard 7900 printer

Oct 2013
 Solvent addition (Figure 3-21 on page 3—35)
Under normal operating conditions, the Set Pressure is adjusted as the ink viscosity changes
to maintain a regular TOF. For example, as the ink viscosity increases caused by solvent
evaporation, the Set Pressure is increased to maintain a fixed TOF (at the Reference TOF)
with the thicker ink. If the Set Pressure reaches the known Solvent Add Pressure, solvent is
added to the ink to decrease the viscosity and so maintain the Actual TOF at Reference TOF.
A solvent addition occurs only if all of the following conditions apply:
 The pressure check is good (that is, the pressure generation circuits operated correctly
at jet startup and the System Warning “3.18 Low Pressure” has not occurred).
 The Set Pressure is greater than the Solvent Add Pressure.
 The Actual TOF is within ±0.3% of the Reference TOF.
 The warm-up time has expired (that is, the jet has been in operation for 45 minutes).
 The solvent level is acceptable (that is, the printer solvent level is above the minimum
required and the System Warning “3.04 Solvent Low” has not occurred).
NOTE: Solvent is not added if the System Warning “3.18 Low Pressure” occurs, because
this warning indicates that there is a loss of pressure in the system. In this condition
a higher pressure is then required to get the correct TOF, although the ink viscosity
is probably acceptable.
During a solvent addition sequence, the Solvent Add (Solvent Top-up) valve is energized.
The venturi vacuum is now applied through the energized Solvent Add (Solvent Top-up)
valve, as well as the Gutter valve. The venturi vacuum draws solvent from the solvent tank,
through the Solvent Flush valve and the energized Solvent Add (Solvent Top-up) valve to
the venturi. At the venturi, the solvent mixes with the ink that is returning to the ink tank.
The lower viscosity ink that is now in the ink tank is then fed to the printhead.
The Solvent Add (Solvent Top-up) valve is energized for a set time, which is calculated to
allow an exact quantity of solvent to be added in a single ‘solvent add’ sequence. This
Solvent Add Time depends on the ink type and printhead type. Refer to the ‘Ink type
dependent parameters’ tables at the end of this section for more information.
When solvent is added to the ink in the ink tank, the viscosity of the ink is lowered. This
thinner ink reaches the printhead within 3 minutes, and the jet speed increases. The Set
Pressure is then decreased to maintain the jet speed at the Reference TOF. If after
20 minutes (the Viscosity Settle Time), the Set Pressure value remains above the Solvent Add
Pressure value, more solvent is added to the ink tank.
After solvent is added, further solvent additions are prevented for the Viscosity Settle Time.
This time allows the solvent to mix in the ink tank, and for the effects of the solvent addition
to begin to be seen at the printhead.

FA69398–1
Oct 2013 3—34 Linx 7900 Maintenance Manual
 Gun Printhead Printhead Feed valve and filter assembly
chamber Purge valve (35 µm filter—Ultima plus and Midi plus 75 µm printheads;
15 µm filter—Ultima and Midi 62 µm, Mini 50 µm and Micro 40 µm printheads)
Purge line

Printhead ON Feed line Gutter restrictor

FA69398–1
(2-metre printhead conduits only—Ultima and Midi 62 µm,
Gutter line Mini 50 µm, and Micro 40 µm printheads)

Restrictor

10 µm Main ink 3-way fluid connector and in-line feed filter assembly
filter (35 µm filter—Ultima plus and Midi plus 75 µm printheads;
15 µm filter—Ultima and Midi 62 µm, Mini 50 µm
Damper and Micro 40 µm printheads)
7 25 1 21 79088_04_SolvAdd

19 20

Linx 7900 Maintenance Manual

Venturi
24

14 ON 15 OFF 16 OFF 17 ON 18 OFF

8
Pressure
transducer
9 3 10 4 11 5 12 6 13

3—35
Feed Purge Gutter Solvent Solvent
valve valve valve Add Flush
A valve valve
C

Vent
Pump
22
Vent
PIPE FLUID KEY
40 µm in-line
Ink filter fitted in
Ink with air bubbles ink pick-up tube 20 µm in-line
filter fitted in
Solvent
INK SOLVENT solvent
pick-up tube
This drawing provides details for all Mk7 printheads regardless
of which model of printer they can be fitted to.

Figure 3-21. Solvent addition—standard 7900 printer

Oct 2013
 Gun Printhead Printhead Feed valve and filter assembly
chamber Purge valve (35 µm filter—Ultima plus and Midi plus 75 µm printheads;
15 µm filter—Ultima and Midi 62 µm, Mini 50 µm and Micro 40 µm printheads)
Purge line

Oct 2013
Printhead OFF Feed line Gutter restrictor
(2-metre printhead conduits only—Ultima and Midi 62 µm,
Gutter line Mini 50 µm, and Micro 40 µm printheads)

Restrictor

10 µm Main ink 3-way fluid connector and in-line feed filter assembly
filter (35 µm filter—Ultima plus and Midi plus 75 µm printheads;
15 µm filter—Ultima and Midi 62 µm, Mini 50 µm
Damper and Micro 40 µm printheads) 79088_05_
7 25 1 21 AfterSdown

19 20
Venturi
24
Normal Shutdown sequence.

14 OFF 15 OFF 16 OFF 17 OFF 18 OFF

8
Normal shutdown (Figure 3-22)

Pressure
transducer
9 3 10 4 11 5 12 6 13

3—36
Feed Purge Gutter Solvent Solvent
valve valve valve Add Flush
A valve valve
C

Vent
Pump
22
Vent
PIPE FLUID KEY
40 µm in-line
Ink filter fitted in
Ink with air bubbles ink pick-up tube 20 µm in-line
cleans the nozzle and gutter, which prepares the printer for the next jet startup.

filter fitted in
Solvent
INK SOLVENT solvent
pick-up tube
This drawing provides details for all Mk7 printheads regardless
of which model of printer they can be fitted to.
through the printhead to clean the gun, and the feed and purge lines. Then a solvent jet

The following diagram shows the state of the ink system after successful completion of the
During a Normal Shutdown, the ink is removed from the printhead nozzle and the gun by
venturi suction through the feed and purge lines. Before final shutdown, solvent is flushed

Figure 3-22. Ink system after a successful normal shutdown—standard 7900 printer

FA69398–1
Linx 7900 Maintenance Manual
 INK TYPE DEPENDENT PARAMETERS (ULTIMA PRINTHEAD)
Parameters Ink Data
Ink type 3103 1010 1014 1016 1018 1065 1070 1075 1085 1121 1240 1243 1248 1270 1405 2030 2035 2250 3123 3124 3160 3240 3401
Solvent type 3501 1505 1505 1506 1505 1565 1560 1575 1585 1590 1512 1512 1517 1540 1705 2500 2500 2750 3501 3501 3560 3710 3905
Nominal Reference Pressure PREF (bits) 178 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
Adjusted manually according to published offset data table

FA69398–1
Reference Pressure Offset (bits) †
Normal Solvent Add Pressure Offset from PREF
+4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4
(bits)
Maximum number of consecutive Solvent Adds 12 12 12 12 12 12 1212 12 12 12 12 12 12 24 12 12 12 12 12 12 12 12
Reference Modulation Offset (VM + offset) (V) Adjusted manually according to published offset data table
Reference TOF (µs) 766 766 766 766 766 766 766 766 766 766 766 766 766 766 766 766 766 766 766 766 766 766 766
Normal Solvent Add Time tSA (s) 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10
Warm Up tSA if PSET > PSA (s) 10 10 9 10 10 10 10 10 10 10 9 9 9 10 10 10 10 10 10 10 10 9 10
Scheduled Maintenance interval (hr) 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000
5900 max. extended maintenance interval (hr) 6000 6000 6000 6000 N/A N/A N/A N/A N/A N/A 6000 N/A N/A N/A N/A N/A 6000 6000 N/A N/A N/A 6000 N/A
7900 max. extended maintenance interval (hr) 9000 9000 9000 9000 N/A N/A N/A N/A N/A N/A 9000 N/A N/A N/A N/A N/A 9000 9000 N/A N/A N/A 9000 N/A
Scheduled Maintenance interval (mth) 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12

Linx 7900 Maintenance Manual

5900 max. extended maintenance interval (mth) 12 12 12 12 N/A N/A N/A N/A N/A N/A 12 N/A N/A N/A N/A N/A 12 12 N/A N/A N/A 12 N/A
7900 max. extended maintenance interval (mth) 18 18 18 18 N/A N/A N/A N/A N/A N/A 18 N/A N/A N/A N/A N/A 18 18 N/A N/A N/A 18 N/A
Modulation Tracking Slope (V/bit) 2.5 2.0 2.0 1.0 2.0 1.0 1.5 2.3 1.2 2.0 2.0 2.0 1.1 1.0 1.3 1.4 1.4 2.0 2.5 2.5 2.5 2.0 2.5
† Relative to 3103 ink.

Table 3-1. Ink type dependent parameters table (Ultima printhead)

3—37
INK TYPE DEPENDENT PARAMETERS (MIDI PRINTHEAD)
3.6.8 Ink type dependent parameters

Parameters Ink Data

Ink type 3103 1010 1014 1016 1018 1065 1070 1075 1085 1121 1240 1243 1248 1270 1405 2030 2035 2250 3123 3124 3160 3240 3401
Solvent type 3501 1505 1505 1506 1505 1565 1560 1575 1585 1590 1512 1512 1517 1540 1705 2500 2500 2750 3501 3501 3560 3710 3905
Nominal Reference Pressure PREF (bits) 179 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 185 N/A N/A N/A N/A N/A N/A N/A N/A
Reference Pressure Offset (bits) † Adjusted manually according to published offset data table
Normal Solvent Add Pressure Offset from PREF
+4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4
(bits)
Maximum number of consecutive Solvent Adds 12 12 12 12 12 12 12
12 12 12 12 12 12 12 24 12 12 12 12 12 12 12 12
Reference Modulation Offset (VM + offset) (V) Adjusted manually according to published offset data table
Reference TOF (µs) 1262 1262 1262 1262 1262 1262 1262 1262 1262 1262 1262 1262 1262 1262 1262 1262 1262 1262 1262 1262 1262 1262 1262
Normal Solvent Add Time tSA (s) 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10
Warm Up tSA if PSET > PSA (s) 10 10 9 10 10 10 10 10 10 10 9 9 9 10 10 10 10 10 10 10 10 9 10
Scheduled Maintenance interval (hr) 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000
5900 max. extended maintenance interval (hr) 6000 6000 6000 6000 N/A N/A N/A N/A N/A N/A 6000 N/A N/A N/A N/A N/A 6000 6000 N/A N/A N/A 6000 N/A
7900 max. extended maintenance interval (hr) 9000 9000 9000 9000 N/A N/A N/A N/A N/A N/A 9000 N/A N/A N/A N/A N/A 9000 9000 N/A N/A N/A 9000 N/A
Scheduled Maintenance interval (mth) 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12
5900 max. extended maintenance interval (mth) 12 12 12 12 N/A N/A N/A N/A N/A N/A 12 N/A N/A N/A N/A N/A 12 12 N/A N/A N/A 12 N/A
7900 max. extended maintenance interval (mth) 18 18 18 18 N/A N/A N/A N/A N/A N/A 18 N/A N/A N/A N/A N/A 18 18 N/A N/A N/A 18 N/A
Modulation Tracking Slope (V/bit) 2.0 2.0 2.0 1.5 1.0 1.0 2.0 2.0 1.2 1.0 1.0 1.0 1.0 1.0 1.5 1.0 1.0 1.0 2.0 2.0 2.0 1.0 2.5
† Relative to 3103 ink.

Table 3-2. Ink type dependent parameters table (Midi printhead)

Oct 2013
 INK TYPE DEPENDENT PARAMETERS (ULTIMA A PRINTHEAD)
Parameters Ink Data
Ink type 3103 1035 1055 1056 1058 1280 1290
Solvent type 3501 1535 1555 1555 1558 1540 1540
Nominal Reference Pressure PREF (bits) 180 N/A N/A N/A N/A N/A N/A
Adjusted manually according to published
Reference Pressure Offset (bits) †
offset data table
Normal Solvent Add Pressure Offset from PREF
+4 +4 +4 +4 +4 +4 +4
(bits)
Maximum number of consecutive Solvent Adds 12 12 12 12 12 12 12
Adjusted manually according to published
Reference Modulation Offset (VM + offset) (V)
offset data table
Reference TOF (µs) 766 766 766 766 766 766 766
Normal Solvent Add Time tSA (s) 10 10 10 10 10 10 10
Warm Up tSA if PSET > PSA (s) 10 10 10 10 10 10 10
Scheduled Maintenance interval (hr) 2000 2000 2000 2000 2000 2000 2000
5900 max. extended maintenance interval (hr) N/A N/A 6000 6000 N/A N/A N/A
7900 max. extended maintenance interval (hr) N/A N/A 9000 9000 N/A N/A N/A
Scheduled Maintenance interval (mth) 12 12 12 12 12 12 12
5900 max. extended maintenance interval (mth) N/A N/A 12 12 N/A N/A N/A
7900 max. extended maintenance interval (mth) N/A N/A 18 18 N/A N/A N/A
Modulation Tracking Slope (V/bit) 1.3 1.7 2.4 2.4 1.9 1.9 1.6
† Relative to 3103 ink.

Table 3-3. Ink type dependent parameters table (Ultima A printhead)

INK TYPE DEPENDENT PARAMETERS (MIDI A PRINTHEAD)

Parameters Ink Data
Ink type 3103 1035 1055 1056 1058 1280 1290
Solvent type 3501 1535 1555 1555 1558 1540 1540
Nominal Reference Pressure PREF (bits) 182 N/A N/A N/A N/A N/A N/A
Adjusted manually according to published
Reference Pressure Offset (bits) †
offset data table
Normal Solvent Add Pressure Offset from PREF
+4 +4 +4 +4 +4 +4 +4
(bits)
Maximum number of consecutive Solvent Adds 12 12 12 12 12 12 12
Adjusted manually according to published
Reference Modulation Offset (VM + offset) (V)
offset data table
Reference TOF (µs) 1262 1262 1262 1262 1262 1262 1262
Normal Solvent Add Time tSA (s) 10 10 10 10 10 10 10
Warm Up tSA if PSET > PSA (s) 10 10 10 10 10 10 10
Scheduled Maintenance interval (hr) 2000 2000 2000 2000 2000 2000 2000
5900 max. extended maintenance interval (hr) N/A N/A 6000 6000 N/A N/A N/A
7900 max. extended maintenance interval (hr) N/A N/A 9000 9000 N/A N/A N/A
Scheduled Maintenance interval (mth) 12 12 12 12 12 12 12
5900 max. extended maintenance interval (mth) N/A N/A 12 12 N/A N/A N/A
7900 max. extended maintenance interval (mth) N/A N/A 18 18 N/A N/A N/A
Modulation Tracking Slope (V/bit) 1.9 1.2 1.2 1.2 1.4 1.1 1.9
† Relative to 3103 ink.

Table 3-4. Ink type dependent parameters table (Midi A printhead)

INK TYPE DEPENDENT PARAMETERS (MIDIEC PRINTHEAD)

Parameters Ink Data
Ink type 6100 6120 6220
Solvent type 6600 6650 6650
Nominal Reference Pressure PREF (bits) 190 190 190
Reference Pressure Offset (bits) – – –
Normal Solvent Add Pressure Offset from PREF
+4 +4 +4
(bits)
Maximum number of consecutive Solvent Adds 25 25 25
Reference Modulation VM (V) 125 125 80 †
Reference Modulation Offset (VM + offset) (V) – – –
Reference TOF (µs) 1262 1262 1262
Normal Solvent Add Time tSA (s) 10 10 10
Warm Up tSA if PSET > PSA (s) 10 10 10
Scheduled Maintenance interval (hr) 2400 2400 2400
Scheduled Maintenance interval (mth) 14 14 14
Modulation Tracking Slope (V/bit) 0.0 0.0 0.0
† For 6220 ink, at 35 °C decrease modulation voltage to 70 V. For temperatures below 25 °C, increase modulation
voltage by 4 V/°C to 140 V at 10 °C.

Table 3-5. Ink type dependent parameters table (MidiEC printhead)

FA69398–1
Oct 2013 3—38 Linx 7900 Maintenance Manual
 INK TYPE DEPENDENT PARAMETERS (MINI PRINTHEAD)
Parameters Ink Data
Ink type 1056 1240 1405
Solvent type 1555 1512 1705
Nominal Reference Pressure PREF (bits) 188 178 178
Reference Pressure Offset (bits) – –2 –2
Normal Solvent Add Pressure Offset from PREF
+4 +4 +4
(bits)
Maximum number of consecutive Solvent Adds 12 12 24
Reference Modulation VM (V) 50 75 75
Reference Modulation Offset (VM + offset) (V) 0 0 0
Reference TOF (µs) 565 565 565
Normal Solvent Add Time tSA (s) 10 10 10
Warm Up tSA if PSET > PSA (s) 10 10 10
Scheduled Maintenance interval (hr) 2000 2000 2000
5900 max. extended maintenance interval (hr) 6000 6000 N/A
7900 max. extended maintenance interval (hr) 9000 9000 N/A
Scheduled Maintenance interval (mth) 12 12 12
5900 max. extended maintenance interval (mth) 12 12 N/A
7900 max. extended maintenance interval (mth) 18 18 N/A
Modulation Tracking Slope (V/bit) 0.0 1.5 1.7

Table 3-6. Ink type dependent parameters table (Mini printhead)

INK TYPE DEPENDENT PARAMETERS (MICRO PRINTHEAD)

Parameters Ink Data
Ink type 1075 1085 1240 1405
Solvent type 1575 1585 1512 1705
Nominal Reference Pressure PREF (bits) 180 – 170 170
fixed fixed fixed
Reference Pressure Offset (bits) +34
ref. ref. ref.
Normal Solvent Add Pressure Offset from PREF
+4 +4 +4 +4
(bits)
Maximum number of consecutive Solvent Adds 12 12 12 24
Reference Modulation VM (V) 65 † – 50 75
fixed fixed fixed
Reference Modulation Offset (VM + offset) (V) –5
ref. ref. ref.
Reference TOF (µs) 572 572 572 572
Normal Solvent Add Time tSA (s) 10 10 10 10
Warm Up tSA if PSET > PSA (s) 10 10 10 10
Scheduled Maintenance interval (hr) 2000 2000 2000 2000
7900 max. extended maintenance interval (hr) N/A N/A 9000 N/A
Scheduled Maintenance interval (mth) 12 12 12 12
7900 max. extended maintenance interval (mth) N/A N/A 18 N/A
Modulation Tracking Slope (V/bit) 0.3 0.0 1.2 1.0
† For 1075 ink, at 5 °C use a reference modulation of 35 V.

Table 3-7. Ink type dependent parameters table (Micro printhead)

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 INK TYPE DEPENDENT PARAMETERS (ULTIMA plus PRINTHEAD)
Parameters Ink Data
Ink type 3103 1009 1010 1014 1016 1018 1033 1035 1039 1043 1055 1056 1059 1065 1069 1070 1085 1121 1240 1243 1248 1270 1280 1290 1305 1306 1310 1311 1370 1405 2030 2035 2250 3123 3124 3160 3240 3401
Solvent type 3501 1505 1505 1505 1506 1505 1505 1535 1505 1505 1555 1555 1505 1565 1505 1560 1585 1590 1512 1512 1517 1540 1540 1540 1605 1606 1605 1606 1670 1705 2500 2500 2750 3501 3501 3560 3710 3905
Nominal Reference Pressure PREF (bits) 148 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

Oct 2013
Reference Pressure Offset (bits) * Adjusted manually according to published offset data table
Normal Solvent Add Pressure Offset from P REF
+4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4
(bits)
Maximum number of consecutive Solvent Adds 12 24 12 12 12 12 24 12 24 24 12 12 24 12 24 12 12 12 12 12 12 12 12 12 24 24 24 24 12 24 12 12 12 12 12 12 12 12
Reference Modulation Offset (VM + offset) (V) † Adjusted manually according to published offset data table
Reference TOF (µs) 1330 1330 1330 1330 1330 1330 1330 1330 1330 1330 1330 1330 1330 1330 1330 1330 1330 1330 1330 1330 1330 1330 1330 1330 1330 1330 1330 1330 1330 1330 1330 1330 1330 1330 1330 1330 1330 1330
Normal Solvent Add Time tSA (s) 10 5 10 10 10 10 5 10 5 5 10 10 5 10 5 10 10 10 10 10 10 10 10 10 5 5 5 5 10 10 10 10 10 10 10 10 10 10
Warm Up tSA if P SET > PSA (s) 10 5 10 10 10 10 5 10 5 5 10 10 5 10 5 10 10 10 10 10 10 10 10 10 5 5 5 5 10 10 10 10 10 10 10 10 10 10
Scheduled Maintenance interval (hr) 2000 1400 2000 2000 2000 2000 1400 2000 1400 1400 2000 2000 1400 2000 1400 2000 2000 2000 2000 2000 2000 2000 2000 2000 1400 1400 1400 1400 1400 2000 2000 2000 2000 2000 2000 2000 2000 2000
5900 max. extended maintenance interval (hr) 6000 N/A 6000 6000 6000 N/A N/A N/A N/A N/A 6000 6000 N/A N/A N/A N/A N/A N/A 6000 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 6000 6000 N/A N/A N/A 6000 N/A
7900 max. extended maintenance interval (hr) 9000 N/A 9000 9000 9000 N/A N/A N/A N/A N/A 9000 9000 N/A N/A N/A N/A N/A N/A 9000 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 9000 9000 N/A N/A N/A 9000 N/A
Scheduled Maintenance interval (mth) 12 6 12 12 12 12 6 12 6 6 12 12 6 12 6 12 12 12 12 12 12 12 12 12 6 6 6 6 6 12 12 12 12 12 12 12 12 12
5900 max. extended maintenance interval (mth) 12 N/A 12 12 12 N/A N/A N/A N/A N/A 12 12 N/A N/A N/A N/A N/A N/A 12 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 12 12 N/A N/A N/A 12 N/A
7900 max. extended maintenance interval (mth) 18 N/A 18 18 18 N/A N/A N/A N/A N/A 18 18 N/A N/A N/A N/A N/A N/A 18 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 18 18 N/A N/A N/A 18 N/A
Modulation Tracking Slope (V/bit) 1.0 2.2 2.5 2.0 1.0 1.2 3.0 2.0 3.0 2.4 1.6 1.6 1.5 2.0 2.4 1.6 1.2 1.6 2.5 2.5 3.8 1.9 2.0 1.6 1.5 1.5 1.5 1.5 1.6 1.0 1.5 1.5 1.5 2.0 2.0 2.0 2.5 2.5
* Relative to 3103 ink.
† Inks 1059 and 1069. If poor performance is seen at extremes of temperature, adjust the Reference Modulation as follows:
as temperature decreases from 25 °C to 5 °C, change the Reference Modulation by +1.0 V per °C; as temperature increases from 25 °C to 45 °C, change the Reference Modulation by –1.0 V per °C.

Table 3-8. Ink type dependent parameters table (Ultima plus printhead)

3—40
INK TYPE DEPENDENT PARAMETERS (MIDI plus PRINTHEAD)
Parameters Ink Data
Ink type 3103 1009 1010 1014 1016 1018 1033 1035 1039 1043 1055 1056 1059 1065 1069 1070 1085 1121 1240 1243 1248 1270 1280 1290 1305 1306 1310 1311 1370 1405 2030 2035 2250 3123 3124 3160 3240 3401
Solvent type 3501 1505 1505 1505 1506 1505 1505 1535 1505 1505 1555 1555 1505 1565 1555 1560 1585 1590 1512 1512 1517 1540 1540 1540 1605 1606 1605 1606 1670 1705 2500 2500 2750 3501 3501 3560 3710 3905
Nominal Reference Pressure PREF (bits) 142 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
Reference Pressure Offset (bits) * Adjusted manually according to published offset data table
Normal Solvent Add Pressure Offset from P REF
+4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4 +4
(bits)
Maximum number of consecutive Solvent Adds 12 24 12 12 12 12 24 12 24 24 12 12 24 12 24 12 12 12 12 12 12 12 12 12 24 24 24 24 12 24 12 12 12 12 12 12 12 12
Reference Modulation Offset (VM + offset) (V) † Adjusted manually according to published offset data table
Reference TOF (µs) 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950 1950
Normal Solvent Add Time tSA (s) 10 5 10 10 10 10 5 10 5 5 10 10 5 10 5 10 10 10 10 10 10 10 10 10 5 5 5 5 10 10 10 10 10 10 10 10 10 10
Warm Up tSA if P SET > PSA (s) 10 5 10 10 10 10 5 10 5 5 10 10 5 10 5 10 10 10 10 10 10 10 10 10 5 5 5 5 10 10 10 10 10 10 10 10 10 10
Scheduled Maintenance interval (hr) 2000 1400 2000 2000 2000 2000 1400 2000 1400 1400 2000 2000 1400 2000 1400 2000 2000 2000 2000 2000 2000 2000 2000 2000 1400 1400 1400 1400 1400 2000 2000 2000 2000 2000 2000 2000 2000 2000
5900 max. extended maintenance interval (hr) 6000 N/A 6000 6000 6000 N/A N/A N/A N/A N/A 6000 6000 N/A N/A N/A N/A N/A N/A 6000 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 6000 6000 N/A N/A N/A 6000 N/A
7900 max. extended maintenance interval (hr) 9000 N/A 9000 9000 9000 N/A N/A N/A N/A N/A 9000 9000 N/A N/A N/A N/A N/A N/A 9000 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 9000 9000 N/A N/A N/A 9000 N/A
Scheduled Maintenance interval (mth) 12 6 12 12 12 12 6 12 6 6 12 12 6 12 6 12 12 12 12 12 12 12 12 12 6 6 6 6 6 12 12 12 12 12 12 12 12 12
5900 max. extended maintenance interval (mth) 12 N/A 12 12 12 N/A N/A N/A N/A N/A 12 12 N/A N/A N/A N/A N/A N/A 12 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 12 12 N/A N/A N/A 12 N/A
7900 max. extended maintenance interval (mth) 18 N/A 18 18 18 N/A N/A N/A N/A N/A 18 18 N/A N/A N/A N/A N/A N/A 18 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 18 18 N/A N/A N/A 18 N/A
Modulation Tracking Slope (V/bit) 1.0 2.2 2.5 1.7 1.5 1.2 3.0 2.0 3.0 2.4 1.6 1.6 1.5 2.0 2.4 1.6 1.2 1.6 2.5 2.5 3.8 2.0 2.0 1.6 1.5 1.5 1.5 1.5 2.0 1.0 1.5 1.5 1.5 2.0 2.0 2.0 2.5 2.5
* Relative to 3103 ink.
† Inks 1059 and 1069. If poor performance is seen at extremes of temperature, adjust the Reference Modulation as follows:
as temperature decreases from 25 °C to 5 °C, change the Reference Modulation by +1.0 V per °C; as temperature increases from 25 °C to 45 °C, change the Reference Modulation by –1.0 V per °C.

Table 3-9. Ink type dependent parameters table (Midi plus printhead)

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3.7 Electrical components
3.7.1 Summary
The 7900 printers have the following main electrical components:
 Mains electrical supply cable and connector
 Mains electrical supply switch
 Power on switch
 Mains electrical supply filter
 Mains electrical supply fuses
 Low voltage power supply unit (LVPSU)
 EHT power supply unit (EHTPSU)
 Ink system pump
 Ink system valves and cableform assembly
 Cooling fan
 Printhead positive air pump (optional)

3.7.2 Mains electrical supply cable

The mains electrical supply cable connects to the printer on the rear right side of the base
unit.
IMPORTANT: For the printer to comply with EN 60950-1:2006 Information technology
equipment. Safety. General requirements, the printer must be connected to the
mains electrical supply by one of the following two methods:
 A plug and socket arrangement.
 If the printer is hard wired to the mains electrical supply, a mains
disconnecting device must be used between the printer and the mains
electrical supply.

Cable connector protection

The mains electrical supply cable connector is protected by an environmentally-sealed box
with a hinged cover, which must be opened to disconnect the cable from the printer. The
cover is secured by three screws, and the cable is routed out of the box through an opening
in the bottom. Orientation of the cable exit cannot be altered.

3.7.3 Mains electrical supply switch

The mains electrical supply switch is fitted above the protection box for the mains electrical
supply cable connector, on the rear outside face of the base unit on the right side.
It is a two-position, mains-rated rocker switch, protected by a splashproof cover, that
disconnects the printer from the mains electrical supply. The on position is labelled ‘I’ and
the off position is labelled ‘0’.
The switch is a ‘fit once only’ component. The IP rating will be invalid if the switch is
removed and refitted or replaced.

3.7.4 Power on switch

This switch is fitted on the front right of the base unit. The device is a 2-pole,
momentary-action ‘on’ switch, which, when pressed and released, connects the mains
electrical supply to the LVPSU and thereby turns on the printer. Although it switches the
mains electrical supply within the printer, it is not classified as a mains isolating switch, but
is a mains voltage-rated control device. To turn off the printer, either the Auto Power Down
feature must be enabled, or the mains electrical supply switch on the rear of the printer
must be manually set to the ‘off’ position.

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 3.7.5 Mains electrical supply filter
The mains electrical supply filter assembly is fitted on the rear inside face of the base unit
on the right side, below the mains electrical supply switch.
This unit isolates and filters the mains electrical supply input, preventing electrical noise
and ‘spikes’ from having an effect on the operation of the printer. It also prevents any
electrical noise from being transmitted from the printer to the mains electrical supply
wiring.

3.7.6 Mains electrical supply fuses

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

EQUIPMENT IS PROTECTED BY DOUBLE-POLE FUSING. THAT IS, FUSES ARE FITTED IN THE
LIVE AND NEUTRAL CONDUCTORS OF THE MAINS ELECTRICAL SUPPLY. IF THE NEUTRAL
FUSE OPERATES, PARTS OF THE EQUIPMENT THAT REMAIN ENERGIZED CAN BE AN
ELECTRICAL HAZARD DURING MAINTENANCE WORK.
TURN OFF AND DISCONNECT THE PRINTER FROM THE MAINS ELECTRICAL SUPPLY
BEFORE THE COVER IS REMOVED.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS SAFETY
WARNING IS IGNORED.
Two input fuses for the live and neutral conductors of the mains electrical supply are
housed in a dual fuse holder, which is part of the mains electrical supply filter assembly.
The fuses are located below the mains electrical supply cable connector, on the rear right
side of the base unit. To gain access to the fuses, the protection box for the mains electrical
supply cable connector must be removed.
The fuses are 20 mm antisurge, ceramic, sand-filled, rated at 4 A for both 115 volts and 230
volts AC operation.

3.7.7 Low voltage power supply unit (LVPSU)

A bracket is attached to the base of the LVPSU, and this assembly is then fitted to the
bottom of the base unit on the right side of the ink system enclosure.
It is a switch mode unit that provides the necessary voltages to power various systems
within the printer.
The input voltage range of the unit is between 85 volts and 264 volts AC, 50/60 Hz. A
10-way Molex minifit junior connector receives the mains electrical supply input as shown
in the following table.

Input 10-way Molex pin number

Live 1, 6
Neutral 3, 8
Earth 5, 10

Table 3-10. LVPSU input details

There are four outputs of +5.1 V, +12 V, –16 V and +24 V DC, and six outputs of 0 volts (all
commoned).

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 The following table provides details of the outputs on connector PL8, including connector
pin numbers.

Output (V DC) Max. current (A) 16-way Molex pin number

+5.1 2.5 2, 10
+12.0 0.9 5, 13
–16.0 0.4 6, 14
+24.0 2.5 8, 16
0.0 N/A 3, 4, 7, 11, 12, 15
Power Fail N/A 1, 9

Table 3-11. LVPSU output details

3.7.8 EHT power supply unit (EHTPSU)

The EHT power supply unit has a mounting plate included in its structure. The mounting
plate attaches the unit to the top right side of the air filter housing at the front of the base
unit.
The unit generates the high voltages required for the printhead positive deflector plate, and
the modulation and charge generation circuits. It is powered by +24 volts DC from the
LVPSU via the IPM PCB.
A variable EHT output of 0 volts to +10 kV at 10 µA is provided, which creates the +8 kV
(maximum for all Mk7 printheads) electrostatic field between the printhead deflector
plates. The level of this output is determined by the EHT Program Input, which is an
analogue voltage of between 0 volts and 10 volts DC, with 10 volts equating to 10 kV. The
value required to generate 8 kV ±1.7% is entered into the printer (refer to ‘Charge
Calibration’ in Chapter 5: ‘Maintenance’.)
The EHT default value for the particular message type (raster) being used is displayed (in
volts) on the Print Settings page (Print Monitor > Print Settings).
The EHT output is routed from the unit to the printhead via a red cable to a white
Highvol-style connector.
A further output of +300 volts, at a maximum current of 46 mA, supplies the charge and the
modulation amplifiers on the IPM PCB. If an output over-current between 52 mA
and58 mA is detected, the output voltage falls to 0 volts.
Except for the EHT output, all other voltages and signals are routed to and from the unit
through a 12-way Molex Mini-Fit Junior connector (PL7).
The following table provides details of the inputs and outputs.

Input Output 12-way Molex pin number

+24 V Power 6
EHT Program Input (0–10 V) 3
/EHT Enable 4
/300 V Enable 9
0V 5, 12
Chassis 11
+300 V 1
/EHT Over Current 10
Not connected 2, 7, 8

Table 3-12. EHTPSU input/output details

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 3.7.9 Ink system pump
This unit is a pump and DC motor assembly, which is fitted through the front wall of the
ink system enclosure.

79082

Figure 3-23. Ink system pump and motor assembly—standard 7900 printer
The pump and motor assembly circulates ink around the ink system at different pressures,
as required by the ink system control electronics. These pressure values depend on the
different functions performed by the printer during startup, normal operation, shutdown,
and other maintenance sequences.
The motor controller circuit on the IPM PCB provides the drive signal on connector PL3 for
pressure control of the pump. The requested pressure (Set Pressure) signal and the output
signal from the pressure transducer (Actual Pressure) are used to create the drive signal for
the pump motor.
Magnetic coupling from the motor to the pump provides separation of the ink from the
electrical drive parts.
The pump used in the standard 7900 printer includes an internal pressure relief valve
(PRV), which is set to a maximum pressure of 6.21 bar (90 p.s.i.).

3.7.10 Ink system valves and cableform assembly

The five valves are fitted through the front wall of the ink system enclosure. The fluid
connections are on the inside of the enclosure and the electrical connections are on the
outside. This arrangement isolates the electrical and fluid connections from each other.
Electrical connections to the valves are provided by the valve cableform assembly, which
has a 24-way Mini-Fit Junior connector (SK1). This connector is fitted to PL1 on the edge of
the 7900 IPM PCB. The cableform also includes electrical connections for the pressure
transducer, fluid level sensors (float switches), and ink spillage detection.
The following table provides information about the pin numbers and wire colour-codes of
the valve cableform assembly. Each valve electrical connector has a number on the top
surface for easy valve identification to prevent incorrect connection, and this information is
also provided in the table.

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 VALVE CABLEFORM ASSEMBLY (SK1)
Component Pin number Wire colour
Feed valve (1) 13; 14 Black; purple
(red heatshrink)
Purge valve (2) 19; 20 White/yellow; yellow/brown
(yellow heatshrink)
Gutter valve (3) 15; 16 Grey/pink; red/blue
(green heatshrink)
Solvent Add valve (4) 17; 18 White/green; brown/green
(blue heatshrink)
Solvent Flush valve (5) 21; 22 White/grey; grey/brown
(violet heatshrink)
Pressure transducer 6; 7; 8; 9 Brown; green; yellow; grey
(black heatshrink)
Ink spillage detection 10 Pink
(green/yellow heatshrink)
Level sensor—solvent 5; 11 White; blue
Level sensor—ink 12; 24 Red; white/pink

Table 3-13. Valve cableform connections

3.7.11 Cooling fan

The cooling fan is fitted on the top left side of the air filter housing. It is a 24 volts DC device
supplied directly from the LVPSU and operates all the time that the printer is switched on.
Air is drawn in by the fan through the base of the cabinet, through the air filter, around the
inside of the cabinet and out through the vent holes in the sides.
The 7900 (IP55 version) uses a fan that has a rating of 2.4 watts. In the 7900 (IP65 version) the
fan is a more powerful 6 watts unit because of the much thicker air filter used.
The cabinet air temperature is monitored by a thermistor set at a limit of 58 °C. If this
temperature is exceeded (for example, because of a fan failure or a blocked air filter), the
printer fails and the Print Failure message “2.08 Printer Over Temperature” is displayed.

3.7.12 Printhead positive air pump

The printhead positive air pump is fitted to the top of the air filter housing, between the
EHTPSU and the cooling fan.
The pump has a rating of 2.4 watts and is supplied by +12 volts DC from connector PL9 on
the IPM PCB.
The purpose of the pump is to improve printer performance in environments where there is
dust, damp and condensation. A positive air pressure is supplied to the printhead to reduce
the ingress of airborne particles. The unit pumps filtered air from inside the printer cabinet,
along the printhead conduit to a stainless steel outlet fitting on the printhead. The air flow
to the printhead is greater than that through the gutter, which creates a positive air pressure
inside the printhead cover tube. This positive air pressure helps to keep the printhead free
of dust and other airborne particles.
The air supply pipe is fitted as standard to all Mk7 printheads. However, the pump is not
fitted as a standard part to any of the 7900 printers, but is available as an option (refer to the
Linx Ink Jet Printers Parts and Prices manual or contact your Linx Distributor).

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3.8 Electronics and software
3.8.1 Summary
The main electronics system in 7900 printers is contained on one printed circuit board (PCB)
called the integrated processor module (IPM) PCB, which is fitted vertically on the left side
of the cabinet. The keyboard and display assembly in the printer top cover contains the
display PCB.
There are also options of additional auxiliary PCBs, which are installed vertically towards
the rear of the base unit, to the left of the IPM PCB.
The functions of the circuit boards are briefly described as follows:
IPM PCB: Contains the main central processing unit, which controls the
printer operation. The PCB also contains the unique number
identification chip (UNIC), and amplifiers that process the
printhead control signals. The PCB also processes the inputs from
the keyboard and provides control of the display.
Display PCB: Provides connections from the IPM PCB for the display.
Auxiliary PCB: Optional PCB that provides a parallel input/output (PIO)
capability.

3.8.2 System diagram

The electrical system diagram for the standard 7900 printer is provided at the end of this
manual.

3.8.3 IPM PCB

WARNING: LETHAL VOLTAGE HAZARD. DANGEROUS VOLTAGES EXIST IN THIS
EQUIPMENT WHEN ELECTRICAL POWER IS APPLIED.
MAXIMUM CAUTION MUST BE USED WHEN WORK IS DONE ON THE IPM PCB, BECAUSE
THERE CAN BE A MAXIMUM OF 300 VOLTS DC ON THE PCB WHEN THE PRINTER IS TURNED
ON. THE CORRECT, STANDARD ELECTRICAL SAFETY PRECAUTIONS MUST BE TAKEN.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS SAFETY
WARNING IS IGNORED.

Test points and links

Test points and links are provided on the IPM PCB to help fault diagnosis. Links are also
used to enable or disable different printer functions, and some of the links must be fitted to
allow the printer to operate correctly.
The test points and links for the IPM PCB are identified below with descriptions of their
functions. The information is applicable to Revision 1 of the 7900 IPM PCB, unless
otherwise stated.
To make the test points and links easier to find, the PCB edges are marked with grid square
identifiers—A to D vertically, and 1 to 10 horizontally. A grid reference is provided in
brackets after each test point and link number in the following lists, which identifies the
location on the IPM PCB. Further help to find test points and links is provided after the
following lists in an illustration of a reference grid drawn on top of the IPM PCB.

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 Test points
TP1 (B8) HD TEMP. Analogue voltage of 0 volts to 11 volts DC relating to the
temperature sensed at the printhead by an embedded thermistor.
Hardware detects when the temperature exceeds +60 °C ±3 °C, at which
time Print Failure “2.00 Printhead Over Temperature” is reported.
TP2 (B9) 300V. EHTPSU output of 300 volts DC.
TP3 (A8) EHT. The EHTPSU requires calibrating to give a specific output of 8 kV by
entering a calibration figure into the printer. An analogue voltage of
between 0 volts and 10 volts DC can be measured at this test point, with
10 volts equating to 10 kV.
TP4 (C7) –10VREF. This is the output of the –10 volts DC reference.
TP5 (C7) 5VREF. This is the output of the +5 volts DC reference.
TP6 (C9) GUTSENSE. The gutter sense circuit detects the presence of ink flow in the
gutter during a normal jet start sequence and under normal jet running
conditions (it is switched off during a Jet Test – Start sequence). If ink flow
is not detected in the gutter for any reason (for example, a misaligned jet),
the software shuts down the jet. The voltage measured at this test point
should be +5 volts DC if there is no ink jet detected, and less than +4 volts
DC if the jet is present in the gutter. These voltages may vary with time.
TP7 (C9) 10VREF. This is the output of the +10 volts DC reference.
TP9 (C8) VPOWERS. The energizing voltage rail for the valves can be checked at
this test point. It is either the energizing voltage of +24 volts DC, or the
valve hold-on voltage of +12 volts DC.
TP10 (C9) PUMP. Variable pump control voltage between 0 volts and +5.6 volts DC.
TP11 (C7) READPRESS. This is the amplified output of the pressure transducer and
is a voltage representation of the pressure in the ink system of between
0 volts and +5 volts DC. During normal operation, with link LK6 fitted, the
voltages measured at TP11 and TP12 are almost identical. The Actual
Pressure and Set Pressure values observed on the Monitor Jet page
(Maintenance page) are almost never the same due to tolerances in the
electronics.
TP12 (C6) SETPRESS. This is the Set Pressure value and has a range of 0 volts to
+5 volts DC. It represents the pressure set by the electronics to maintain the
required ink flow. During normal operation, with link LK6 fitted, the
voltages measured at TP11 and TP12 are almost identical.
TP13 (C2) 0V. Zero volts test point.
TP14 (C3) 0V. Zero volts test point.
TP16 (A2) SEC–DET. Secondary trigger input. This is the opto-isolated secondary
trigger signal (buffered output from IC10E), and is a 0 volts to 5 volts
digital signal.
TP17 (A7) 0V. Zero volts test point.
TP18 (C9) 0V. Zero volts test point.
TP19 (C7) 0V. Zero volts test point.
TP20 (C7) 12V. A convenient point to test for the presence of the supply on the
+12 volts rail from the LVPSU.
TP21 (C7) –16V. A convenient point to test for the presence of the supply on the
–16 volts rail from the LVPSU.
TP22 (C7) 5V. A convenient point to test for the presence of the supply on the
+5.1 volts rail from the LVPSU.

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 TP23 (C7) 24V. A convenient point to test for the presence of the supply on the
+24 volts rail from the LVPSU.
TP24 (A8) PHASE A. Amplified analogue signal from the phase detector in the range
of approximately +11 volts to –15 volts. There should be less than 1 volt
peak-to-peak noise during quiescent (non-printing) conditions. When
printing, this signal looks erratic as the amplifier is driven firmly into
saturation by the presence of charged printing drops.
TP26 (B8) PHASE D. This is the peak value of the TOF digital signal of approximately
5 volts.
TP27 (A2) PRI–DET. Next object input. This is the opto-isolated primary trigger
signal (buffered output from IC10D). It is a 0 volts to 5 volts digital signal,
with the falling or rising edge indicating the presence of the object.
TP28 (A2) MAINSE. Single-ended shaft encoder input. This is the opto-isolated shaft
encoder input, and is a 0 volts to 5 volts digital signal.
TP29 (C10) CHARGE. Charge amplifier output that is applied to the charge electrode.
The typical output range is 0 volts to +255 volts DC.
TP30 (B9) CHG–LOW. Low voltage charge signal, before amplification, of between
0 volts and –8 volts.
TP31 (A9) MOD–LOW. Low voltage modulation signal, before amplification, of
between 0 volts and –8 volts. A sine wave should be observed with a
frequency dependent on the type of printhead fitted: 64 kHz (Ultima plus
and Midi plus 75 µm); 80 kHz (Ultima and Midi 62 µm); 96 kHz (Mini
50 µm); 120 kHz (Micro 40 µm).
TP32 (A10) MOD. Modulation amplifier output. A sine wave of between 0 volts and
255 volts AC should be observed with a frequency dependent on the type
of printhead fitted: 64 kHz (Ultima plus and Midi plus 75 µm); 80 kHz
(Ultima and Midi 62 µm); 96 kHz (Mini 50 µm); 120 kHz (Micro 40 µm).
The signal should be AC coupled with the peaks of the sine wave going
positive and negative with respect to 0 volts.
TP46 (A2) QUADSE. Quadrature shaft encoder input. This is the opto-isolated
quadrature shaft encoder signal, and is a 0 volts to 5 volts digital signal.
TP49 (A8) VBAT. The state of the NiMH battery can be monitored at this test point,
and should be a maximum of 2.9 V DC and a minimum of 2.2 V DC.
TP50 (C3) 3.3V. A regulated supply voltage of 3.3 volts for the CPU, gate array, and
memory circuits taken from the LVPSU +5.1 volts supply.
TP51 (B4) 30.72MHZ. The clock for the drop control logic.
TP52 (B3) 2.5V. A regulated supply voltage of 2.5 volts for the CPU, gate array, and
memory circuits taken from the LVPSU +5.1 volts supply.
TP53 (C7) PF. Not used.
TP54 (C7) PRESST–. Pressure transducer output. A differential of 0 volts to 33 mV,
where 33 mV equates to 255 pressure bits. Measurement must be taken
between this test point and TP55.
TP55 (C7) PRESST+. Pressure transducer output. A differential of 0 volts to 33 mV,
where 33 mV equates to 255 pressure bits. Measurement must be taken
between this test point and TP54.
TP56 (B8) AIR TEMP. Analogue voltage of 0 volts to 5 volts DC, relating to the air
temperature sensed inside the printer enclosure by a thermistor located
close to the charge amplifier on the IPM PCB. The voltage rises with
increasing temperature but is non-linear. Hardware detects when the
temperature exceeds +58 °C ±2 °C, at which point Print Failure “2.08
Printer Over Temperature” is reported.

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 TP57 (B2) PRI–DET. Next object input. This is the opto-isolated primary trigger
signal, and is an inverted version of the signal seen at TP27. It is a 0 volts to
5 volts digital signal, with the falling or rising edge indicating the presence
of the object.
TP58 (A2) SEC–DET. Secondary trigger input. This is the opto-isolated secondary
trigger signal, and is an inverted version of the signal seen at TP16. It is a
0 volts to 5 volts digital CMOS signal.
TP59 (A7) CLKOUT. This is the 50 MHz output of the SDRAM clock.
TP60 (C8) 0V. Zero volts test point.
TP61 (B2) 0V. Zero volts test point.
TP62 (B8) A-A28. Address lines.
TP63 (B8) A-A29. Address lines.
TP64 (B6) ADC-A28. Address lines for the analogue to digital converter (ADC).
TP65 (B6) ADC-A29. Address lines for the analogue to digital converter (ADC).

Links
LK4 (A7/A8) BAT. (Battery). Connects the NiMH battery to the message store so that
data is retained when the printer is switched off. The NiMH battery is also
trickle charged when this link is fitted. Removing this link deletes all
messages, datasets, downloaded fonts, logos and passwords from the NVR
(SRAM). In addition, various other parameters in flash memory are reset to
their default values, for example: Printhead Code, Ref Modulation,
Conduit Length, Ink Type, Head Height—these will all need to be
re-entered. It is recommended that the USB facility is used to back up the
data before this link is removed.
LK5 (B4) MONITOR. This link can be fitted to boot the software from a temporarily
fitted EPROM (IC62).
LK6 (C7) OPEN LOOP. Removal of this link breaks the feedback loop that controls
the pump and pressure circuits. By removing the link it is possible to
energize the pump even though there may be a fault in the pressure
transducer circuit or ink system. Because of the non-linearities in the
control loop, the scaling factors for the Set Pressure commands on the
Monitor Jet page (Maintenance page) do not apply when the link is
removed. The Actual Pressure command is unaffected. This link should
normally be fitted.
LK7 (A5/B5) S/W LINKS. Links LK7A, LK7B, LK7C, LK7D, LK7E, LK7F, LK7G, and
LK7H are software-readable links and must not be moved or interfered
with. More specifically, when link LK7B is fitted, the 7900 Spectrum ink
options are enabled.When link LK7F is fitted, the 7900 Food Grade ink
options are enabled. Refer to ‘Electronics and software’ in
Appendix A: ‘7900 Food Grade Printer’ for more information about link
LK7.
LK8 (B9) VC. Connects the 300 volts DC stabilized supply to the charge amplifier.
Selective removal of either LK8 or LK25 can be useful to isolate a fault if a
“2.04 300V Power Supply” fault is reported.
LK9 (B1/C1) 5V/24V. Selects the appropriate line driver for a single-ended shaft
encoder: either position A (pins 1 and 2) for 5 volts DC, or position B (pins 2
and 3) for 24 volts DC. For an open-collector device the position of link LK9
is irrelevant.
LK11 (A1) ROLLBACK. When a quadrature shaft encoder is used, this link selects
between secondary sensor input and rollback output for direction sensing
of the production line. Position A (pins 1 and 2) selects secondary sensor
input, and position B (pins 2 and 3) selects rollback.

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 LK12 (B1) 5V/24V. Selects the appropriate line driver for a quadrature shaft encoder:
either position A (pins 1 and 2) for 5 volts DC, or position B (pins 2 and 3)
for 24 volts DC. For an open-collector device the position of link LK12 is
irrelevant.
LK19 (B4) SAFETY O/R. (Safety Override). Software-readable link.

WARNING: LETHAL VOLTAGE HAZARD. IF THE ‘SAFETY OVERRIDE’ LINK

LK19 IS FITTED WHILE THE “PRINTHEAD OVER TEMPERATURE” OR “EHT
TRIP” FAULT CONDITIONS EXIST, 300 VOLTS DC CONTINUES TO BE
SUPPLIED TO THE PRINTHEAD.
THE CORRECT, STANDARD ELECTRICAL SAFETY PRECAUTIONS MUST BE
TAKEN WHEN WORK IS DONE ON THE PRINTHEAD WITH LINK LK19 FITTED.
DO NOT FIT LINK LK19 PERMANENTLY AND DO NOT LEAVE THE PRINTER
UNATTENDED WHILE THE LINK IS FITTED.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF
THIS SAFETY WARNING IS IGNORED.
When this link is fitted, the printhead Over Temperature sense and the
EHT Trip sense signals do not disable the 300 V, ink system pump, Feed
valves and EHT. However, the EHT Trip sense will disable the EHT
internally on the EHTPSU regardless of LK19 being fitted. The link may be
fitted with caution to aid fault diagnosis. See also System Warning “3.15
Safety Override Active”.
LK20 (B4/B5) POWER OFF O/R. (Power Off Override). Software-readable link. When
this link is fitted, the auto power down mains on/off switch cannot be
switched off by the software. See also System Warning “3.14 Power Off
Override Active”.
LK21 (B4) COVER OFF O/R. (Cover Off Override). Software-readable link.

WARNING: LETHAL VOLTAGE HAZARD. WHEN THE ‘COVER OFF

OVERRIDE’ LINK LK21 IS FITTED AND THE PRINTHEAD COVER TUBE IS
REMOVED, 300 VOLTS DC CONTINUES TO BE SUPPLIED TO THE CHARGE
ELECTRODE. THE EHT ALSO CONTINUES TO BE SUPPLIED TO THE
DEFLECTOR PLATES.
THE CORRECT, STANDARD ELECTRICAL SAFETY PRECAUTIONS MUST BE
TAKEN WHEN WORK IS DONE ON THE PRINTHEAD WITH LINK LK21 FITTED
AND WITH THE COVER TUBE REMOVED. DO NOT FIT LINK LK21
PERMANENTLY AND DO NOT LEAVE THE PRINTER UNATTENDED WHILE
THE LINK IS FITTED.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF
THIS SAFETY WARNING IS IGNORED.
When this link is fitted, the EHT and charge voltage remain on when the
printhead cover tube is removed (that is, they are not automatically
disabled). This useful function allows printing to continue for fault
diagnosis purposes. The red strobe LED also remains lit. See also System
Warnings “3.12 Printhead Cover Off” and “3.13 Cover Override Link
Fitted”. After removing the printhead cover tube and then fitting the link
(or refitting the printhead cover tube), a period of approximately 3 to 4
seconds elapses before printing recommences.
See also: ‘Cover Override’ in Chapter 4: ‘System Options’ (Menu > Setup >
Installation > Printhead > Cover Override).

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 LK23 (A2) SMRXD2. Comms selection for SMRXD2. The options are:
Position A (pins 1 and 2)—RS-422 Remote Display
Position B (pins 3 and 4)—RS-232 SMC2 port (debug)
Position C (pins 5 and 6)—Auxiliary PCB
LK25 (A9) VM. Connects the 300 volts DC stabilized supply to the modulation
amplifier. Selective removal of either LK8 or LK25 can be useful to isolate a
fault if a “2.04 300V Power Supply” fault is reported.
LK26 (B4/B5) BIST. (Built In Self-Test). Software-readable link. When fitted it puts the
gate array (IC41) in self-test mode, which generates a staircase waveform
with historic correction.
LK27 (B4/B5) GUTTER O/R. (Gutter Sense Override). The gutter sense circuit detects the
presence of ink flow in the gutter during a normal jet start sequence and
under normal jet running conditions (it is switched off during a Jet Test –
Start sequence). If ink flow is not detected in the gutter for any reason (for
example, a misaligned jet), the software shuts down the jet. Absence of ink
in the gutter is detected within approximately 2 seconds. With link LK27
fitted, the software starts and maintains the jet regardless of the gutter
detection status. See also System Warning “3.16 Gutter Override Active”.
LK29 (C6) SPECTRUM. The ink system pump control characteristics are different in
the 7900 Spectrum printer from those in the standard 7900 printer. This link
determines the response time of the pump feedback loop, and its position
depends on which type of printer is being operated. It is fitted in position A
(pins 1 and 2) for a standard 7900 printer, and in position B (pins 2 and 3)
for the 7900 Spectrum printer. This link is to be used in conjunction with
link LK30.
LK30 (C6) SPECTRUM. The ink system pump control characteristics are different in
the 7900 Spectrum printer from those in the standard 7900 printer. This link
determines the response time of the pump feedback loop, and its position
depends on which type of printer is being operated. It is fitted in position A
(pins 1 and 2) for a standard 7900 printer, and in position B (pins 2 and 3)
for the 7900 Spectrum printer. T his link is to be used in conjunction with
link LK29.
LK31 (C3) 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.
LK32 (B1) NPN/PNP. (Primary). Selects the circuitry to accept either an NPN or a
PNP type of primary trigger. Position A (pins 1 and 2) for NPN; position B
(pins 2 and 3) for PNP. This link is used in conjunction with links LK33 and
LK34.
LK33 (B1) NPN/PNP. (Primary). Selects the circuitry to accept either an NPN or a
PNP type of primary trigger. Position A (pins 1 and 2) for NPN; position B
(pins 2 and 3) for PNP. This link is used in conjunction with links LK32 and
LK34.
LK34 (B1) NPN/PNP. (Primary). Selects the circuitry to accept either an NPN or a
PNP type of primary trigger. Position A (pins 1 and 2) for NPN; position B
(pins 2 and 3) for PNP. This link is used in conjunction with links LK32 and
LK33.
LK35 (B1/B2) PRI–DBM. When this link is fitted in position B (between pins 2 and 3), and
LK36 is fitted in position A (between pins 1 and 2), MEDIUM debounce of
1 ms is set on the primary trigger input. The default position for this link
and link LK36 is position A (between pins 1 and 2), which both together
give FAST or ‘normal’ debounce of 55 µs. (See ‘Primary trigger’ on
page 3—56, in the ‘External signals’ section.)

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 LK36 (B1/B2) PRI–DBS. When this link is fitted in position B (between pins 2 and 3), and
LK35 is fitted in position A (between pins 1 and 2), SLOW debounce of up
to 25 ms is set on the primary trigger input, which filters out multiple
primary trigger edges to give one genuine pulse. This is particularly useful
when a relay contact is used as a trigger source. The default position for
this link and link LK35 is position A (between pins 1 and 2), which both
together give FAST or ‘normal’ debounce of 55 µs. (See ‘Primary trigger’ on
page 3—56, in the ‘External signals’ section.)
LK37 (A1) NPN/PNP. (Secondary). Selects the circuitry to accept either an NPN or a
PNP type of secondary trigger. Position A (pins 1 and 2) for NPN; position
B (pins 2 and 3) for PNP. This link is used in conjunction with links LK38
and LK39.
LK38 (A1) NPN/PNP. (Secondary). Selects the circuitry to accept either an NPN or a
PNP type of secondary trigger. Position A (pins 1 and 2) for NPN; position
B (pins 2 and 3) for PNP. This link is used in conjunction with links LK37
and LK39.
LK39 (A1) NPN/PNP. (Secondary). Selects the circuitry to accept either an NPN or a
PNP type of secondary trigger. Position A (pins 1 and 2) for NPN; position
B (pins 2 and 3) for PNP. This link is used in conjunction with links LK37
and LK38.
LK40 (B1/B2) SEC–DBM. When this link is fitted in position B (between pins 2 and 3),
and LK41 is fitted in position A (between pins 1 and 2), MEDIUM debounce
of 1 ms is set on the secondary trigger input. The default position for this
link and link LK41 is position A (between pins 1 and 2), which both
together give FAST or ‘normal’ debounce of 55 µs. (See ‘Secondary trigger’
on page 3—58, in the ‘External signals’ section.)
LK41 (A1/A2) SEC–DBS. When this link is fitted in position B (between pins 2 and 3), and
LK40 is fitted in position A (between pins 1 and 2), SLOW debounce of up
to 25 ms is set on the secondary trigger input, which filters out multiple
secondary trigger edges to give one genuine pulse. This is particularly
useful when a relay contact is used as a trigger source. The default position
for this link and link LK40 is position A (between pins 1 and 2), which both
together give FAST or ‘normal’ debounce of 55 µs. (See ‘Secondary trigger’
on page 3—58, in the ‘External signals’ section.)
LK42 (A1) ISOL/NON–ISOL. Selects between an isolated or a non-isolated secondary
trigger input. The link can be fitted in the ISOL position when triggering
from a device that has its own power supply (for example, a PLC) that
needs to be isolated from the printer, or when the printer is being operated
in particularly electrically noisy environments. Position A (pins 1 and 2) for
non-isolated; position B (pins 2 and 3) for isolated.
LK43 (A6) Not used.
LK50 (C8) Pressure transducer selection. This link connects the pressure transducer
to the ink system and must be fitted in the default position A for the 7900
printer.
LK51 (C8) Pressure transducer selection. This link connects the pressure transducer
to the ink system and must be fitted in the default position B for the 7900
printer.
LK52 (C8) Pressure transducer selection. This link connects the pressure transducer
to the ink system and must be fitted in the default position B for the 7900
printer.
LK53 (B3) FPGA programming link. Remove LK53 for programming.
LK54 (C8) 5V/12V. Selects the hold-on voltage for the valves. The default position for
this link is position A for +12 volts DC.

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 Link default positions
The following table gives the IPM PCB links, their functions and default positions.
Representations of some links are also provided (where applicable) that show their default
positions and orientations when looked at on the IPM PCB. This information helps the
maintenance technician to make sure that links are fitted to the correct pins for the required
functions.
59014
Link Function Default position and orientation
LK4 BAT Fitted
LK5 MONITOR Not fitted
LK6 OPEN LOOP Fitted
LK7 S/W LINKS Position 7B—Spectrum only
LK8 VC Fitted

LK9 5V/24V Position A—5V

LK11 ROLLBACK Position A—Secondary sensor input

LK12 5V/24V Position A—5V

LK19 SAFETY O/R Not fitted
LK20 POWER OFF O/R Not fitted
LK21 COVER OFF O/R Not fitted

LK23 SMRXD2 Position C—Auxiliary PCB

LK25 VM Fitted
LK26 BIST Not fitted
LK27 GUTTER O/R Not fitted

LK29 SPECTRUM Position A—Standard printer

LK30 SPECTRUM Position A— Standard printer

LK31 BUZZER Fitted

LK32 NPN/PNP (Primary) Position A—NPN

LK33 NPN/PNP (Primary) Position A—NPN
LK34 NPN/PNP (Primary) Position A—NPN

LK35 PRI–DBM Position A—Fast debounce

LK36 PRI–DBS Position A—Fast debounce

LK37 NPN/PNP (Secondary) Position A—NPN

LK38 NPN/PNP (Secondary) Position A—NPN

LK39 NPN/PNP (Secondary) Position A—NPN

LK40 SEC–DBM Position A—Fast debounce

LK41 SEC–DBS Position A—Fast debounce

LK42 ISOL/NON–ISOL Position A—NON–ISOL

Pressure transducer Position A—7900 and 5900 ink

LK50 selection systems

Pressure transducer Position B—7900 and 5900 ink

LK51 selection systems

Pressure transducer Position B—7900 and 5900 ink

LK52 selection systems
LK53 FPGA programming Fitted

LK54 5V/12V Position A—12V

Table 3-14. IPM PCB link default positions

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Linx 7900 Maintenance Manual 3—53 Oct 2013
Oct 2013
1 2 3 4 5 6 7 8 9 10

D D

C 79063A C

B B

3—54
A A

1 2 3 4 5 6 7 8 9 10

Test point Test pad Link

Figure 3-24. IPM PCB test points and links locations

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Linx 7900 Maintenance Manual
 Safety functions
Detection and safety lock-out hardware guards against electrical hazards that can occur as a
result of fault conditions, according to the following table.

Fault condition Action

Turn off Turn off Turn off Turn off Turn off
EHT 300 V Ink Feed Printhead pump
valve Feed valve
EHT Over Current     
Printhead Over Temp.     
Printhead Cover Off     

Table 3-15. Fault conditions and actions

NOTES:
1. Links enable unsafe conditions to be overridden.
2. The Cover Off Override link defeats the Printhead Cover Off detector.
3. The Safety Override link defeats all safety detectors.
4. All override links are readable by the software.

Replacement and calibration

If the IPM PCB or pressure transducer is replaced, or the software is updated, the
electronics system must be calibrated. If calibration is required, refer to the ‘Charge
Amplifier Calibration’ and ‘Pressure Transducer Calibration’ maintenance instructions in
Chapter 5: ‘Maintenance’.
In addition, unless the USB facility is used to back up the parameter settings of the printer
before the IPM PCB is replaced, the original settings must be re-entered. The same applies if
the software is upgraded, which restarts the NVR and causes the line configuration settings
of the printer to be reset to the default values. For the installation of system software
Version 5.2 and earlier versions, refer to the ‘Linx Sync (Service Tool) v4.0 Procedures’
maintenance instruction in Chapter 5: ‘Maintenance’.
The UNIC for the printer is installed on the IPM PCB and also must be removed and fitted
to the replacement PCB. The printer configuration code must then be re-entered to enable
the printer to access the required options (Print Monitor > Menu > Setup > Installation > ID
> Printer Configuration Code).

3.8.4 Display PCB

The user interface consists of a full QWERTY membrane keypad (see Figure 3-2), a 1/4
VGA colour TFT-LCD display screen, and a display PCB.
The display PCB is fitted to the rear of the display screen, and the combined assembly is
fitted inside the top cover of the printer. A single power PC CPU on the IPM PCB processes
the input from the keyboard and provides control of the display screen.
There are no test points or links on the display PCB.

3.8.5 Auxiliary PCB

An optional auxiliary PCB is available for 7900 printers that provides a parallel input/
output (PIO) capability. The PIO PCB is fitted to a plate on the rear panel of the printer. This
accessory provides remote control of, for example, message selection, printing start and
stop, and indications for warnings and faults.
Refer to the section ‘External signals’ on page 3—56 for more information about the parallel
I/O interface option.

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 3.8.6 System Software
Downloading software
The system software program is stored in flash memory (IC58 and IC59) on the IPM PCB.
The Linx Sync Service Tool is required to download 7900 Version 5.2 System Software and
earlier versions. The software is downloaded to the printer from a desktop or laptop PC
through the serial communications link. This comms link communicates between the PC
and the printer, and internally between the IPM PCB and the Display PCB. Connection
between the PC and the printer is done through an RS-232 interface cable connected to the
printer rear panel RS232 INTERFACE connector.
The procedure for downloading the 7900 system software is included in the ‘Linx Sync
(Service Tool) v4.0 Procedures’ maintenance instruction in Chapter 5: ‘Maintenance’.
Version 5.2 System Software enables a USB software download facility. Future software
upgrades can then be downloaded to the printer from a USB memory device through the
USB port on the front of the printer. This new upgrade process is easier and quicker than
using the Linx Sync Service Tool and does not require a PC to be connected to the printer.
IMPORTANT: The printer cannot detect a USB memory device that has a capacity greater
than 4 GB.
The 7900 system software file has an ‘.lsf’ file extension.
Refer to the option ‘Software Upgrade’ in Chapter 5: ‘Maintenance’ (Print Monitor > Menu
> Maintenance > Software Upgrade) for a description of the software download process.

3.9 External signals

The following external signals information contains descriptions of the primary trigger,
secondary trigger, shaft encoders, alarm output, alarm accessory upgrades, RS-232 serial
interface, parallel I/O interface, Ethernet interface, and the USB facility.

3.9.1 Primary trigger

Trigger device types
The primary trigger input can be from a photocell, a contact switch, a relay contact, a signal
from a PLC, or many other sources.
A photocell is normally used to detect the presence of the product on the production line as
it approaches the printhead, and to supply a ‘next object’ signal to the printer firmware.
This signal initiates a print delay, after which a message is printed. By correctly positioning
the photocell and programming a suitable delay, the position of the message on the product
(print registration) can be controlled. The primary trigger can also perform the same
function as the secondary trigger.
The input is connected to either SK1 or SK2 on the IPM PCB. These two connectors are fitted
through the printer rear panel, and identified as PRIMARY TRIGGER/SHAFT ENCODER
and SECONDARY TRIGGER/SHAFT ENCODER, respectively. The two connectors are
wired in parallel so either can be used for a primary trigger device. The hardware input
circuit is separate from, but identical to, that of the secondary trigger.
Signal conditions for the primary trigger are a sink/source (NPN/PNP) current of greater
than 20 mA per printer input, and a signal duration of greater than 100 µs.
The primary trigger source can be an open-collector device, of either NPN or PNP type,
capable of using a 24 volts supply only, or it can be a volt-free relay contact. The choice of
photocell type is determined by fitting the three links LK32, LK33 and LK34 in one of two
positions—position A (between pins 1 and 2) for NPN, or position B (between pins 2 and 3)
for PNP.

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 Typical configurations for NPN and PNP photocells used as primary triggers are shown in
the following two simplified illustrations.
69083
SK1/SK2
6900 / 7300 / 7900 / 5900 PRINTERS
NPN PHOTOCELL 1 24VF

LK33

PRIMARY
3 2 1
TRIGGER 6
3 x 560R

75k
Internal
LK32 LK34 signal to
24V IC73 printer
3 2 1 3 2 1 logic
2 0VF

Figure 3-25. Primary trigger—NPN configuration

69084
SK1/SK2
6900 / 7300 / 7900 / 5900 PRINTERS
PNP PHOTOCELL 1 24VF

LK33

PRIMARY
3 2 1
TRIGGER 6
3 x 560R

75k
Internal
LK32 LK34 signal to
24V IC73 printer
3 2 1 3 2 1 logic
2 0VF

Figure 3-26. Primary trigger—PNP configuration

Debounce
The software determines from which edge of the input signal (leading or trailing edge) the
‘next object’ triggers are being generated. SLOW debounce of approximately 25 ms can be
set on the primary trigger input by fitting link LK35 in position A (between pins 1 and 2), and
link LK36 in position B (between pins 2 and 3), which filters out multiple primary trigger
edges to give one genuine pulse. This is particularly useful when a relay contact is used as a
trigger source.
When link LK35 is fitted in position B (between pins 2 and 3), and link LK36 in position A
(between pins 1 and 2), MEDIUM debounce of approximately 1 ms is set on the primary
trigger input. The default position for links LK35 and LK36 is position A (between pins 1
and 2), which both together give FAST or ‘normal’ debounce of approximately 50 µs.

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 3.9.2 Secondary trigger
Trigger device types
The secondary trigger input can be from a photocell, a contact switch, a relay contact, a
signal from a PLC, or many other sources. The secondary trigger is normally used to
increment or reset sequential numbers or messages, or to change from printing one message
to another. The secondary trigger can also perform the same function as the primary
trigger.
The input is connected to either SK1 or SK2 on the IPM PCB. These two connectors are fitted
through the printer rear panel, and identified as PRIMARY TRIGGER/SHAFT ENCODER
and SECONDARY TRIGGER/SHAFT ENCODER, respectively. The two connectors are
wired in parallel so either can be used for a secondary trigger device. The hardware input
circuit is separate from, but identical to, that of the primary trigger.
Signal conditions for the secondary trigger are a sink/source (NPN/PNP) current of greater
than 20 mA per printer input, and a signal duration of greater than 100 µs.
The secondary trigger source can be an open-collector device, of either NPN or PNP type,
capable of using a 24 volts supply only, or it can be a volt-free relay contact. The choice of
trigger device type is determined by fitting the three links LK37, LK38 and LK39 in one of
two positions—position A (between pins 1 and 2) for NPN, or position B (between pins 2
and 3) for PNP.
Typical configurations for NPN and PNP photocells used as secondary triggers are shown
in the following two simplified illustrations. Note that, for clarity, the isolated secondary
input is not shown.
69085
SK1/SK2
6900 / 7300 / 7900 / 5900 PRINTERS
NPN PHOTOCELL 1 24VF

LK38

3 2 1
SECONDARY
TRIGGER 4
3 x 560R

75k
Internal
24V
LK37 LK39 signal to
IC74 printer
3 2 1 3 2 1 logic
2 0VF

Figure 3-27. Secondary trigger—NPN configuration

69086
SK1/SK2
6900 / 7300 / 7900 / 5900 PRINTERS
PNP PHOTOCELL 1 24VF

LK38

3 2 1
SECONDARY
TRIGGER 4
3 x 560R

75k
Internal
24V
LK37 LK39 signal to
IC74 printer
3 2 1 3 2 1 logic
2 0VF

Figure 3-28. Secondary trigger—PNP configuration

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 Isolated/non-Isolated secondary trigger input
There is a choice of an isolated or non-isolated secondary trigger input. Link LK42 can be
fitted in the ISOL position (between pins 2 and 3) in the following circumstances:
 When triggering from a device that has its own power supply (for example, a PLC) and
it is preferred that this is not connected to the printer.
 When the printer is being operated in an environment where there is a high level of
electrical noise.
If an isolated secondary trigger input is used, links LK37, LK38, and LK39 must be fitted in
the NPN configuration. Also, the PRIMARY TRIGGER/SHAFT ENCODER connector must
have the positive trigger connected to pin 5, and the negative trigger connected to pin 4.
Fitting link LK42 between pins 1 and 2 selects the non-isolated secondary trigger input.

Debounce
The software determines from which edge of the input signal (leading or trailing edge) the
secondary triggers are being generated. SLOW debounce of approximately 25 ms can be set
on the secondary trigger input by fitting link LK40 in position A (between pins 1 and 2), and
link LK41 in position B (between pins 2 and 3), which filters out multiple secondary trigger
edges to give one genuine pulse. This is particularly useful when a relay contact is used as a
trigger source.
When link LK40 is fitted in position B (between pins 2 and 3), and link LK41 in position A
(between pins 1 and 2), MEDIUM debounce of approximately 1 ms is set on the secondary
trigger input. The default position for links LK40 and LK41 is position A (between pins 1
and 2), which both together give FAST or ‘normal’ debounce of approximately 50 µs.

3.9.3 Shaft encoders

Either a 5-volt or a 24-volt, single-ended or quadrature shaft encoder can be used. The input
circuit of the single-ended shaft encoder has a maximum frequency response of 80 kHz.
The shaft encoder is connected to either SK1 or SK2 on the IPM PCB. These two connectors
are fitted through the printer rear panel, and identified as PRIMARY TRIGGER/SHAFT
ENCODER and SECONDARY TRIGGER/SHAFT ENCODER. The two connectors are
wired in parallel so either can be used for a shaft encoder.
The supply voltage selection for a shaft encoder is determined by fitting link LK9
(single-ended shaft encoder) or link LK12 (quadrature shaft encoder) in one of two
positions. Pins 1 and 2 are linked for a 5-volt shaft encoder, and pins 2 and 3 are linked for a
24-volt shaft encoder. The position of link LK9 or link LK12 is irrelevant when an
open-collector type of shaft encoder is used. Regardless of the supply voltage setting, the
shaft encoder must be capable of sinking 10 mA per printer.
NOTE: If a quadrature shaft encoder is used, the printer counts two pulses per encoder
pulse. For example, a 2500 ppr encoder is seen as 5000 pulses per revolution.

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 The following two simplified illustrations show the input connections for a 5-volt and a
24-volt single-ended shaft encoder, respectively.
69087
5 V SINGLE-ENDED SK1/SK2 6900 / 7300 / 7900 / 5900 PRINTERS
SHAFT ENCODER 3 5VF
24VF
1
SE INPUT 8
4 x 910R 470R

NOTE: 2
LK9
Connections and
LK9 shown for a 3 1
5 V Shaft Encoder 1
ANODE
IC11A 7
OUTPUT
2
CATHODE
2 0VF

Figure 3-29. 5 V single-ended shaft encoder connections

69088
24 V SINGLE-ENDED SK1/SK2 6900 / 7300 / 7900 / 5900 PRINTERS
SHAFT ENCODER 3 5VF
1 24VF

SE INPUT 8
4 x 910R 470R

NOTE: 2
LK9
Connections and
LK9 shown for a 3 1
24 V Shaft Encoder 1
ANODE
IC11A 7
OUTPUT
2
CATHODE
2 0VF

Figure 3-30. 24 V single-ended shaft encoder connections

The following two simplified illustrations show the input connections for the second
channel of a 5-volt and a 24-volt quadrature shaft encoder, respectively.
69089
5 V QUADRATURE SK1/SK2 6900 / 7300 / 7900 / 5900 PRINTERS
SHAFT ENCODER 3 5VF
24VF
1
QSE INPUT 9
4 x 910R 470R

NOTE: 2
LK12
Connections and
LK12 shown for a 3 1
5 V Shaft Encoder 4
ANODE
IC11B 6
OUTPUT
3
CATHODE
2 0VF

Figure 3-31. 5 V quadrature shaft encoder connections

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 69090
24 V QUADRATURE SK1/SK2 6900 / 7300 / 7900 / 5900 PRINTERS
SHAFT ENCODER 3 5VF
1 24VF

QSE INPUT 9
4 x 910R 470R

NOTE: 2
LK12
Connections and
LK12 shown for a 3 1
24 V Shaft Encoder 4
ANODE
IC11B 6
OUTPUT
3
CATHODE
2 0VF

Figure 3-32. 24 V quadrature shaft encoder connections

Width adjuster unit

A Width Adjuster Unit (WAU) is available, which can be connected between the shaft
encoder and the printer to intercept the shaft encoder signal. The WAU allows the printed
length of a message to be more finely adjusted to suit the application than is possible with
the Pitch setting on the printer alone. Alternative values for print pitch 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 (part number FA65362) for details about how to
set up and use the unit.

3.9.4 Alarm output

The alarm internal switching signal can be used to operate either a 24 volts external alarm,
or a mains-powered external alarm through a volt-free contact (VFC) relay.
The printer is shipped in the 24 volts alarm configuration, but the mains-powered external
alarm capability is available as an option.

24 volts external alarm

CAUTION: Printer Electrical Damage. Do not connect the ALARM OUTPUT connector of the
printer to the mains electrical supply or any other power source. Damage to the printer can
occur if this caution is ignored.
The output circuit for the 24 volts external alarm is protected by a 200 mA, self-resetting
thermal fuse, designated F3 on the IPM PCB. The alarm output is routed from connector
PL10 on the IPM PCB to the Alarm PCB, which is fitted to the back of the ALARM OUTPUT
connector. The output of the Alarm PCB is routed to the ALARM OUTPUT connector on
the rear panel of the printer.

24 VOLTS ‘ALARM OUTPUT’ CONNECTOR

Signal Connector pin
24 V L
Return N

Table 3-16. 24 volts external alarm pin connections

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 Mains (VFC) external alarm
For a mains-powered external alarm, the alarm switching signal operates a volt-free contact
(VFC) relay (RLA1) on the IPM PCB.

WARNING: LETHAL VOLTAGE HAZARD. DANGEROUS VOLTAGE EXISTS IN THE PRINTER

WHEN IT IS DISCONNECTED FROM THE MAINS ELECTRICAL SUPPLY, BUT A
MAINS-OPERATED EXTERNAL ALARM IS CONNECTED TO THE PRINTER. THERE CAN BE
MAINS VOLTAGE ON THE PCB ATTACHED TO THE ALARM CONNECTOR AND ON THE IPM
PCB IN THE AREA OF THE EXTERNAL ALARM RELAY.
WHEN THE PRINTER COVER IS REMOVED, DO NOT TOUCH THE ALARM CONNECTOR PCB,
OR THE IPM PCB IN THE AREA OF THE EXTERNAL ALARM RELAY.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS SAFETY
WARNING IS IGNORED.
The alarm relay is protected by a 1 A, sand-filled, ceramic, slow-blow fuse (F2). The output
is routed from connector PL11 on the IPM PCB to the Alarm PCB, which is fitted to the back
of the ALARM OUTPUT connector. The output of the Alarm PCB is routed to the ALARM
OUTPUT connector on the rear panel of the printer.
Either ‘normally open’ (NO) or ‘normally closed’ (NC) VFC relay contact operation is
available at the ALARM OUTPUT connector. The external alarm equipment connected to
this output must have its wiring connected in accordance with the following table.

MAINS (VFC) ‘ALARM OUTPUT’ CONNECTOR

Signal Connector pin
Common L
Normally closed (NC) N
Normally open (NO) E

Table 3-17. Mains (VFC) external alarm pin connections

VFC relay operation (events only)

In the following description of the VFC relay contact operation, it is accepted that all failure
and warning events are set to Pulsed on the Alarm Setup page.

Normally closed (NC)

Before electrical power is applied to the printer, the NC relay contact is closed. When
electrical power is applied to the printer, the NC relay contact state is determined by
whether or not any failures or warnings are present. If no failures or warnings are detected,
the alarm relay is not energized and therefore the NC relay contact remains closed. When
any failures or warnings are detected, the alarm relay is energized and the NC relay contact
opens. Note that with ‘Pulsed’ applied to all failure and warning events, the relay contact is
activated twice for warnings, and remains open continuously for failures.

Normally open (NO)

Before electrical power is applied to the printer, the NO relay contact is open. When
electrical power is applied to the printer, the NO relay contact state is determined by
whether or not any failures or warnings are present. If no failures or warnings are detected,
the alarm relay is not energized and therefore the NO relay contact remains open. When any
failures or warnings are detected, the alarm relay is energized and the NO relay contact
closes. Note that with ‘Pulsed’ applied to all failure and warning events, the relay contact is
activated twice for warnings, and remains closed continuously for failures.

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 VFC relay operation (printing only)
In the following description of the VFC relay contact operation, it is accepted that the
‘Printing’ event is set to Constant on the Alarm Setup page.

Normally closed (NC)

Before electrical power is applied to the printer, the NC relay contact is closed. When
electrical power is applied to the printer, the alarm relay is not energized and therefore the
NC relay contact remains closed. When the printer enters the ‘Printing’ state, the alarm relay
is energized and the NC relay contact opens. Note that with ‘Constant’ applied to the
‘Printing’ event, the relay contact remains open continuously while the printer is in the
‘Printing’ state.

Normally open (NO)

Before electrical power is applied to the printer, the NO relay contact is open. When
electrical power is applied to the printer, the alarm relay is not energized and therefore the
NO relay contact remains open. When the printer enters the ‘Printing’ state, the alarm relay
is energized and the NO relay contact closes. Note that with ‘Constant’ applied to the
‘Printing’ event, the relay contact remains closed continuously while the printer is in the
‘Printing’ state.
Refer to the ‘Mains (VFC) External Alarm Conversion’ maintenance instruction in
Chapter 5: ‘Maintenance’ for fitting instructions.

3.9.5 Dual alarm

The dual alarm upgrade for 7900 printers allows both the mains (VFC) external alarm
accessory and the standard 24 volts external alarm to be used. A replacement rear panel
plate is supplied in the upgrade kit, which has three holes that allow the connectors of the
two different alarms and the Ethernet connector to be fitted.
A configuration code is required that enables the second alarm in the software. When
enabled, the Alarm 2 Setup option is available on the Alarm page (Print Monitor > Line
Setup > Alarm).
The software detects the presence of the additional VFC alarm accessory and controls the
two alarm outputs. When an alarm condition is detected by the printer, the alarm software
selects which output is triggered.
The following example is a common arrangement:
 The 24 volts external alarm is activated when there is a System Warning, for example,
“Ink Low”, “Solvent Low”, or Printhead Cover Off”.
 The VFC external alarm is activated when there is a Print Failure, for example, “Time of
Flight Failure”, “Phase Failure”, or “Internal Spillage”.
Refer to the ‘Dual Alarm Installation’ maintenance instruction in Chapter 5: ‘Maintenance’
for fitting instructions.

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 3.9.6 Multi-stage alarms
The 7900 printers can be fitted with an optional multi-stage alarm accessory. To operate,
this accessory also requires the parallel I/O interface upgrade accessory to be installed. Up
to four outputs are provided that can be used to control multi-stage alarm beacons.
The purpose of a multi-stage alarm is to provide more information on the printer status to
operators who are at a distance from the printer. An example of a multi-stage alarm is a
three-stage alarm with three different coloured beacons. These beacons are configured as
follows:
 Green beacon for ‘printing’.
 Amber beacon for ink or solvent low warnings.
 Red beacon for ‘not printing’.
The operator can configure the printer conditions that illuminate each beacon.
Two types of multi-stage alarm accessory are available to replace the standard 24 V external
alarm output or the VFC alarm conversion:
 A 24 V multi-stage alarm type.
 A VFC multi-stage alarm type.
The external alarm equipment connected to the 24 V multi-stage alarm outputs must have
its wiring connected according to the following table.

MULTI-STAGE ALARM (24 V) OUTPUT CONNECTOR

Signal Connector pin
Alarm 1 1
Alarm 2 2
Alarm 3 3
24 V 4
Not used 5
Alarm 4 6
Not used 7

Table 3-18. Multi-stage alarm (24 V) pin connections

The external alarm equipment connected to the VFC multi-stage alarm outputs must have
its wiring connected according to the following table.

MULTI-STAGE ALARM (VFC) OUTPUT CONNECTOR

Signal Connector pin
Normally closed (NC) 4 1
Normally open (NO) 4 2
Common 3
Normally open (NO) 3 4
Normally open (NO) 2 5
Normally closed (NC) 1 6

Table 3-19. Multi-stage alarm (VFC) pin connections

For more information about alarms, see ‘Alarm output’ on page 3—61.
Refer to the section ‘Maintenance instructions’ in Chapter 5: ‘Maintenance’ for fitting
instructions.

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 3.9.7 Serial interface
The 7900 printers have a serial interface called the remote communications interface (RCI).
This facility provides a method to control all the functions of the printer from a remote
device, for example, a PC or PLC through the serial port. The printer is a ‘slave’ that
receives commands from a remote host, and returns status information and data as
requested.
The printer uses the RS-232 interface as the standard, which gives point to point
communications. The protocol used is defined by Linx and is described in detail in the Linx
Remote Communications Interface Reference Manual.

Cable connections
Connection for the RS-232 interface is by the RS232 INTERFACE connector on the rear
panel of the printer, which is a 9-way, D-type connector with numeric pin-out designations.
Pin connections for the RS-232 interface cable are shown in the following illustration.
COMPUTER 68047 PRINTER
"RS232 INTERFACE"

1 1 not connected
RxD RxD
2 2
TxD TxD
3 3
4 4 not connected
Gnd Gnd 5
5
6 6 not connected
7 7 not connected
8 8 not connected
9 9 not connected

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

to ensure correct fitting orientation of the cable assembly.
Figure 3-33. RS-232 interface cable pin connections

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 3.9.8 Parallel I/O interface
An optional auxiliary PCB is available for 7900 printers that provides a parallel input/
output (PIO) capability. The PIO PCB with a 25-way, D-type connector is fitted to an option
plate on the rear panel of the printer. This accessory provides 8-off 24 V DC inputs and 8-off
24 V DC outputs.
With this accessory, the input and output signals can be used by the software in the printer
for a variety of applications, including:
 Selecting a message for printing from a list.
 Remote start and stop, and production line interlocks.
 Separate indications for warnings and faults.
The following are two typical applications for the PIO accessory:
 Typical application 1: connect the printer to a programmable logic controller (PLC) to
stop the printer at the end of the day, or pause print if the guards of the machine are
open.
 Typical application 2: use a series of photocells to sense the size of the product and
select the correct message to print.
Refer to the section ‘Maintenance instructions’ in Chapter 5: ‘Maintenance’ for fitting
instructions.

Supply voltage for the inputs and outputs

Link positions for the inputs

The selection of the supply voltage for the PIO inputs is determined by fitting links
LK2 (0 V) and LK3 (24 V) on the PIO PCB in one of two positions. Position A (between
pins 1 and 2) for the internal (printer) 24 volts supply, or position B (between pins 2 and 3)
for an external 24 volts supply.

Link positions for the outputs

The selection of the supply voltage for the PIO outputs is determined by fitting links
LK4 (24 V) and LK5 (0 V) on the PIO PCB in one of two positions. Position A (between pins
1 and 2) for the internal (printer) 24 volts supply, or position B (between pins 2 and 3) for an
external 24 volts supply.

Sinking or sourcing the supply voltage

Regardless of the supply voltage setting, the inputs must be able to ‘sink’ or ‘source’ greater
than 10 mA, and the outputs can ‘sink’ or ‘source’ up to 160 mA.
Linx recommends to sink instead of source both the inputs and the outputs, as this
arrangement is easier and safer for the printer.
If the ‘Sink’ option is selected on the printer interface, connect any inputs that are not active
to the 24 V line. To connect an active input, use a pull-up resistor on the input. If the ‘Source’
option is selected, connect any inputs that are not active to the 0 V line. To connect an active
input, use a pull-down resistor on the input. Refer to the Linx 5900 & 7900 How To Use the
Parallel I/O Option document for more information.

Auxiliary bus position

The auxiliary bus position is determined by fitting link LK1 (Auxiliary Bus Pos) on the PIO
PCB in one of two positions. Position 0 (between pins 1 and 2) for the lower bus, or position
1 (between pins 2 and 3) for the higher bus.
Position 0 is the default position and the correct position for link LK1 on 7900 printers.
NOTE: Position 1 is the setting used when a second PIO PCB is installed.

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 If the Parallel I/O option is not displayed in the Setup menu (Print Monitor > Menu >
Setup) after the PIO accessory is installed, move link LK1 to the other position.
The following illustration shows the positions of all the links on the PIO PCB.
73058

LK4 LK5

LK2 LK3 LK1

Figure 3-34. Parallel I/O PCB links

Pin connections
Pin connections for the PIO Interface are shown in the following table.

PARALLEL I/O PIN CONNECTIONS

Pin no. Function Pin no. Function
1 0 V (for inputs) 14 Input 2
2 Input 1 15 Not connected
3 Not connected 16 Input 8
4 Input 7 17 Input 6
5 Input 5 18 Input 4
6 Input 3 19 Latch input
7 +24 V supply (for inputs) 20 Latch output
8 0V 21 0 V (for outputs)
9 Output 8 22 Output 7
10 Output 6 23 Output 5
11 Output 4 24 Output 3
12 Output 2 25 Output 1
13 +24 V supply (for outputs) — —

Table 3-20. Parallel I/O interface pin connections

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 3.9.9 Ethernet interface
Ethernet capability is fitted as standard to all 7900 printers. This interface has a cable
assembly that is fitted between SK9 on the IPM PCB and a connector fitted to an option
plate on the rear panel of the printer. The Ethernet connector is an RJ45 socket that has a
bayonet-type connection and a minimum rating of IP65.
The standard internet protocol (IP) over Ethernet (10Base-T, half-duplex standard) is used,
which allows the printer to be connected to a standard Ethernet network or directly to a
local PC. RCI over IP is the only protocol currently supported.
The Ethernet interface provides a high-speed data interface to the printer. There is no
configuration required for the Ethernet physical interface, but the IP network settings do
require configuration.
Refer to the section ‘Maintenance instructions’ in Chapter 5: ‘Maintenance’ for fitting
instructions.

3.9.10 USB facility

The USB facility allows an operator to transfer message data to and from a USB memory
device connected to the printer. The facility can also be used to copy or back up the
configuration of a printer and to restore a configuration to any printer.
At Service Level E a maintenance technician can also upgrade the system software from a
USB memory device. Refer to the section ‘Software Upgrade’ on page 5—30 of
Chapter 5: ‘Maintenance’ for a description of the software download process.
The USB Type A connector is fitted to the front left of the base unit and includes a protective
sealing cap, and has a minimum rating of IP65.

3.9.11 Alarm and interface upgrade combinations

The standard configuration for 7900 printers is the 24 volts external alarm and Ethernet
interface combination.
All of the different alarm and parallel I/O upgrade combinations that are available for 7900
printers are shown in the following table. The Ethernet interface is provided as standard in
all upgrade combinations.

Ethernet 24 volts Mains (VFC) 24 volts Mains (VFC) Parallel I/O

interface external external multi-stage multi-stage interface
alarm alarm alarm alarm
 
 
  
  
  
  
  

Table 3-21. Alarm and interface upgrade combinations

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 3.9.12 D-type connector assembly
Correct assembly of the D-type connectors used for trigger devices, shaft encoder, serial
interface, and parallel interface connections to the printer, is shown in the following
illustration.
Cable screen to be terminated by removing the
outer sheath and folding the braid back on itself
by approximately 10 mm. Braid to be secured
by the cable clamp over the exposed braid.
6321

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 (where applicable), item 9 is a female connector.
2. Test all cable connections for continuity and short circuits before use.
3. The cable clamp over the screen braid is to be pulled into the connector
hood until it 'clicks' into place.
4. Pad out the cable outside diameter with heatshrink, if necessary, to
ensure a good seal at the rubber gasket.

Figure 3-35. Correct assembly of the IP67 D-type connector

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 This page left blank intentionally

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 CHAPTER 4: SYSTEM OPTIONS
4.1 Introduction
This chapter describes the system options that are available in Linx 7900 printers. The
information shown in this chapter refers to printers with Version 5.2 System Software
installed, unless otherwise stated.
Refer to the Linx 5900 & 7900 How To ... guides for more information about how to edit
messages and how to use other functions that are available from the 7900 user interface.

4.2 Print Monitor

The Print Monitor is the first page that is displayed after the startup (splash) screen, when
the printer is turned on. During startup, the system performs automatic self-tests while the
splash screen is displayed.
The message that was last used is displayed in the Current Message area of the Print
Monitor page.
69151

Figure 4-1. Print Monitor page

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 4.2.1 How to select and change options
Six soft keys to the left of the display are related to the available options shown on the left
side of the displayed page. Press the soft key that is related to the required option to select
it. For example, to select the Menu option on the Print Monitor page, press the fifth soft
key. The Menu page is then displayed with a further list of options on the right of the page.
73085

73086

Figure 4-2. Soft keys and related options

Use the Up and Down arrow keys to the right of the display to move the dark blue highlight
box to the menu option that is required. When the option is highlighted, press the Select soft
key. This action can display a further page of options. Continue to use this procedure to
select options until the required page is reached.
How the option settings are changed depends on the type of option page that is selected.
Some option pages have a list of settings, and the Up and Down arrow keys are pressed to
highlight the required setting. For example, the list of printheads on the Printhead Type
page, or the lengths of printhead conduit on the Conduit Length page. Other option pages
allow a value to be entered, for example, numbers on the Printer Serial Number page.
When the option setting has been changed, press the OK soft key to save the change. The
new setting is displayed in the option on the previous page. If a setting is made but the
change is not required, press the Cancel soft key instead of the OK soft key. This action
returns the display to the previous page and to the setting in use before the page was
opened.
To return to the Print Monitor page, continue to press the Exit soft key until the page is
reached.

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 4.2.2 Total system options
When the Menu key is pressed, the system options are displayed on the Menu page. The
complete list of system options that are available at security access Level D and Level E is
shown in the following illustration.
73063

Figure 4-3. Total Menu page options

Refer to Chapter 5: ‘Maintenance’ > ‘Maintenance page’ for information about the available
Maintenance options and how to use them.

4.2.3 Password access

The correct access level password must be entered on the Change User Level page before
the required list of system options can be accessed.
Five security access levels are used: Level A (Base), Level B (User 1), Level C (User 2),
Level D (Service 1) and Level E (Service 2). For the purposes of this maintenance manual,
only the Service 1 and Service 2 access levels are described.
Each access level has its default password, but the Service level passwords are not printed
in this manual. This precaution is because, not all personnel who have access to this manual
have received enough training to use the complete range of Maintenance options. This
complete range is only available with the Level E (Service 2) password. However, the two
Service access levels that are applicable to 7900 printers are printed on a separate page
(without a page number) at the end of this chapter. The related Service level default
passwords are supplied to personnel who are authorized by Linx and to those technicians
who have been given training on a maintenance course approved by Linx. These passwords
must be written in against the access levels on this last page. The page must then be
removed from the manual and kept in a safe location.

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 To get access to the complete range of system options (and therefore all of the Maintenance
options), perform the following steps:
If the system is set to Level D (Service 1) or lower level:
1 On the Print Monitor page, press the Menu key.
2 On the Menu page, select the Change User Level option.
3 On the Change User Level page, enter the Level E password.
4 Press the OK key.
NOTE: All passwords are case sensitive. The default passwords are in upper case letters
and must be entered as such. If “ABC” is entered, it will be accepted, but “abc” or
“Abc” will be rejected. Passwords created by the operator can be a mixture of upper
and lower case letters.
69155

Figure 4-4. Change User Level page

Service level timeout

There is a security timeout for the two Service access levels. When the printer is at security
access Level D or Level E, the printer automatically changes to the default Level A (Base)
after 24 hours. The change of access level only occurs when the operator returns through
the menu structure to the Print Monitor page. This feature prevents printers being
accidentally left in a Service access level condition.

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 4.2.4 Option availability
The printer has three states: ‘Idle’, ‘Jet Running’, and ‘Printing’ (printing or ready to receive
a ‘print go’ signal). Some options on the Menu pages are influenced by these states, which
can change the availability of some options and also the ability to select an option or change
its parameters.
Menu pages and their options are only displayed if they are valid for the security access
level used and the current printer state. For example, the Conduit Length option (Print
Monitor > Menu > Setup > Installation > Printhead) is only displayed at the two Service
access levels. The Conduit Length option can be selected or changed only at Level E, and
only when the printer is in the ‘Idle’ (jet off) state. At Level D or when the printer is in the
‘Jet Running’ or ‘Printing’ states, the Conduit Length option is displayed but is dimmed
and cannot be selected or changed.
The following table shows when each page, and the options the page contains, are
available, related to the printer state and the security access level. The symbols used in the
table to show when the pages and options are available are described in the following:
 Pages and options that are displayed and can be selected or changed are identified with
a solid circle.
 Pages and options that are displayed, but cannot be selected or changed are identified
with an empty circle.
 Pages and options that are not available because of the printer state or access level, and
therefore are not displayed, are identified with a grey box.
NOTE: The Line Setup option on the Print Monitor page (shown in the following table) is
described first in this chapter.

LEVEL D LEVEL E

1st level page 2nd level page 3rd level page 4th level page Idle Jet Print- Idle Jet Print-
Runn- ing Runn- ing
ing ing

Print Monitor > Line Setup >

Trigger Refer to the Linx 5900 & 7900 How To ... guides ● ● ● ● ● ●
Speed Refer to the Linx 5900 & 7900 How To ... guides ● ● ● ● ● ●

Alarm Refer to the Linx 5900 & 7900 How To ... guides ● ● ● ● ● ●

Power Down — — — ● ● ● ● ● ●

After Jet Shutdown — — ● ● ● ● ● ●

Delayed on Idle — — ● ● ● ● ● ●

Delayed on Jet Run. — — ● ● ● ● ● ●

Delayed on Printing — — ● ● ● ● ● ●

Delay — — ● ● ● ● ● ●

Print Monitor > Menu >

Event Log — — — ● ● ● ● ● ●

Show Event History — — ● ● ● ● ● ●

Event Setup — — ● ● ●

Block New Events — — ● ● ● ● ● ●

Event Filtering — — ● ● ● ● ● ●

Clear Event History — — ● ● ●

Hide Faults — — ● ● ● ● ● ●

Hide Warnings — — ● ● ● ● ● ●

Hide Information — — ● ● ● ● ● ●

Stores Refer to the Linx 5900 & 7900 Quick Start Guide ● ● ● ● ● ●

Table 4-1. System options availability table

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 LEVEL D LEVEL E

1st level page 2nd level page 3rd level page 4th level page Idle Jet Print- Idle Jet Print-
Runn- ing Runn- ing
ing ing
Maintenance Refer to Chapter 5: ‘Maintenance’ ● ● ● ● ● ●

Setup Installation — — ● ● ● ● ● ●

Date & Time — ● ●  ● ● 

Current Time ● ●  ● ● 

Current Date ● ●  ● ● 

Hijri Date      
Nudge Hijri Date ● ●  ● ● 

Printhead — ●   ●  

Printhead Type    ●  

Conduit Length    ●  

Printhead Height ● ● ● ● ● ●

Cover Override ● ● ● ● ● ●

Printhead Code ●   ●  

Mod Slope    ●  

ID — ●   ●  
UNIC Code      

Printer Conf Code ●   ●  

Printer Serial No.    ● ● ●

Ink/Solvent — ●   ●  

Ink/Solvent Type    ●  

Next Mix    ●  

Last Mix      

Mix Time      

Disable Mix    ●  

Locale — ● ● ● ● ● ●

Language ● ● ● ● ● ●

Use Lang. Defaults ● ● ● ● ● ●

Units ● ● ● ● ● ●

Calendar ● ●  ● ● 

Keyboard ● ● ● ● ● ●

Sec. Keyboard ● ● ● ● ● ●

Photocells — ● ● ●

Pri. Photocell
● ● 
Deadtime
Sec. Photocell
● ● 
Deadtime

USB Refer to the Linx 5900 & 7900 How To ... guides ● ● ● ● ● ●

Change User Level — — — ● ● ● ● ● ●

Nozzle Flush Refer to the Linx 5900 & 7900 Quick Start Guide ●   ●  

Nozzle Clear Refer to the Linx 5900 & 7900 Quick Start Guide ●   ●  

System Information Refer to the Linx 5900 & 7900 How To ... guides ● ● ● ● ● ●

Table 4-1. System options availability table (continued)

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4.3 Line Setup page
There are four options on the Line Setup page:
 Trigger
69154
 Speed
 Alarm
 Power Down

Figure 4-5. Line Setup page

Only the Power Down option is described in this chapter, because it is the only option of
the four that requires Service Level D or Level E for access. Refer to the Linx 5900 & 7900
How To ... guides for descriptions of the Trigger, Speed, and Alarm options.

4.3.1 Power Down

The Power Down option allows the printer to be configured for automatic power-down.
The electrical power is supplied to the printer by the mains electrical supply switch, which
is on the rear panel. To turn on the printer, set the mains electrical supply switch from the
‘0’ (off) position to the ‘I’ (on) position. Then press and hold (for 2 seconds) the power on
push-button switch on the front of the printer.
A latching relay is fitted to 7900 printers, which enables the printer to turn off automatically
under defined conditions.
The printer is turned off by the following methods:
 The power save functions on the Power Down page.
 The red [stop] key when the jet is not running (‘Idle’ state).
 The mains electrical supply switch on the rear panel. This is not a recommended
method to use to turn off the printer and must be used only in an emergency.
IMPORTANT: Although the automatic power-down function allows the printer to turn off
automatically, it is the responsibility of the operator to make sure that the
printer does actually turn off. The automatic power-down function must be
regarded as a convenience, NOT a safety device.
IMPORTANT: The automatic power-down function on 7900 printers removes electrical
power from the control electronics, which safely disables the functions of
the printer. However, when power-down is completed, electrical power is
present in the internal cableform from the mains electrical supply switch
on the rear panel. This cableform is connected to the power on push-button
switch on the front panel, and the relay on the IPM PCB.
During normal day-to-day routine maintenance, for example, when the
printer is washed, there is no need to turn off the printer at the rear.
IMPORTANT: The automatic power-down function is disabled if the Power Off Override
link LK20 is fitted. The Power Down option is not displayed on the Line
Setup page, and therefore the option cannot be activated.

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 The power-down options and conditions are displayed when the Power Down option is
selected on the Line Setup page.
69157

Figure 4-6. Power Down page

The printer can be set to automatically power down under configured conditions.
These conditions are shown on the Power Down page as After Jet Shutdown, Delayed on
Idle, Delayed on Jet Running, and Delayed on Printing. The required condition is enabled
when it is highlighted and the Select key is pressed. This action changes the state of the
condition from No to Yes. The default condition is After Jet Shutdown set to Yes. A
combination of these conditions can be enabled at the same time.
The Delay option changes the power-down delay time.
If there are no conditions enabled, the printer will not automatically power down. The red
[stop] key on the control panel turns off the printer manually in this configuration.
Automatic power-down is disabled if the keylock timer is enabled and the time has expired.
Automatic power-down is disabled while a printer fault (System Failure or Print Failure) is
active. With either of these conditions, the printer must be turned off manually with the red
[stop] key on the control panel, and not with the mains electrical supply switch on the rear
of the printer. This method makes sure that data is saved before the printer is turned off.
The word ‘activity’ in the following descriptions is defined as:
 Any events that cause the printer to print.
 Any external events that change the print data (that is, not time-based events that are
generated in the printer).
 Keyboard activity (that is, if any key is pressed).
 External communications (transmitted or received data over the remote interface).
The descriptions of the four conditions when they are in their enabled states, and the Delay
option are as follows:

After Jet Shutdown

After the jet has shut down, the printer will automatically power down immediately
without any delay.

Delayed on Idle
If there has been no activity during the power-down delay time, and the printer is in the
‘Idle’ state, the printer will automatically power down.

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 Delayed on Jet Running
If there has been no activity during the power-down delay time, and the printer is in the ‘Jet
Running’ state, a normal jet shutdown is performed followed by automatic power-down.

Delayed on Printing
If there has been no activity during the power-down delay time, and the printer is in the
‘Printing’ state, printing is stopped and a normal jet shutdown is performed followed by
automatic power-down.

Delay
The power-down delay is the time, in minutes, during which there must be no activity
before the power-down sequence can begin. If any activity occurs during the power-down
delay time, the delay period is restarted. To change the delay time, highlight the Delay
option and press the Select key. The Up or Down arrow keys are used to increase or
decrease the time, and the OK key is pressed to accept the change. The default setting for
the Delay option is 60 minutes, the minimum setting is 1 minute, and the maximum setting
is 36000 minutes (600 hours).
When the power-down delay time has expired and the jet has shut down, a 5-second delay
occurs before power-down. This additional delay allows the printer data to be saved. After
this period, an information message is displayed that shows a countdown from 10 seconds.
Any activity during this period cancels the whole process and the printer remains turned
on.

4.4 Menu page

73063

Figure 4-7. Menu page

Only the Event Log, Maintenance, Setup, and Change User Level options are described in
this manual. This is because some of the submenu options require Service Level D or
Level E for access. Refer to the Linx 5900 & 7900 Quick Start Guide and the Linx 5900 & 7900
How To ... guides for descriptions of the remaining options.

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 4.4.1 Event Log
The Event Log (Print Monitor > Menu > Event Log) contains information about the current
state of the printer. The information includes all current events and an event history.
Functions are also available for event filtering, and for configuring how and when each
event is logged. The total number of times an event has occurred is also provided.

Current Events
69093

Figure 4-8. Current Events page

The Current Events page shows all the events that are present on the printer. All the events
are recorded in the lower Event part of the page in group order, that is, failures together at
the top of the list followed by warnings and then information events.

Show Event History

When the Show Event History key is pressed on the Current Events page, the Event
History page is displayed.

69094

Figure 4-9. Event History page

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 All logged events, up to a maximum of 1000, are displayed in the lower part of the page
with a timestamp for each one. All the events in the list appear in date and time order, with
the most recent displayed at the top of the list.
The convention for the timestamp is ‘year-month-day hours:minutes:seconds’. For example,
13-12-31 23:59:59 means that the event occurred on the 31st of December 2013 at 59 minutes
and 59 seconds past 11 o’clock at night (or 1 minute before midnight).
When the list is full (1000 events), the next event to occur is added to the top of the list and
the oldest event at the bottom of the list is deleted, and so on for all subsequent events.

Block New Events

When the Block New Events key is pressed on the Event History page, all further new
events are prevented from being added to the list. This function can be used when there are
many occurrences of a particular event in quick succession, for example, Over Speed errors.
The events continue to be logged, but are not reported in the list.
The key switches between the Block New Events and the Track New Events options (see
the following ‘Track New Events’ description).

Track New Events

69095

Figure 4-10. Track New Events option

This key switches off the ‘Block New Events’ function and the system returns to reporting
all new events that occur. The list scrolls to the top to show the most recent event first. All
new events that occurred while the ‘Block New Events’ function was used continue to be
logged, but are not reported in the list. When the Track New Events key is pressed, these
logged events are added to the list.

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 Event Filtering
When the Event Filtering key is pressed on the Event History page, the Event Filtering
page is displayed.
69096

Figure 4-11. Event Filtering page

This page provides three keys—Hide Faults, Hide Warnings, and Hide Information—for
selecting which events from the Event History are displayed in the lower part of the page.
The keys switch between the Hide … and Show … options for each of the three groups of
events. Any combination of failures, warnings, and information events can be configured
for display.
When different combinations of groups are selected for display (Show …), events that
occur but are not in the selected groups are still logged but not displayed until that group is
selected. The System Event page is still displayed for all events that occur. System Failures
are always displayed in the Event History.

Hide/Show Faults
If the Show Faults key is pressed, all Print Failures that have occurred since the last Clear
Event History option was used are displayed.

Hide/Show Warnings
If the Show Warnings key is pressed, all System Warnings that have occurred since the last
Clear Event History option was used are displayed.

Hide/Show Information
If the Show Information key is pressed, all Information Events that have occurred since the
last Clear Event History option was used are displayed.
There are five Information Events, which are designated as follows:
 4.00 Jet Test Start
 4.01 Jet Test Stop
 4.02 Normal Start
 4.03 Normal Stop
 4.04 Nozzle Clear

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 Clear Event History
When the Clear Event History key is pressed on the Event History page, the Clear Event
History page is displayed.
69097

Figure 4-12. Clear Event History page

Yes
When the Yes key is pressed, all the events in the Event History are cleared and also all
event counts (see Reset Count on the Event Setup page). The confirmation message “The
Event Log has been cleared.” is then displayed.
After the log is cleared, any current events remain visible on the Current Events page.
No
When the No key is pressed, the display returns to the Event History page.

Event Setup
How each event is reported and logged is configured on the Event Setup page.
69098

Figure 4-13. Event Setup page

All the possible events that can occur in the printer are displayed in a list in the lower Setup
part of the Event Setup page. The events are displayed in group order, that is, failures
together at the top of the list followed by warnings and then advisory messages.
To configure an event, the Up or Down arrow key is pressed to scroll the list until the
required event is highlighted. The highlighted event is displayed in the top box of the Event
Setup page and includes the numbers of times the event has occurred. The following key
options are used to configure the events.

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Linx 7900 Maintenance Manual 4—13 Oct 2013
 Always Log
When this key is pressed, every new occurrence of the selected event is always reported and
logged. The condition for the event is displayed in the second box from the top of the page.
69099

This event is always logged.

Figure 4-14. Always Log option

NOTE: This function must be used with discretion when the printer is receiving many
events in quick succession, for example, Over Speed errors. In this situation, the
user interface can become swamped with continuously displayed reports.

Log At Intervals
This function applies a default time interval, after an event has occurred, during which new
occurrences of the same event are not reported or logged. When the time interval has
elapsed, the next new occurrence of the same event is then reported and logged.
The default setting for all events is ‘Log At Intervals’.
When the Log At Intervals key is pressed, the selected event is logged at intervals of
20 seconds (the default interval). The condition for the event is displayed in the second box
from the top of the page (see Figure 4-13).

Never Log
When this key is pressed, the selected event is never reported but is logged. This function
contradicts the label for the key and is a known software error.
The condition for the event is displayed in the second box from the top of the page.
69101

This event is never logged.

Figure 4-15. Never Log option

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 Edit Interval
When this key is pressed, the Edit Interval page is displayed.
69100

Figure 4-16. Edit Interval page

This page is used to change the reporting interval for the selected event. The time interval
(in minutes and seconds) is highlighted ready for a different time to be entered. When the
OK key is pressed, the display returns to the Event Setup page and the new reporting
interval is shown in the event condition box.
If the Cancel key is pressed, the display returns to the Event Setup page and the reporting
interval in the event condition box remains the same.

Reset Count
Every occurrence of an event is automatically logged, regardless of the rate at which it is
reported (see the preceding ‘Log At Intervals’ description). The number of times the event
occurs is included in the selected event that is displayed in the top box of the Event Setup
page.
When the Reset Count key is pressed, the number of times the event has occurred is reset
to 0 (zero).

4.4.2 Maintenance
For full information about the Maintenance options, refer to ‘Maintenance page’ in
Chapter 5: ‘Maintenance’.

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Linx 7900 Maintenance Manual 4—15 Oct 2013
 4.4.3 Setup
When the Setup option is highlighted on the Menu page and the Select key is pressed, the
following page is displayed.
73084

79033

Figure 4-17. Setup page

When the Installation option is highlighted on the Setup page and the Select key is
pressed, the following page is displayed.
73067

Figure 4-18. Installation page

The Installation page allows configuration of the printer date and time, printhead
parameters, printer identification, the type of ink and solvent, locale parameters, and
photocell debounce.

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Oct 2013 4—16 Linx 7900 Maintenance Manual
 Date & Time
When the Date & Time option is highlighted on the Installation page and the Select key is
pressed, the following page is displayed.
69162

Figure 4-19. Date & Time page

The Date & Time page sets the correct date and time in European and Hijri formats.
NOTE: The Hijri Date and Hijri Date Offset (Days) options only appear on the Date &
Time page when the Hijri calendar is selected on the Calendar page (Print Monitor
> Menu > Setup > Installation > Locale > Calendar). See also ‘Use Language
Defaults’ in the ‘Locale’ option on page 4—23.

Current Time
This option displays the current time in the form ‘HH:MM:SS’, which can be changed if necessary.
When the Current Time option is highlighted and the Select key is pressed, a page is
displayed that allows the current time to be changed. The current local time is entered from
the keyboard, in the 24-hour format, as follows:
 Enter two digits for the hours.
2. Enter two digits for the minutes after the first colon.
3. Enter two digits for the seconds after the second colon.
4. Press the OK key.
If a time setting is made but the change is not required, press the Cancel key instead of the
OK key. This action returns the display to the Date & Time page, and the Current Time is
not changed.

Current Date
This option displays the current, Gregorian calendar date in the form ‘YYYY-MM-DD’,
which can be changed if necessary.
When the Current Date option is highlighted and the Select key is pressed, a page is
displayed that allows the current date to be changed. The current date is entered from the
keyboard, in the numeric European format, as follows:
 Enter four digits for the year.
2. Enter two digits for the month after the first hyphen.
3. Enter two digits for the day after the second hyphen.
4. Press the OK key.
If a date setting is made but the change is not required, press the Cancel key instead of the
OK key. This action returns the display to the Date & Time page, and the Current Date is
not changed.

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 Hijri Date
This option displays the current, Hijri calendar date in the form ‘yyyy-mm-dd’, which is for
display only and cannot be changed. The Hijri date is automatically calculated from the
Gregorian date.

Hijri Date Offset (Days)

The Hijri calendar is a lunar calendar used by many Muslim countries. Each month has
either 29 or 30 days. The first day of each month is the day that the moon is first seen after
sunset. Different Muslim countries use different rules to decide exactly when the moon is
first seen. The Hijri Date Offset (Days) facility allows one or more days to be added or
subtracted to adjust for the different rules in different countries. Press the Up and Down
arrow keys to add or subtract a maximum of 4 days.

Printhead
When the Printhead option is highlighted on the Installation page and the Select key is
pressed, the following page is displayed.
73068

Figure 4-20. Printhead page

The Printhead page configures the printhead-related parameters.

Printhead Type
The 7900 printers can use any of the following eight printhead types: Ultima, Ultima plus,
Micro, Midi, Midi plus, Mini, Ultima A, and Midi A. The printhead type that is fitted to the
printer is selected from the list on the Printhead Type page. The default printhead type is
Ultima. If a printhead type is not selected, the printer will not start. When a printhead type
is selected, a default printhead code is displayed. See ‘Printhead Code’ on page 4—19 for
more information.

Conduit Length
The Conduit Length page selects which of the two standard lengths of conduit is fitted to
the printhead. The correct length must be selected, which makes sure that the correct
timings for the startup and shutdown sequences are used. There are two printhead conduit
lengths, 2 metres and 4 metres. The default conduit length is 2 metres.

Printhead Height
The ink system pressure must be compensated for when the printhead is installed above or
below the height of the printer. Pressure is altered by 0.0047 bar (0.0012 p.s.i.) for every
millimetre the printhead is above or below the printer. For practical purposes, the
measurement is made vertically from the keyboard space bar to the printhead nozzle. (In
reality, the vertical distance is from the printer pressure transducer to the printhead nozzle.)

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 The vertical distance is entered on the Printhead Height page in millimetres (mm). The
maximum distance accepted by the software is +2000 millimetres to –2000 millimetres. If a
greater distance is entered, the displayed value changes from black text to red text and the
OK key is dimmed.
If the printhead is installed below the printer, the distance is entered in the format ‘–X.X’. If
the printhead is installed above the printer, it is not necessary to enter a ‘+’ prefix; the value
is entered simply as ‘X.X’. The default setting is ‘0 mm’.
If the Printhead Height setting is changed, the printhead Reference Pressure is also
automatically changed. The Solvent Add Pressure value is calculated from the Reference
Pressure. Therefore, the Monitor Jet page (Print Monitor Menu > Maintenance > Monitor
Jet) displays different Solvent Add pressures for different Printhead Height settings.
IMPORTANT: Be careful with this option, otherwise bad printer performance can occur if
incorrectly set.

Cover Override
When the Yes option is selected on the Cover Override page, the Cover Off Override link
LK21 on the IPM PCB is enabled. The function of link LK21 is described as follows:
 If the Yes option is selected and link LK21 is fitted, the link overrides the automatic
‘printhead cover off’ function. The printer does not disable the printhead EHT and
charge voltage when the removal of the printhead cover tube has been detected.
 If the No option is selected and link LK21 is fitted, the link is ignored. The printer
automatically disables the printhead EHT and charge voltage when the removal of the
printhead cover tube has been detected.
See also: Chapter 3: ‘Technical Description’ > Electronics and software > IPM PCB > Test
points and links > LK21 (Cover Off Override).
Chapter 6: ‘System Events’ > System Warnings > 3.13 Cover Override Link Fitted.

Printhead Code
All 7900 printhead conduit labels contain important calibration information. This
information must be entered on the Printhead Code page when a new printhead is fitted,
when the software is reloaded, or when the IPM PCB is replaced. These calibration
parameters are used by the printer to get the best performance. An example of a printhead
conduit label and the calibration parameters are shown in the following illustration.
69173
Vmod

Reference SERIAL No. DV040 130

Pressure MIDI 3103
MODEL / INK
Reference
CAL. CODE 179 255 Modulation

DANGER - HIGH VOLTAGE. DISCONNECT FROM MAINS BEFORE REMOVING COVER

LINX PRINTING TECHNOLOGIES plc

Charge
MADE IN ENGLAND Calibration
Factor
Figure 4-21. Printhead conduit label
The composition of the nine-digit code displayed in the Printhead Code option is as
follows:
 Digits 1 to 3 give the Reference Pressure value. The normal range of operation is 000 to
255 bits. This value is always displayed in bits, regardless of the units of measurement
selected in the Units option of the Locale page (Print Monitor > Menu > Setup >
Installation > Locale > Units).
 Digits 4 to 6 give the Reference Modulation voltage, in the range 000 to 255 volts.
 Digits 7 to 9 give the Charge Calibration Factor, in the range 050 to 300.

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 When a replacement printhead is fitted, the related code must be entered correctly on the
Printhead Code page. Make sure that every digit is exactly as shown on the printhead
conduit label.
The printhead code can be entered when the printer is in the ‘Idle’ (jet off) state only. When
a correct code has been entered, the code is stored in the printer memory until a new code is
entered.
IMPORTANT: Be careful with this option, otherwise bad printer performance can occur if
incorrectly set. When a new printhead type and printhead code are
entered, the printhead type must be entered first. If the printhead code is
changed first, when the printhead type is changed the printhead code
reverts to the default printhead code.

Mod Slope
The Modulation Tracking Slope (measured in V/bit of pressure) is normally set as a default
that depends on the printhead type and ink type being used.
When the printhead type or ink type is changed (and the Printhead Type option in the
Printhead menu, or the Ink/Solvent Type option in the Ink/Solvent menu is changed), the
default Modulation Tracking Slope value for the new printhead and ink type combination
is used.
The Mod Slope option allows the maintenance technician to manually adjust the
Modulation Tracking Slope setting to match a different printhead and ink type
combination. This facility allows support of special printheads and inks.
The setting is variable from 0.0 V/bit to 5.0 V/bit in 0.1 increments. For example, a setting
of 1.0 is equal to an increase in modulation voltage of 1.0 V for every 1 bit of pressure
change. A setting of 5.0 is equal to an increase in modulation voltage of 5.0 V for every 1 bit
of pressure change. The setting is stored in non-volatile memory.
This option is only available at security access Level E (Service 2) and only when the printer
is in the ‘Idle’ (jet off) state.

ID
When the ID option is highlighted on the Installation page and the Select key is pressed,
the following page is displayed.
69166

Figure 4-22. ID page

The ID page allows the printer to be configured with codes supplied by Linx to the
requirements of a customer.

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 UNIC Code
The UNIC Code option displays the 12-character serial number used to identify each
printer. The number is provided by the Unique Number Identification Chip (UNIC) on the
IPM PCB, which has the same number printed on the chip, for example, ‘000002D9899F’.
The system software detects the presence of the UNIC on power-up and displays the serial
number in the UNIC Code option. If a UNIC is not found on power-up, an error page with
the advisory message “Valid UNIC Chip not found” is displayed. (“Invalid UNIC” is also
displayed in the UNIC Code option.) The printer must then be turned off and a valid UNIC
must be fitted before the printer can continue. To turn off the printer, press either the red
[stop] key or the OK key on the error page.
If the IPM PCB is replaced, the UNIC must be removed from the old PCB and fitted to the
replacement one. If this is not done, the replacement PCB will not acknowledge any
configuration code (see the following ‘Printer Configuration Code’ description).

Printer Configuration Code

The Printer Configuration Code is a 24-character code, which tells the system software:
 What the printer configuration is (for example, 2-Line SS or 4-Line HP).
 What message types (rasters) are available.
 What software options are enabled to the customer.
This Printer Configuration Code is supplied with the printer and is different for each
printer. The serial number from the UNIC, and the printer configuration and software
option information are combined to generate the Printer Configuration Code at Linx.
All printer software options are programmed into the software, but only those options that
a customer has requested are enabled with the applicable configuration code.
During manufacturing, the printer serial number, the printer UNIC serial number, and the
Printer Configuration Code are associated and held on the Configuration Database. Linx
Order Administration can supply the code again if the code is lost, or a new code can be
purchased to enable additional printer options.
NOTE: The printhead type and the ink type are not configured through the Printer
Configuration Code. These parameters are selected separately through the
Printhead and Ink/Solvent pages. The software also cannot tell if the printer is a
7900 (IP55 version) or a 7900 (IP65 version).
The Printer Configuration Code is entered in four sets of six characters each, and each set is
separated by a hyphen. When a code is entered, the hyphens are automatically inserted
after each set of six characters. If a Configuration Code is not entered, the default of a 2-Line
SS (Standard Speed) printer is used, but the default code is not displayed. Only another
valid code (other than the default code) can be entered and remain displayed. For example,
when a customer requests a change to the configuration.
When a valid Printer Configuration Code is entered and the OK key is pressed, the code is
accepted, remembered, and displayed in the Printer Configuration Code option.
As a code is entered, the digits are displayed as red text and the OK key is dimmed. If the
completed code is valid, the displayed digits change from red text to black text and the OK
key is available. If an invalid code is entered, the displayed digits remain as red text and the
OK key remains dimmed.
If three invalid codes are entered, the following advisory message is displayed and the code
is ignored:
“Please Wait”
After 1 minute, another code can be entered. If the code is again invalid, the “Please Wait”
advisory message is displayed again. The time is doubled on every occurrence of another
invalid code entry.

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 Printer Serial Number
The printer serial number is also on the printer identification label found on the rear panel
of the chassis. This label is not always easy to access because of the installation in some
environments. This software feature allows operators and maintenance personnel to easily
find the serial number of the printer.
The serial number is not entered by Linx, but is entered by the maintenance technician who
installs the printer.
NOTE: The serial number is cleared from the memory of the printer if a new version of
system software is installed.

Ink/Solvent
When the Ink/Solvent option is highlighted on the Installation page and the Select key is
pressed, the following page is displayed.
69649

Figure 4-23. Ink/Solvent page

The ink type being used in the printer is selected on this page.

Ink/Solvent Type
All the inks available for use in 7900 printers are displayed in a list on the Ink/Solvent Type
page when the Select key is pressed. The inks are identified by their type number followed
by their related solvent-type number. For example, MEK ink ‘Black Water Removable ink
1035’ is identified as ‘1035/1535’, and ‘Black Ethanol ink 2035’ is identified as ‘2035/2500’.
Refer to the ‘Ink Conversion Calibration (Offset Calibration)’ maintenance instruction in
Chapter 5: ‘Maintenance’ for a complete list of inks approved for use in 7900 printers.

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 Locale
When the Locale option is highlighted on the Installation page and the Select key is
pressed, the following page is displayed.
69499

Figure 4-24. Locale page

This page allows the international parameters of the printer to be configured for different
countries and languages.

Language
The language that pages and system messages are displayed in is selected on the Language
page (English is always present and is the default language).
NOTE: When the language is changed, the new language is used immediately the
Language page is exited.

Use Language Defaults

If the Use Language Defaults option is set to Yes and the language is changed, the Units,
Calendar, and Keyboard settings are automatically changed to the default values for that
language. Metric, Gregorian and European are selected for all the European languages.
The Units, Calendar, and Keyboard options are dimmed in this configuration and cannot
be changed.
If the Use Language Defaults option is set to No, the Units, Calendar, and Keyboard
settings can be changed (refer to these options below for more information).

Units
There are three available units-of-measurement systems: Metric, Engineering, and Imperial.
The required units of measurement are selected from the list on the Units page. The units of
the three systems are:
 Metric units—bar, m/s and mm
 Engineering units—bits, m/s and mm
 Imperial units—p.s.i., ft/minute and inches
The default units-of-measurement system is Metric.

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 Calendar
The type of calendar is selected from the list on the Calendar page—Gregorian, Gregorian
(USA) or Hijri. How the date field formats are calculated depends on which type of
calendar is selected. When the type of calendar is changed, this only affects any new date
format calendars that are created. Existing date format calendars that have been created are
not affected. The default calendar is Gregorian.
If a message contains ‘day of the year’ numbers, the displayed number depends on which
calendar is selected—Gregorian or Gregorian (USA). The difference between these two
calendars is shown in the following table.

Gregorian Gregorian (USA)

Non-leap year 01 Jan. = Day 001 01 Jan. = Day 001
28 Feb. = Day 059 28 Feb. = Day 059
01 Mar. = Day 060 01 Mar. = Day 060
31 Dec. = Day 365 31 Dec. = Day 365
Leap year 01 Jan. = Day 001 01 Jan. = Day 001
28 Feb. = Day 059 28 Feb. = Day 059
29 Feb. = Day 366 29 Feb. = Day 60
01 Mar. = Day 060 01 Mar. = Day 061
31 Dec. = Day 365 31 Dec. = Day 366

Table 4-2. Gregorian calendars

Keyboard
The correct keyboard for the language that messages are created in is selected on the
Keyboard page.
The printer can create and print messages in one language while the display uses a different
language for the pages and system messages. For example, to create messages in Russian,
but read the display in English, set the Keyboard option to Russian, and set the Language
option to English.
On power-down, the keyboard selection is remembered by the software.
Refer to the Linx 5900 & 7900 How To ... guides for more information.

Secondary Keyboard
This option allows the operator to select a secondary keyboard layout that is different from
the primary keyboard. For example, to use the European keyboard to generate Japanese
characters, set the Keyboard option to European, and set the Secondary Keyboard option
to Japanese.
If a different secondary keyboard is selected, the [alt] + [k] keyboard shortcut can be used to
change between the selected primary and secondary keyboards.
On power-down, the secondary keyboard selection is remembered by the software.
Refer to the Linx 5900 & 7900 How To ... guides for more information.

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 Photocells
When the Photocells option is highlighted on the Installation page and the Select key is
pressed, the following page is displayed.
69647

Figure 4-25. Photocells page

The Photocells option is only available at security access Level E (Service 2).
Normally, hardware debounce links on the IPM PCB are used to help filter out several
primary and secondary trigger edges to give one true pulse. The Photocells option uses
software ‘deadtime’ as an alternative and faster method to give a true trigger pulse.
The printer responds to a level change immediately, but does not respond to further level
changes during the ‘deadtime’ period. A deadtime of 0 ms, 1 ms, 5 ms or 25 ms can be set
for either the primary or secondary photocell.
Linx recommends that this feature is not used with a printer that has the IPM PCB
debounce links (LK35, LK36, LK40 and LK41) fitted in any position except the default
position.
The Primary Photocell Deadtime and the Secondary Photocell Deadtime options are only
available at security access Level E (Service 2) and only when the printer is in the ‘Idle’ (jet
off) or ‘Jet Running’ states.
Refer to Chapter 3: ‘Technical Description’ > External signals > Primary/Secondary trigger
> Debounce for more information about the debounce links.

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 4.4.4 Change User Level
When the Change User Level option is highlighted on the Menu page and the Select key is
pressed, the following page is displayed.
73087

73088

Figure 4-26. Change User Level page

The ability to access the system options depends on the security access level used. To get
access to all of these options and their related pages, Level E must be used.
The Change User Level page displays the soft keys for all the access levels that are available
at the current access level. The Change User Level page shown in Figure 4-26 above has all
the access levels available (from Level A to Level D) because the current access level is
Level E (Service 2).
To change the access level to a different (but lower only) level, press the soft key for the
access level that is required. The display then returns to the Menu page. When the Change
User Level page is opened again, the page is changed to display only those access levels
that are lower than the current new level.
To get access at a higher security level, select the Change User Level option. Enter the
password for the (higher) access level that is required, and then press the OK key. If the
password is valid, it is accepted and the display returns to the Menu page.
If an invalid password is entered and the OK key is pressed, the following advisory
message is displayed:
“The password was not recognised”
The display returns to the Change User Level page in approximately 3 seconds, where a
valid password can be entered.

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 Passwords
Write the related service password against the printed service access level below. Remove
this page and keep it in a safe location.

Level D (Service 1): “ ....................................”

Level E (Service 2): “ ....................................”

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 CHAPTER 5: MAINTENANCE
5.1 Introduction
This chapter is divided into two parts. The first part describes the functions that are
available on the Maintenance menu. The second part contains Maintenance Instruction
procedures, which describe how to test and repair 7900 printers, and how to install
additional features.
The information shown in this chapter refers to printers with Version 5.2 System Software
installed, unless otherwise stated.

5.2 Maintenance options

5.2.1 How to select and change options
Six soft keys to the left of the display are related to the available options shown on the left
side of the displayed page. Press the soft key that is related to the required option to select
it. For example, to select the Menu option on the Print Monitor page, press the fifth soft
key. The Menu page is then displayed with a further list of options on the right of the page.
73085

73086

Figure 5-1. Soft keys and related options

Use the Up and Down arrow keys to the right of the display to move the dark blue highlight
box to the menu option that is required. When the option is highlighted, press the Select
soft key. This action can display a further page of options. Continue to use this procedure to
select options until the required page is reached.
How the option settings are changed depends on the type of option page that is selected.
Some option pages have a list of settings, and the Up and Down arrow keys are pressed to
highlight the required setting. For example, the list of calibration modes on the Calibration
Mode page. Other option pages allow a value to be entered, for example, a time period on
the Maintenance Due In page.
When the option setting has been changed, press the OK soft key to save the change. The
new setting is displayed against the option on the previous page. If a setting is made but the
change is not required, press the Cancel soft key instead of the OK soft key. This action
returns the display to the previous page and to the setting in use before the page was opened.
To return to the Print Monitor page, continue to press the Exit soft key until the page is reached.

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 5.2.2 Total Maintenance options
When the Maintenance option is highlighted on the Menu page and the Select soft key is
pressed, the following page is displayed. The complete list of Maintenance options that are
available at security access Level E is shown in the following illustration.
69170

Figure 5-2. Total Maintenance options

5.2.3 Security access levels

Access to the system options is by password, which is described in Chapter 4: ‘System
Options’.
Five security access levels are used: Level A (Base), Level B (User 1), Level C (User 2),
Level D (Service 1) and Level E (Service 2). Level A (Base) and Level B (User 1) are for use
by operators at the basic operation level of the printer and allow controlled or no access to
the Maintenance options. Level C (User 2) allows increased access to the options. Level D
(Service 1) allows access to most of the options, and Level E (Service 2) allows full access to
all of the Maintenance options. These options are only for use by maintenance technicians
who are trained and authorized by Linx. Only Level D and Level E access levels are
described in this chapter.
The default passwords for the two Service levels are not printed in this manual. This
precaution is because, not all personnel who have access to this manual have received
enough training to use the complete range of Maintenance options. However, the two
Service access levels that are applicable to 7900 printers are printed on a separate page
(without a page number) at the end of Chapter 4: ‘System Options’. The related Service
level default passwords are supplied to personnel who are authorized by Linx, and to those
technicians who have been given training on a maintenance course approved by Linx.
These two passwords must be written in against the access levels on this last page. The
page must then be removed from the manual and kept in a safe location.

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 5.2.4 Option availability
The printer has three main states: 'Idle', 'Jet Running', and 'Printing' (printing or ready to
receive a ‘print go’ signal). Some options on the Maintenance pages are influenced by these
states, which can change the availability of some options and also the ability to select an
option or change its parameters.
Menu pages and their options are only displayed if they are valid for the security access
level used and the current printer state. For example, the System Flush option (Print
Monitor > Menu > Maintenance) is only displayed at Level E access level. The System
Flush option can be selected only at Level E, and only when the printer is in the ‘Idle’ (jet
off) state. When the printer is in the ‘Jet Running’ or ‘Printing’ states, the System Flush
option is displayed but is dimmed and cannot be selected.
The following table shows when each page, and the options the page contains, are
available, related to the printer state and the security access level. The symbols used in the
table to show when the pages and options are available are described in the following:
 Pages and options that are displayed and can be selected or changed are identified with
a solid circle.
 Pages and options that are displayed, but cannot be selected or changed are identified
with an empty circle.
 Pages and options that are not available because of the printer state or access level, and
therefore are not displayed, are identified with a grey box.

LEVEL D LEVEL E

1st level page 2nd level page 3rd level page Idle Jet Print- Idle Jet Print-
Runn- ing Runn- ing
ing ing

Print Monitor > Menu >

Maintenance — — ● ● ● ● ● ●

Jet Functions — ● ● ● ● ● ●

Jet Test – Start ●   ●  

Jet Test – Stop  ●   ● 

Start Print  ●   ● 

Stop Print   ●   ●
Test Print   ●   ●

Monitor Jet — ● ● ● ● ● ●

Edit Pressure ● ● ● ● ● ●

Edit Modulation  ● ●  ● ●

TOF Mode  ● ●  ● ●

Pressure in … ● ● ● ● ● ●
Maintenance Times — ● ● ● ● ● ●

Power On Times      

Jet Run Times      

Maintenance Due Within    ● ● ●

Maintenance Due By    ● ● ●

Maintenance Finished ● ● ● ● ● ●

Table 5-1. Maintenance options availability table

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 LEVEL D LEVEL E

1st level page 2nd level page 3rd level page Idle Jet Print- Idle Jet Print-
Runn- ing Runn- ing
ing ing
Maintenance Charge Calibration — ● ● ● ● ● ●

(continued) Calibration Mode ●   ●  

Calibration Value ●   ●  

XCAL125 ●   ●  

XCAL255 ●   ●  

CALCHG1 ● ● ● ● ● ●
EHTPSU1 ●   ●  

Jet Sequences — ● ● ● ● ● ●

Start Sequence ●   ●  

Stop Sequence ●   ●  

Reset Sequence Count ● ● ● ● ● ●

Valves — ● ● ● ● ● ●

Open/Close ●   ●  

Valve Reset ●   ●  

Test Message — ● ● ● ● ● ●
System Flush — ●  

Empty Tank ●  

Flush Cycle ●  

Solvent Drain ●  
Stop Sequence  ● 

Print and Consumables — ● ● ● ● ● ●

History Messages      
Drops      

Ink Bottles      

Solvent Bottles      
Recent Messages      

Recent Drops      

Recent Ink Bottles      

Recent Solvent Bottles      

Reset Recent ● ● ●

Software Upgrade — ●  

Table 5-1. Maintenance options availability table (continued)

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5.3 Maintenance page
All of the options on the Maintenance page are described in this chapter. This is because all
of the options or submenu options require Service Level D or Level E for access.
69170

Figure 5-3. Maintenance page

5.3.1 Jet Functions

The Jet Functions page contains options to start and stop the jet and print, which can help
with fault diagnosis. The following page is shown for a jet state of ‘Idle’.
69171

Figure 5-4. Jet Functions page

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 Jet Test – Start
The Jet Test – Start option starts the jet but with a shorter method than a Normal Start
sequence to help with fault diagnosis. The differences between a Normal Start sequence
and a Jet Test – Start sequence are described below.
The sequence for a Normal Start is as follows:
1. Check the pressure.
2. Start the jet.
3. Make sure that the jet is in the gutter.
4. Set the pressure to the Reference Pressure.
5. Apply a ‘block’ charge to all the drops (“TOF Only” message is displayed).
6. Measure the Time Of Flight.
7. Adjust the pressure if the Time Of Flight is out of range.
8. Repeat steps 5 to 7 until the Time Of Flight is in range.
9. Find the phase position (“Phase/TOF” message is displayed).
10. Jet state is ‘Jet Running’.
When the Jet Test – Start function is used, the sequence is arranged as follows:
1. Check the pressure.
2. Start the jet.
3. Set the pressure to the Reference Pressure.
4. Jet state is ‘Jet Running’.
5. Try to get good jet-phase.
6. Measure the Time Of Flight.
7. Adjust the pressure if the Time Of Flight is out of range.
8. Repeat steps 5 to 7 until the Time Of Flight is in range.
It can be seen from the above Jet Test – Start 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 ignored, and the printer uses the printhead reference
pressure and reference modulation values to start the jet. The printer enters the ‘Jet
Running’ state, then adjusts the pressure to get the correct TOF.
When Jet Test – Start is used, Print Failure reports are disabled, except for the following:
 2.00 Printhead Over Temperature
 2.01 EHT Trip
 2.04 300V Power Supply
 2.07 Internal Spillage
After 45 minutes, the printer returns to the Normal Start mode and all Print Failures are
reported again as they occur.
If the Monitor Jet page is examined to check the jet control values when the jet is first
started, the readings may not equal their reference values until TOF is established.
The system can only use TOF correction if all the feedback signals are present. If the
feedback signals are not present, the printer operates at the printhead reference values.

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 When Jet Test – Start is used and the fault is repaired, stop the jet and turn off the printer.
Then turn on and start the printer normally with the [start] key. These actions are necessary
because the fault can continue to be present when the jet is started with the Normal Start
sequence.
CAUTION: Pump Damage. The Jet Test – Start option starts the jet even if the ink level is low.
Do not allow the ink system pump to run in a dry condition. The pump must not be run for
longer than 30 seconds after the change in the sound of the pump indicates that cavitation (no
ink in the pump) has occurred. Damage to the pump can occur if the pump is allowed to run
continuously in a dry condition.
While the jet is starting, the following message is displayed in the top line of the Printer
Status area of the Print Monitor page:
“JET STARTING”
NOTE: If [ctrl] + [start] are pressed when the jet is in the ‘Idle’ state, a Normal jet start is
performed but print is not started. This shortcut is an additional help during fault
diagnosis.

Jet Test – Stop

The Jet Test – Stop facility is the quickest method to stop the jet and must be used only by
maintenance technicians for fault diagnosis purposes. Do NOT use the Jet Test – Stop
option to shut down the printer before a period during which the printer will not be used.
This method does not prepare the printer enough for a restart.
When this option is used, the printer immediately stops any other jet sequence and
performs this one.
The Jet Test – Stop sequence stops the jet, and then quickly clears the feed line, then the
nozzle, feed and gutter lines, followed by the feed and purge lines. Finally, the sequence
clears the gutter line.
While the Jet Test – Stop sequence is performed, the following message is displayed in the
top line of the Printer Status area of the Print Monitor page:
“JET STOPPING”

A shortcut can also be used to perform a quick stop. Press and hold the [ctrl] key, and then
press the [stop] key.
NOTE: Auto Power Down is disabled if a Jet Test – Stop occurs. When the jet has shut
down after a Jet Test – Stop, Auto Power Down remains disabled until the power is
turned off and then turned on again, or a jet start is performed.

Start Print
The Start Print option changes the jet state from ‘Jet Running’ to ‘Printing’ only, that is, the
option does not start the jet. The change of jet state only occurs if a message is currently
selected and displayed in the Current Message area of the Print Monitor page. Refer to the
Linx 5900 & 7900 Quick Start Guide for descriptions of how to select and edit messages.
An advisory message is displayed if the Start Print key is pressed and no print message is
selected.
If the jet was started with the Jet Test – Start key, when the Start Print option is used the
disabled Print Failures are reported again as they occur.

Stop Print
The Stop Print option changes the jet state from ‘Printing’ to ‘Jet Running’ only, that is, the
option disables printing, but maintains the jet. The change of jet state allows some other
diagnostic options to be displayed and selected, which are not available in the ‘Printing’
state.

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 Test Print
The Test Print option is only available in the ‘Printing’ state.
The Test Print option generates a simulation of a single ‘print trigger’ to print a single
message manually, instead of from an automatically generated signal from a trigger device.
The current message displayed in the Current Message area of the Print Monitor page is
printed. The Trigger to Printhead Distance setting (Print Monitor > Line Setup > Trigger)
and the Print Delay setting (Print Monitor > Print Settings) apply like a normal trigger
device. The Test Print function also updates sequential numbers and print counters.
If the Speed Selection option is set to Shaft Encoder (Print Monitor > Line Setup > Speed),
printing will only start when shaft encoder pulses are received, as is normally the condition
when a production line is in operation. The shaft encoder is disabled when Fixed Speed or
Dual Trigger are selected on the Speed Selection page. The printer then prints at a speed
calculated by the Trigger to Printhead Distance and Print Delay settings.
The printer operates normally for all the other functions. For example, checks for the
printhead cover not fitted, and overspeed are made, and any associated event messages are
displayed.

5.3.2 Monitor Jet

The Monitor Jet page displays the main jet control parameters on a single page. The values
shown in the following example are for a Midi printhead with the jet in operation, and 3103
ink. The values are like those that are normally seen. Some parameters are for display only,
while other parameters can be changed.
69172

3.37 3.04 3.24 3.04

90 67

1262 1261

15
0
24

Figure 5-5. Monitor Jet page

All displayed values on the Monitor Jet page are updated every second.
The following paragraphs describe each of the options and parameters on the Monitor Jet
page.

Pressure
The Pressure area of the Monitor Jet page displays four pressure values: Solvent Add
Pressure, Set Pressure, Reference Pressure, and Actual Pressure.

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 SOLV (Solvent Add Pressure)
The value displayed in the SOLV box is the Solvent Add Pressure, which is a pressure
value that the printer uses as a trigger to add solvent. This Solvent Add Pressure value,
which is different for every single printhead, is calculated from the printhead Reference
Pressure value (default pressure in normal operation) with an offset added.
See also: Chapter 3: ‘Technical Description’ > Printhead theory of operation > Viscosity
control.
Chapter 3: ‘Technical Description’ > Ink system > Ink and solvent flows >
Solvent addition.

SET (Set Pressure)

The value displayed in the SET box is the ink system pressure that is used by the software
for the following functions.
Set Pressure performs two separate functions. First, when the printer is in the ‘Jet Running’
or ‘Printing’ states, the Set Pressure is adjusted by the software to maintain the Time Of
Flight (TOF) within the control parameters. The Set Pressure value also indicates the
different pressures required by the software to perform the different jet sequences, for
example, startup and shutdown. Therefore, the Set Pressure value can be used to monitor
the series of pressure changes during each jet sequence.
Second, when the jet is stopped, the Set Pressure function becomes a very useful diagnostic
tool. The pressure can be used to start and stop the pump. Also, if the pump is operating
and ink is flowing through the venturi, the pressure can help with fault diagnosis of the ink
system. Under these conditions the pressure provides a vacuum in the gutter line, which
can be used to help clear blockages or to flush the printhead.

Edit Pressure
When the Edit Pressure key is pressed, the Set Pressure can be changed to a different value.
The Edit Pressure page allows values in the range of 0 to 4.49 bar (0 to 65.00 p.s.i. or 0 to 255
bits) to be set.
NOTE: 1.0 bar = 14.49 p.s.i.  56 bits.
4.49 bar = 65.00 p.s.i. = 255 bits.
Also refer to the ‘Pressure conversion table’ on page 5—11.
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Figure 5-6. Edit Pressure page

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 Diagnostic uses for setting a Set Pressure value are as follows:
 To find faults caused by pressure loss.
 To clean the printhead.
 To purge the main ink filter.
 When the Jet Test – Start function is used, the pressure can be increased and decreased
to try to get TOF measurements, to see if the ink is of high or low viscosity.

Automatic Tracking (Pressure)

During normal operation (Jet Running), the Set Pressure value is automatically adjusted by
the system to maintain the correct TOF.
For diagnostic purposes, it may be required to change the Set Pressure value while the jet is
in operation. If the Set Pressure was manually changed, the system would automatically
correct the pressure again to maintain the correct TOF. When the Edit Pressure key is
pressed on the Monitor Jet page, the automatic pressure control (Automatic Tracking) is
disabled. This action allows the Set Pressure to be freely adjusted as required.
By default, automatic pressure control is enabled during startup, and disabled during
shutdown.
When the Set Pressure value is manually changed on the Edit Pressure page and the Exit
key or [enter] key is pressed, the system uses the new pressure. The printer returns to the
Monitor Jet page and the new pressure value is displayed in the SET box. If the Up and
Down arrow keys are used to change the value, the new pressure value is applied
immediately.
When the Automatic Tracking key is pressed on the Edit Pressure page (after the Set
Pressure has been manually changed), the printer returns to the Monitor Jet page and
automatic pressure control is enabled again. The value then displayed in the SET box is the
pressure that the system uses to automatically control the jet.

REF (Reference Pressure)

The value displayed in the REF box is the Reference Pressure used by the printer during
normal operation. The value is for display only and cannot be changed.
The Reference Pressure value, which is different for every printhead, forms part of the
printhead code. The Reference Pressure is also found on the printhead conduit label. The
complete printhead code must be entered into the printer on the Printhead Code page
(Print Monitor > Menu > Setup > Installation > Printhead > Printhead Code).
NOTE: The printhead Reference Pressure value is automatically adjusted when the
Printhead Height option is changed (Print Monitor > Menu > Setup > Installation >
Printhead > Printhead Height).
See also: Chapter 4: ‘System Options’ > Installation > Printhead > Printhead Code and
Printhead Height.

ACT (Actual Pressure)

The value displayed in the ACT box is the pressure measured by the ink system pressure
transducer. The value normally reflects the Set Pressure value (refer to ‘SET (Set Pressure)’
earlier in this section) with only a small difference of normally 0.07 to 0.09 bar (1.02 to 1.27
p.s.i.). During the pressure and filter check part of the Normal Start sequence, if the Actual
Pressure is more than 0.09 bar (1.27 p.s.i.) below the Set Pressure, the System Warning “3.18
Low Pressure” is reported.
See also: Chapter 6: ‘System Events’ > System Warnings > 3.18 Low Pressure.

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 Pressure in p.s.i./bar/bits
The units of measurement for the system parameters are normally selected on the Units
page (Print Monitor > Menu > Setup > Installation > Locale > Units). However, on the
Monitor Jet page there is a Pressure in… key that allows the local pressure values to be
displayed in p.s.i., bar, or bits. The label on the key changes and depends on which units are
currently used to display the pressure values. For example, when the Monitor Jet page is
first opened, the pressure values are displayed in bits and the key label is Pressure in p.s.i.
When the Pressure in p.s.i. key is pressed, the pressure values are displayed in p.s.i. and
the key label changes to Pressure in bar.
A pressure conversion table is provided below, for quick reference, which shows
conversions in steps of 5 pressure bits. Conversion factors are also given at the bottom of
the table if intermediate pressure calculations are required.

PRESSURE CONVERSION TABLE

bits bar p.s.i. bits bar p.s.i.
100 1.76 25.49 180 3.17 45.88
105 1.85 26.76 185 3.26 47.16
110 1.94 28.04 190 3.34 48.43
115 2.02 29.31 195 3.43 49.71
120 2.11 30.59 200 3.52 50.98
125 2.20 31.86 205 3.61 52.25
130 2.29 33.14 210 3.70 53.53
135 2.38 34.41 215 3.78 54.80
140 2.46 35.69 220 3.87 56.08
145 2.55 36.96 225 3.96 57.35
150 2.64 38.23 230 4.05 58.63
155 2.73 39.51 235 4.14 59.90
160 2.82 40.78 240 4.22 61.18
165 2.90 42.06 245 4.31 62.45
170 2.99 43.33 250 4.40 63.73
175 3.08 44.61 255 4.49 65.00

Approximate conversions
1 bit = 0.0176 bar = 0.255 p.s.i.
1 bar = 14.503 p.s.i. = 56.818 bits
1 p.s.i. = 3.923 bits = 0.069 bar

Table 5-2. Pressure conversion table

NOTE: The maximum pressure that the ink system can develop under normal operating
conditions is 65.00 p.s.i. (lb/in2) or approximately 4.5 bar, and 90.00 p.s.i. (6.21 bar)
under fault conditions.

Modulation
The Modulation area of the Monitor Jet page displays the Reference Modulation, and the
Actual Modulation.

REF (Reference Modulation)

The value displayed in the REF box is the Reference Modulation (shown in volts) used by
the printer during normal operation. The value is for display only and cannot be changed.

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 During normal operation, there is normally a small difference between the Reference
Modulation value and the Actual Modulation value (refer to ‘ACT (Actual Modulation)’
later in this section). These two values are approximately the same voltage when the
Automatic Tracking function is disabled (refer to ‘Automatic Tracking (Modulation)’ later
in this section). The value is also the same as the ‘Vmod’ value found on the printhead
conduit label. The complete printhead code must be entered into the printer on the
Printhead Code page (Print Monitor > Menu > Setup > Installation > Printhead > Printhead
Code).
See also: Chapter 4: ‘System Options’ > Installation > Printhead > Printhead Code.

ACT (Actual Modulation)

The Actual Modulation value displayed in the ACT box is the current modulation voltage
used by the printer to control the break-up of the jet.
During normal operation, there is normally a small difference between this value and the
Reference Modulation value (refer to ‘REF (Reference Modulation)’ earlier in this section).
These two values are approximately the same voltage when the Automatic Tracking
function is disabled (refer to ‘Automatic Tracking (Modulation)’ later in this section).

Edit Modulation
When the Edit Modulation key is pressed, the Actual Modulation can be changed to a
different value. The Edit Modulation page allows values in the range of 0 to 255 volts to be
set.
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Figure 5-7. Edit Modulation page

Automatic Tracking (Modulation)

The current Reference Modulation values are set as defaults of modulation and viscosity
slopes. During normal operation (Jet Running), the Actual Modulation is used by the
printer to control the drop break-off point of the jet. As the Set Pressure moves away from
the Reference Pressure, the modulation voltage is adjusted to follow the Set Pressure by an
offset value (in V/bit). This offset depends on the type of ink and the printhead.
For diagnostic purposes, it may be required to change the Actual Modulation voltage while
the jet is in operation. If the Actual Modulation was manually changed, the system would
automatically correct the modulation again to maintain the correct point of drop break-off.
When the Edit Modulation key is pressed on the Monitor Jet page, the automatic
modulation control (Automatic Tracking) is disabled. This action allows the Actual
Modulation to be freely adjusted as required.
If the jet is stopped then restarted while the automatic modulation control (Automatic
Tracking) is disabled, the modulation is set to the Reference Modulation.

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 By default, automatic modulation control is enabled during power-up, and disabled during
power-down.
When the Actual Modulation voltage is manually changed on the Edit Modulation page
and the Exit key or [enter] key is pressed, the system uses the new modulation voltage. The
printer returns to the Monitor Jet page and the new modulation voltage is displayed in the
ACT box. If the Up and Down arrow keys are used to change the value, the new
modulation voltage is applied immediately.
When the Automatic Tracking key is pressed on the Edit Modulation page (after the
Actual Modulation has been manually changed), the printer returns to the Monitor Jet page
and automatic modulation control is enabled again. The value then displayed in the ACT
box is the modulation voltage that the system uses to automatically maintain the correct
point of drop break-off.

TOF
The TOF (Time Of Flight) area of the Monitor Jet page displays the Reference TOF and the
Actual TOF. The TOF values are displayed in microseconds (µs).

Reference TOF
The value displayed in the REF box is the Reference TOF, which is the jet velocity reference.
The software uses this value with the Actual TOF value to maintain the correct TOF. The
value is for display only and cannot be changed.

Actual TOF
The value displayed in the ACT box is the Actual TOF. This value is the measured TOF
displayed as an average reading. The displayed value is related to the jet speed—the higher
the reading, the slower the jet; the lower the reading, the faster the jet.
The time taken for a special ‘packet’ of low-charged drops to pass between two datum
points (the phase and TOF sensors) is measured to get TOF values. These sensors are in the
printhead Deflector and Phase Plate (DPP). The software makes a number TOF
measurements, all of which must be within ±40% of the Reference TOF. An average of these
TOF measurements is the displayed TOF value. Three average readings, one after the other,
must be more or less than ±0.3% (or ±0.2%—see below) of the Reference TOF before the
readings can be used to control the system pressure.
The software uses the average value to increase or decrease the pressure, as necessary, to
maintain the TOF at the Reference TOF. There is a small tolerance of ±0.3% for all Mk7
printheads except the Ultima, where the tolerance is ±0.2%.
The Print Failure message “2.03 Time Of Flight Failure” is displayed if there are no valid
TOF readings for a period of 40 minutes.

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 TOF Mode
The TOF Mode key selects how TOF and Phasing are performed. During normal operation
the printer changes between these two functions automatically, but with this option the
operation of these functions can be changed.
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Figure 5-8. TOF Mode page

TOF/Phase
When the TOF/Phase key is pressed on the TOF Mode page, TOF and Phasing
measurements are both performed at the same time. TOF/Phase is the normal mode when
the jet is in operation.

TOF Only
When the TOF Only key is pressed on the TOF Mode page, Phase measurements are not
performed. When this mode is selected, a TOF can be found for an ink jet that has bad
break-up.
The TOF Only mode is automatically used for a short period during jet startup while the
pressure is being adjusted to get the correct TOF.

Manual Phase
For diagnostic purposes, it may be required to change the phase position (drop break-off
point) while the jet is in operation (refer to ‘Phase’ later in this section).
When the Manual Phase key is pressed on the TOF Mode page, the Phase value can be
changed. The Manual Phase function allows phase positions in the range of 0 to 15 to be set.
The main use for this function is for calibration. The Manual Phase option can also be used
to find the size of the phase window so that the best phase position can be manually set.
When the Phase value is manually changed on the TOF Mode page and the Exit key or
[enter] key is pressed, the system uses the new phase position. The printer returns to the
Monitor Jet page and the new phase position is displayed in the Phase box. If the Up and
Down arrow keys are used to change the value, the new phase position is applied
immediately.
When the TOF/Phase key is pressed on the TOF Mode page and the Exit key or [enter] key
is pressed, the printer returns to the Monitor Jet page and automatic phase measurements
are performed again. The value then displayed in the Phase box is the phase position that
controls the drop break-off point of the jet.

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 Off
When the Off key is pressed on the TOF Mode page, neither TOF measurements nor
Phasing are performed. The Off setting is the normal mode when the jet is not in operation
(‘Idle’ state).
When this function is set to Off, the pressure can be manually changed, which changes the
jet speed and therefore the TOF. The TOF Mode can then be reset to TOF/Phase so that the
pressure can be monitored as control of the jet is restored. This test can confirm the correct
operation of the jet control system.

Phase
The value displayed in the Phase box reflects the drop break-off point of the jet (phase
position). The phase position makes sure that the drop break-off and the drop charge occur
at the same time. The printer checks the phase position at regular intervals during jet
startup, jet running, or printing. The period between checks changes, and depends on the
jet state.
The displayed Phase value depends on the setting of the TOF Mode option (refer to ‘TOF
Mode’ earlier in this section). When the TOF Mode is set to TOF/Phase, the value is the
phase position when the jet is in normal operation. This value is for display only and cannot
be changed.
When the TOF Mode is set to TOF Only, there are no phase position checks made and there
is no phase position displayed.
When the TOF Mode is set to Manual Phase, the phase position can be changed (refer to
‘Manual Phase’ earlier in this section).

Solvent Add Count

The value displayed in the Solvent Add Count box is the number of times solvent has been
added, from the time the jet was last started. The value is reset to 0 (zero) when the jet is
started. The Solvent Add Count value is for display only and cannot be changed.

Temp
The value displayed in the Temp box is the printhead temperature. If the temperature
inside the printhead reaches more than 60 °C, the Print Failure message “2.00 Printhead
Over Temperature” is displayed.

WARNING: HIGH TEMPERATURE HAZARD. WHEN THIS FAULT IS REPORTED, THE

PRINTHEAD AND COVER TUBE CAN BE VERY HOT.
MAXIMUM CARE MUST BE TAKEN TO PREVENT SKIN BURNS AND TO DECREASE THE RISK
OF A FIRE. DO NOT TOUCH THE PRINTHEAD, OR TRY TO REMOVE THE PRINTHEAD COVER
TUBE UNTIL THE PARTS BECOME SAFELY COOL NATURALLY.
THERE IS A DANGER OF SEVERE BURNS TO THE HANDS IF THE PRINTHEAD COVER TUBE
IS REMOVED BEFORE IT HAS BECOME SAFELY COOL. THERE IS ALSO AN INCREASED RISK
OF FIRE CAUSED BY THE SUDDEN INCREASE OF AIR AROUND THE OPEN PRINTHEAD.
See also: Chapter 3: ‘Technical Description’ > Printhead components > Printhead
temperature sensor.

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 5.3.3 Maintenance Times
The Maintenance Times page displays the operating times of the printer in three
categories.
69177

Figure 5-9. Maintenance Times page

The two Power On Time … and the two Jet Run Time … options are for display only at the
Level D and Level E access levels, and cannot be changed. The Maintenance Due Within
and Maintenance Due By times can be changed by the maintenance technician only at
Level E access.
NOTES:
1. The Power On Time (Total) and Jet Run Time (Total) stored values are reset to
zero if the battery link LK4 on the IPM PCB is removed.
2. A note must be made of the Maintenance Due Within and Maintenance Due By
times before the system software is changed, the battery link LK4 is removed, or the
IPM PCB is replaced. If the system software is changed or link LK4 is removed, the
printer memory is initialized and the maintenance times are reset to their default
settings.
3. Linx recommends that the USB facility is used to save the data (which includes the
Maintenance Due … times) before the system software is changed or the battery
link LK4 is removed. When the maintenance is completed, the USB facility is then
used to restore the data.

Power On Time (Total)

The Power On Time (Total) displays the total time (from manufacturing), in hours and
minutes, that the printer has been turned on. This value is for display only and cannot be
changed. The time is updated while the printer is turned on.

Power On Time (Present)

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

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 Jet Run Time (Total)
The Jet Run Time (Total) displays the total time (from manufacturing), in hours and
minutes, that the jet has been in the ‘Jet Running’ or ‘Printing’ states. This value is for
display only and cannot be changed. The time is updated while the jet is in operation.

Jet Run Time (Present)

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

Maintenance Due Within

The Maintenance Due Within option displays the time that remains, in hours and minutes,
until the next scheduled maintenance of the printer is required. The time decreases (when
the jet is in operation) from a basic maximum interval for the scheduled maintenance (refer
to ‘Maintenance Finished’ later in this section).
When the Maintenance Due Within interval reaches zero, the System Warning message
“3.11 Printer Requires Scheduled Maintenance” is displayed. This warning message
continues to be displayed each time the printer is turned on, until the scheduled
maintenance is done and the maintenance intervals are reset by the maintenance technician.
If the warning message is ignored, the Maintenance Due Within time continues to decrease
and the time is displayed as a negative value. This negative time indicates how long ago the
scheduled maintenance should have been done. Refer also to the Print Failure ‘“2.15
Scheduled Maintenance is overdue by 3 months–Please contact your local Linx Service
Centre immediately”’ in Chapter 6: ‘System Events’.
When the Maintenance Due Within key is pressed, the scheduled maintenance interval can
be manually set to a different number of hours from the basic scheduled maintenance
interval for the ink type. The maximum scheduled maintenance interval that can be set in
the software for some inks is 9000:00 hours (see the following ‘Maintenance Finished’
description).

Maintenance Due By
The Maintenance Due By option displays the date that the next scheduled maintenance of
the printer is required.
When the Maintenance Due By date is reached, the System Warning message “3.11 Printer
Requires Scheduled Maintenance” is displayed. This warning message continues to be
displayed each time the printer is turned on, until the scheduled maintenance is done and
the maintenance intervals are reset by the maintenance technician.
If the warning message is ignored, the Maintenance Due By date continues to be compared
with the current date. The Maintenance Due By date then becomes an indication of how
long ago the scheduled maintenance should have been done. Refer also to the Print Failure
‘“2.15 Scheduled Maintenance is overdue by 3 months–Please contact your local Linx
Service Centre immediately”’ in Chapter 6: ‘System Events’.
When the Maintenance Due By key is pressed, the scheduled maintenance interval can be
manually set to a different date from the basic scheduled maintenance interval for the ink
type. The maximum scheduled maintenance interval that can be set in the software for
some inks is 18 months from the current date (see the following ‘Maintenance Finished’
description). This extended interval is the maximum replacement interval for the damper
with those inks.

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 Maintenance Finished
When the printer is commissioned, the Maintenance Due Within and Maintenance Due
By intervals are normally set to the basic maximum intervals, which are
ink-type-dependent, as shown in the following table.

Ink type Basic (maximum) scheduled maintenance intervals

MEK 2000 hours/12 months
Mixed Base 2000 hours/12 months
Ethanol 2000 hours/12 months
Pigmented 1400 hours/6 months

Table 5-3. Basic scheduled maintenance intervals

Some inks allow an extended scheduled maintenance interval up to a maximum of 9000

hours and 18 months. The following ink types can have extended maximum intervals:

 Black ink 1010  Black Fast-Drying ink 1240

 Black Plastic-Adherent ink 1014  Black Ethanol ink 2035
 Black Plastic-Film ink 1016  Black Food-Packaging ink 2250
 Black Wet Process ink 1055  Black Mixed Base ink 3103
 Black Wet Process ink1056  Black ink 3240
The maximum scheduled maintenance interval depends on the environmental conditions,
and other factors (for example, the risk of ink contamination and poor-quality customer
maintenance). Refer to the Linx 5900 & 7900 How To Select the Scheduled Maintenance Interval
Maintenance Level document for more information.
When the printer is commissioned, the maintenance technician sets the scheduled
maintenance intervals according to Table 5-3 above or the Linx 5900 & 7900 How To Select the
Scheduled Maintenance Interval Maintenance Level document. Extended scheduled
maintenance intervals can be set only at Level E access. The intervals can be changed at the
next scheduled maintenance, if necessary, but again only at Level E access.

Level E access
When the scheduled maintenance has been completed and the Maintenance Finished key
is pressed, the scheduled maintenance intervals that were set during the commissioning
process or the last scheduled maintenance are reapplied. If the maintenance technician
changes the scheduled maintenance intervals, these new intervals are applied.

Level D access
When the basic scheduled maintenance intervals have been set or extended during the
commissioning process, a maintenance technician trained by Linx can perform future
scheduled maintenance at Level D access. The scheduled maintenance intervals cannot be
changed at this level, but the intervals already created can be reapplied.

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 Easi-Change code
The original or extended scheduled maintenance intervals cannot be reset until the
Maintenance Finished option is used. When the Maintenance Finished key is pressed, the
Enter Easi-Change Code page is displayed.
79076

Figure 5-10. Enter Easi-Change Code page

A valid Easi-Change® code must be entered before the scheduled maintenance intervals
can be applied. The Easi-Change® code is a 12-character code that is printed on a label
attached to the damper assembly and on the damper packaging, and the code is different
for each damper. The code is entered in three groups of four digits each, and hyphens are
automatically entered between each group.
As a code is entered, the characters are displayed in red text and the OK key remains
dimmed. When the complete code is entered, the displayed characters change from red text
to black text and the OK key is enabled.
When an Easi-Change® code is entered and the OK key is pressed, the code is validated. If
the code is invalid, the following advisory message is displayed:
“Invalid Easi-Change code.”
The Easi-Change Code page is then displayed again, which allows another attempt to enter
the code.
If three invalid codes are entered one after the other, code validation is disabled for 3
minutes. If a code is entered within this time period, the code is rejected and the following
advisory message is displayed:
“Too many attempts at validation.”
If after 3 minutes another invalid code is entered, the invalid code sequence described
above is repeated.
An already used code cannot be used again. If an attempt is made to use the same code
again, the following advisory message is displayed:
“This Easi-Change code has already been used. Please enter another code.”
The life of an Easi-Change® code can expire. If an out-of-date code is entered, the following
advisory message is displayed:
“Easi-Change code out of date. Contact your local Linx Distributor.”
When a valid Easi-Change® code has been accepted, the new scheduled maintenance
intervals are applied.

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 5.3.4 Charge Calibration
The Charge Calibration page provides the functions for the maintenance technician to
calibrate the Charge hardware and to enter different calibration figures.
69178

Figure 5-11. Charge Calibration page

WARNING: LETHAL VOLTAGE HAZARD. WHEN THE CALIBRATION MODE IS SET TO

‘CALIBRATION’, A MAXIMUM OF 300 V DC IS APPLIED TO THE PRINTHEAD CHARGE
ELECTRODE.
MAKE SURE THAT THE PRINTHEAD COVER TUBE IS CORRECTLY FITTED AND THE
SECURING SCREW IS FIRMLY TIGHTENED BEFORE THE CHARGE CALIBRATION
PROCEDURE IS PERFORMED. DO NOT REMOVE THE PRINTHEAD COVER TUBE DURING THE
CHARGE CALIBRATION PROCEDURE.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS SAFETY
WARNING IS IGNORED.
NOTE: Refer to the ‘Charge Amplifier Calibration’ maintenance instruction later in this
chapter for how to correctly perform the calibration procedure referred to in the
following description.

Calibration Mode
The Calibration Mode option has three modes of operation: Off, Zero, and Calibration.
These modes are used during the Charge Amplifier Calibration.

Off
The Off setting resets the charge DAC to normal mode for printing. This setting is the
default mode.

Zero
The Zero setting allows VR3 (Zero Offset) on the IPM PCB to be adjusted to a zero datum
point before the Charge Amplifier Calibration is started.

Calibration
The Calibration setting puts the charge DAC control system in the calibration mode, so that
the charge voltage can be calibrated.

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 Calibration Value
NOTE: The Calibration Value option is only available when the Calibration Mode is set to
Calibration.
Values are entered on the Calibration Value page during the calibration procedure to find
the XCAL125 and XCAL255 voltage levels.
During the calibration procedure, the Apply key on the Calibration Value page is used
after each value change to update the DVM reading.
When a new value is entered on the Calibration Value page and the OK key is pressed, the
new calibration value is used by the system. The printer returns to the Charge Calibration
page and the new value is displayed in the Calibration Value option.

XCAL125/XCAL255
The final calibration values found from the Charge Amplifier Calibration procedure are
entered in these two options.

CALCHG1
The value displayed in the CALCHG1 option must be the final three digits of the printhead
code (refer to Chapter 4: System Options > Menu page > Setup > Printhead > Printhead
Code). Make sure that the digits are the same. If the digits are not the same, enter the correct
value on the CALCHG1 page.

EHTPSU1
The EHT Program Input voltage is used during manufacturing to calibrate each EHTPSU to
give an output of 8 kV ±1.7%. The calibration voltage is printed on a label attached to the
EHTPSU, and this value must be entered on the EHTPSU1 page.

5.3.5 Jet Sequences

The Jet Sequences page provides a range of operating sequences and allows these
sequences to be selected and started individually.
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Figure 5-12. Jet Sequences page

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 Start Sequence
When an operating sequence is highlighted in the Jet Sequences list and the Start Sequence
key is pressed, the selected sequence is started. A progress bar is provided at the bottom of
the Jet Sequences page that shows how much of the sequence has been completed.
NOTE: The printer must be in the ‘Idle’ state (jet off) before any of the sequences can be
started.

Stop Sequence
When a sequence is in operation, the Stop Sequence key can be pressed to stop the
sequence. The Stop Sequence option is dimmed until a sequence is started.

Reset Sequence Count

A temporary record is kept of the number of times each sequence has been used. Next to
each operating sequence in the list is a counter, which increases by one when the sequence
is started. When the Reset Sequence Count key is pressed, the count is reset to zero.

Jet State
The Jet State box below the Jet Sequences list displays the current jet state of the printer.
The following are all of the possible state messages:
“IDLE”
“JET STARTING”
“JET RUNNING”
“JET STOPPING”
“PRINTING”
“JET SEQUENCE”
“JET CALIBRATING”
“JET FAULT”
“MIX” (7900 Spectrum printer only)
While a sequence is being performed, the displayed Jet State is “Jet Sequence”.

Jet Sequences
The following paragraphs describe the operating sequences that are available in the Jet
Sequences list.

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 Nozzle Flush

WARNING: HAZARDOUS SUBSTANCES. THIS PRINTER USES SOLVENT AND

SOLVENT-BASED INKS THAT CAN BE HAZARDOUS. THESE INKS AND SOLVENTS ARE
HIGHLY FLAMMABLE, AND THE LIQUID, VAPOUR OR SPRAY CAN CAUSE IRRITATION TO
THE EYES AND SKIN.
WEAR SAFETY EYE GLASSES AND SOLVENT-RESISTANT PROTECTIVE GLOVES WHEN
THERE IS DIRECT CONTACT WITH THE INKS AND SOLVENTS, WHEN WORK IS DONE ON THE
PRINTER, AND WHEN THE PRINTER IS CLEANED.
THERE IS A RISK OF SEVERE IRRITATION AND TEMPORARY (REVERSIBLE) DAMAGE TO
THE EYES, AND IRRITATION OF THE SKIN IF THIS SAFETY WARNING IS IGNORED.

WARNING: HIGH-PRESSURE SOLVENT JET HAZARD. IT IS VERY IMPORTANT THAT THE

DIFFERENCE BETWEEN THE NOZZLE FLUSH SEQUENCE AND THE NOZZLE CLEAR
SEQUENCE IS UNDERSTOOD. DURING THE NOZZLE FLUSH SEQUENCE, SOLVENT IS
EJECTED FROM THE PRINTHEAD NOZZLE AT MAXIMUM PRESSURE.
WHEN THE NOZZLE FLUSH SEQUENCE IS IN OPERATION, ENCLOSE THE PRINTHEAD IN AN
ACCEPTABLE CONTAINER TO CONTAIN THE SOLVENT JET. WEAR SAFETY EYE GLASSES
AND SOLVENT-RESISTANT PROTECTIVE GLOVES.
THERE IS A RISK OF SEVERE IRRITATION AND TEMPORARY (REVERSIBLE) DAMAGE TO
THE EYES, AND IRRITATION OF THE SKIN IF THIS SAFETY WARNING IS IGNORED.
The Nozzle Clear sequence described later in this section removes particles from the
printhead jewel and nozzle area. These particles can then remain distributed within the gun
chamber where they can collect on the jewel again. This effect can cause the problems of jet
alignment or nozzle blockage to occur again in the future, if not immediately. Therefore, the
Nozzle Flush sequence can be used instead of the Nozzle Clear sequence or with the Nozzle
Clear sequence, when there is a known nozzle obstruction or blockage.
The Nozzle Flush sequence is different from the Nozzle Clear sequence, which draws
solvent into the nozzle. The Nozzle Flush sequence automatically fills the nozzle with
solvent, and then ejects a jet of solvent from the nozzle and into the gutter to flush away any
deposits.
A single Nozzle Flush sequence takes approximately 2 minutes and 40 seconds to complete.
The sequence can also be quickly accessed on the Menu page (Print Monitor > Menu >
Nozzle Flush). The jet must be stopped before the option can be selected.
IMPORTANT: The Nozzle Flush sequence tries to create a solvent jet. If a jet is started, the
solvent is returned to the ink tank, which can decrease the viscosity of the
ink. If the Nozzle Flush sequence is used too many times, the decreased ink
viscosity causes the printer to fail. The Nozzle Flush sequence must not be
used more than three times to clear a nozzle blockage.

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 Nozzle Clear

WARNING: HAZARDOUS SUBSTANCES. THIS PRINTER USES SOLVENT AND

SOLVENT-BASED INKS THAT CAN BE HAZARDOUS. THESE INKS AND SOLVENTS ARE
HIGHLY FLAMMABLE, AND THE LIQUID, VAPOUR OR SPRAY CAN CAUSE IRRITATION TO
THE EYES AND SKIN.
WEAR SAFETY EYE GLASSES AND SOLVENT-RESISTANT PROTECTIVE GLOVES WHEN
THERE IS DIRECT CONTACT WITH THE INKS AND SOLVENTS, WHEN WORK IS DONE ON THE
PRINTER, AND WHEN THE PRINTER IS CLEANED.
THERE IS A RISK OF SEVERE IRRITATION AND TEMPORARY (REVERSIBLE) DAMAGE TO
THE EYES, AND IRRITATION OF THE SKIN IF THIS SAFETY WARNING IS IGNORED.
The Nozzle Clear sequence can be used instead of the Nozzle Flush sequence or with the
Nozzle Flush sequence, when there is a known nozzle obstruction or blockage. (Refer to
‘Nozzle Flush’ earlier in this section.) The sequence can also be quickly accessed on the
Menu page (Print Monitor > Menu > Nozzle Clear). The jet must be stopped before the
option can be selected.
CAUTION: Printhead Damage and Print Failures. The printhead can be damaged or the printer
can fail if the wrong solvent is allowed to enter the ink or solvent tanks. Make sure that the
solvent used during the following procedure is the correct type for the ink and solvent used in
the printer. Use only Linx solvents.
The Nozzle Clear sequence applies vacuum to the printhead nozzle to clear an obstruction
or blockage. While the printer is performing the Nozzle Clear sequence, the printhead must
be turned upside down and solvent applied in small drops to the nozzle assembly face.
Refer to the ‘Nozzle Clear sequence’part of the ‘Jet Alignment and Nozzle Cleaning’
maintenance instruction later in this chapter.
A single Nozzle Clear sequence takes 20 seconds to complete. The pump is run at the
maximum pressure of 4.49 bar (65.00 p.s.i.) for 5 seconds, and then the Gutter valve is
energized (opened). This action transfers the vacuum from the gutter to the nozzle
assembly for a further 15 seconds. The vacuum draws ink and the applied solvent from the
nozzle chamber back along the purge line (through the Printhead Purge NRV and open
Gutter valve) to the ink tank. The vacuum attempts to clear the nozzle blockage by also
drawing air in through the nozzle aperture. The gutter valve is then closed and the pump is
stopped, which decreases the pressure to zero.
Linx recommends that a maximum of eight Nozzle Clear sequences are performed to try to
clear an obstruction or blockage, with an attempt made to start the jet after each sequence.
If this procedure does not remove the nozzle blockage, perform the necessary ‘Nozzle soak’
and ‘Nozzle wash’ procedures described in the ‘Jet Alignment and Nozzle Cleaning’
maintenance instruction. If these procedures do not clear the nozzle blockage, the nozzle
assembly or complete printhead must be replaced.

Filter Purge
The Filter Purge sequence is used during the printer commissioning procedure to circulate
ink through the primary ink circuit to purge the main ink filter of air. During the sequence,
all the valves remain off and the pump is run at a fixed pressure for 5 minutes. Refer to the
‘Main Ink Filter Purge’ maintenance instruction later in this chapter for information about
how to perform this procedure.

Feed Dry
The Feed Dry sequence is used at Linx during printer manufacturing and final test only
and, therefore, the sequence does not have a maintenance application.

Gutter Dry
The Gutter Dry sequence is used at Linx during printer manufacturing and final test only
and, therefore, the sequence does not have a maintenance application.

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 Purge Dry
The Purge Dry sequence is used at Linx during printer manufacturing and final test only
and, therefore, the sequence does not have a maintenance application.

Empty Tank
The Empty Tank sequence is used during the ‘Draining the Ink System’ and the ‘System
Flush’ procedures, which are provided in the ‘Maintenance instructions’ section later in this
chapter. During the sequence, all the valves remain off and the pump is run at the
maximum pressure of 4.49 bar (65.00 p.s.i.) for approximately 1 minute and 40 seconds to
empty the ink tank.

Flush Cycle
The Flush Cycle sequence is used during the ‘System Flush’ procedure, which is provided
in the ‘Maintenance instructions’ section later in this chapter. The sequence takes
approximately 1 minute and 40 seconds to complete.

Solvent Drain
The Solvent Drain sequence is used during the ‘System Flush’ procedure, which is provided
in the ‘Maintenance instructions’ section later in this chapter. During the sequence the
Solvent Add (Solvent Top-up) valve is energized, which connects the solvent tank, through
the Solvent Flush valve and the Solvent Add (Solvent Top-up) valve, to the venturi. The
pump is run at the maximum pressure of 4.49 bar (65.00 p.s.i.) for approximately 10 minutes
to empty the contents of the solvent tank into the ink tank.

Decommission Printhead
If necessary, the Decommission Printhead sequence can be used by maintenance
technicians for the following purposes:
 To clean the printhead more thoroughly before the printer is put into storage for a
number of weeks or months.
 To clean the printhead more thoroughly before the printhead is removed and returned
to Linx for analysis.
The sequence takes approximately 5 and a half minutes to complete.

5.3.6 Valves
The Valves page allows each of the ink system valves to be opened and closed manually to
help fault diagnosis. The state of each valve can also be monitored (to the right of the valve
name) as it opens and closes during any of the operating sequences
69180

Figure 5-13. Valves page

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 Open/Close
When a valve is highlighted in the Valves list and the Open/Close key is pressed, the
selected valve is energized (opened). The valve remains energized until the Open/Close
key is pressed again or the Valve Reset key is pressed (see the following ‘Valve Reset’
description). If a valve is opened and the Exit key is pressed, the valve remains open. The
Valves page must be accessed again to close the valve.
There are six valves displayed in the Valves list:
 Printhead Feed
 Feed
 Purge
 Gutter
 Solvent Add
 Solvent Flush
The valves can be manually operated only when the printer is in the ‘Idle’ state (jet off).
When the printer is in the ‘Jet Running’ or ‘Printing’ states, the Open/Close and Valve
Reset keys are dimmed. The Valves page then shows only the current states of the valves
and they cannot be manually operated.
To help with fault diagnosis, the Set Pressure function (Monitor Jet page) can be used with
the options on the Valves page (refer to ‘SET (Set Pressure)’ on page 5—9, in the ‘Monitor
Jet’ description).

Valve Reset
If more than one valve has been manually opened, all the valves can be closed at the same
time when the Valve Reset key is pressed.

5.3.7 Test Message

A test message can be created for any of the message types (rasters) that are available for
each printhead and printer configuration combination.
The Test Message page displays, by name, all of the current message types that are
available. Figure 5-14 shows the message types for an Ultima printhead and a 3 Line HP
printer, with the 5 Linear Flexible message type selected.
79064

Figure 5-14. Test Message page

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 Create
When a message type has been highlighted in the Test Message list and the Create key is
pressed, the Save As page is displayed.
79065

Figure 5-15. Test Message—Save As page

Save
A default name for the test message is provided on the Save As page. If the message is the
first to be created for a message type, the message name is “Msg1” (by default) followed by
the message type name—for example, in the form “Msg1_5_Linear_Flexible”. If there are
one or more test messages of the same message type stored in the memory, the next
message to be created is given the prefix of the next number in sequence. For example, if
there are three test messages of the same message type, the next message to be created is
given the prefix of the next number—that is, “Msg4_5_Linear_Flexible”.
The default message name can be changed. For example, if a special name is required to fit
the purpose of the test message.
When the name of the test message is confirmed and the Save key is pressed, the test
message is created and stored in the memory.

5.3.8 System Flush

NOTE: The System Flush option can be accessed only at Level E and only when the printer
state is ‘Idle’ (jet off).
The System Flush option provides the functions to completely flush the printer for the
following reasons:
 To prepare the printer to be shipped or stored.
 To remove contaminated ink.
 To change an ‘in use’ printer to a new ink, in preparation for calibration.
 To prepare a new printer with new ink, in preparation for calibration.
The procedure is easy to understand and provides instructions at each step, displayed at
the top of each page, to take the maintenance technician through the procedure.

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 When the System Flush option is selected on the Maintenance page, the first preparation
page of the System Flush procedure is displayed.
69183

Figure 5-16. System Flush—first preparation page

After the first four preparation pages, there is an options page that allows different
operations to be performed.
69184

Figure 5-17. System Flush—options page

Refer to the ‘System Flush’ maintenance instruction later in this chapter for information
about how to perform this procedure.

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 5.3.9 Print and Consumables History
The Print and Consumables History page provides the Distributor and the customer with
an indication of the rate at which the printer has used ink and solvent.
69185

Figure 5-18. Print and Consumables History page

A counter next to each item shows the number of the items that have been used. The
counters calculate from the installation of the printer and from the time that the counters
were reset to zero.
NOTES:
1. A note must be made of the Print and Consumables History counts before the
system software is changed, the battery link LK4 is removed, or the IPM PCB is
replaced. If the system software is changed or link LK4 is removed, the printer
memory is initialized and the counters are reset to zero.
2. Linx recommends that the USB facility is used to save the data before the system
software is changed or the battery link LK4 is removed. When the maintenance is
completed, the USB facility is then used to restore the data.
The information can be used for the following purposes:
 To allow more flexible commercial arrangements between the supplier and the
customer.
 To provide customers with a greater knowledge of ink and solvent use from day to day.
 To provide maintenance technicians with information about the past performance of
the printer.
The information in the Print and Consumables History page is only a general indication.
Many variables control the rate at which ink and solvent are used. For this reason,
calculations for the next time that the ink or solvent are refilled are approximate. Refer to
the information displayed on the Print and Consumables Data page (Print Monitor >
Menu > System Information > Print and Consumables Data).

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 Messages
This item shows the total number of messages that have been printed from the time that the
printer was installed.

Drops
This item shows the total number of drops that have been printed from the time that the
printer was installed.

Ink Bottles
This item shows the total number of ink bottles that have been used in the printer from the
time that the printer was installed.

Solvent Bottles
This item shows the total number of solvent bottles that have been used in the printer from
the time that the printer was installed.

Recent Messages
This item shows the number of messages that have been printed from the time that the
counter was last reset to zero.

Recent Drops
This item shows the number of drops that have been printed from the time that the counter
was last reset to zero.

Recent Ink Bottles

This item shows the number of ink bottles that have been used in the printer from the time
that the counter was last reset to zero.

Recent Solvent Bottles

This item shows the number of solvent bottles that have been used in the printer from the
time that the counter was last reset to zero.

Reset Recent
When the Reset Recent option is highlighted and the Select key is pressed, all four of the
Recent... counters are reset to zero. That is, the Recent Messages, Recent Drops, Recent
Ink Bottles, and Recent Solvent Bottles items.

5.3.10 Software Upgrade

Version 5.2 System Software adds the Software Upgrade option to the Maintenance page.
Future software upgrades can then be downloaded to the printer from a USB memory
device through the USB port on the front of the printer.
NOTE: The Linx Sync Service Tool is required to install 7900 Version 5.2 System Software.
The 7900 Recovery Boot PROM can also be used to install the software (refer to the
‘Software Upgrade Using the 7900 Boot PROM’ maintenance instruction).
The Software Upgrade option is only available on the Maintenance page at Level E and can
only be selected when the printer is in the ‘Idle’ state.

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 Software upgrade process
Linx recommends that a backup copy is made of the printer settings before the upgrade
process is started.
The 7900 system software ‘.lsf’ file must be copied from a PC and saved into the folder:
\Linx\7900\FIRMWARE on the USB memory device. There must be only one software
upgrade file saved in the ‘FIRMWARE’ folder.
IMPORTANT: The printer cannot detect a USB memory device that has a capacity greater
than 4 GB.
To start the software upgrade process, the USB memory device is inserted into the USB port
on the front of the printer, and then the Software Upgrade option is selected. The printer
examines the software file on the USB memory device and displays the first page of the
upgrade process.
79066

Figure 5-19. Software Upgrade verification page

If valid system software is found on the USB memory device, the next page of the process is
displayed with the following instruction:
“Press OK to proceed with the software upgrade.”
If Exit is pressed, the upgrade process is cancelled and the display returns to the
Maintenance page. When OK is pressed, the software upgrade is started and the following
instruction is displayed:
“Software upgrade in progress. Do not remove the USB memory stick. 0% complete.”
The upgrade process takes approximately 12 minutes.
If there is no USB memory device inserted, or a USB memory device is inserted but no
system software file is found, the following instruction is displayed:
“Please insert a USB memory stick containing system software.”
The Exit button cancels the upgrade process and returns the display to the Maintenance
page.
If a USB memory device is inserted but invalid system software is detected, the following
message is displayed:
“Valid system software not found.”
The Exit button cancels the upgrade process and returns the display to the Maintenance
page.

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 During the sequence a progress bar gives an indication of how much of the sequence has
been completed. When the upgrade process is completed, the following message is
displayed and the printer restarts automatically:
“The printer will restart to complete the software upgrade.”
The screen becomes blank until the splash screen is displayed. The first startup after an
upgrade of system software takes longer (approximately 80 seconds) than a normal startup.
The printer needs this longer time to process the additional content of the new system
software. The duration of following startups is as standard. It is important, therefore, that
maintenance technicians start the printer a minimum of once after a software upgrade, so
that the customer is not confused by the longer first startup time.
If corrupt software or a software error is detected during the upgrade, the following
instruction is displayed:
“Software upgrade failed. Insert a USB memory stick containing
valid system software. Do not switch off the printer.”
If this message is displayed, replace the system software file on the USB memory device
with a different copy, or use a different USB memory device.

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5.4 Maintenance instructions
5.4.1 Double pole/neutral fusing

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

EQUIPMENT IS PROTECTED BY DOUBLE-POLE FUSING. THAT IS, FUSES ARE FITTED IN THE
LIVE AND NEUTRAL CONDUCTORS OF THE MAINS ELECTRICAL SUPPLY. IF THE NEUTRAL
FUSE OPERATES, PARTS OF THE EQUIPMENT THAT REMAIN ENERGIZED CAN BE AN
ELECTRICAL HAZARD DURING MAINTENANCE WORK.
TURN OFF AND DISCONNECT THE PRINTER FROM THE MAINS ELECTRICAL SUPPLY
BEFORE THE COVER IS REMOVED.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS SAFETY
WARNING IS IGNORED.

5.4.2 Introduction
The following Maintenance Instructions are provided for use by maintenance technicians
who are trained and authorized by Linx. These instructions describe how to perform a
range of maintenance tasks on the Linx 7900 Continuous Ink Jet Printer. The primary
instruction is the ‘Scheduled Maintenance’ procedure, which describes the maintenance
that is required at the recommended intervals for the ink type used in the printer. The
purpose of scheduled maintenance is to prevent possible future causes of failure.
The remaining instructions describe different tasks to maintain the printer. For example,
how to drain and flush the ink system, replace parts in the ink system, test the valves, align
the jet, calibrate the IPM PCB. Some of these instructions are also referred to in the
‘Scheduled Maintenance’ instruction, and are performed during that maintenance task.

5.4.3 Maintenance terminology

Some maintenance actions used in this section have special meanings, which are defined as
follows:
Check Make a comparison of a measurement of time, pressure, temperature,
resistance, dimension or other quantity, with a known figure for that
measurement.
Test Confirm, with the use of the correct test equipment, that a component or
system correctly functions.
Examine Inspect the condition of an item. For example, any of the following can
have an effect on the condition of an item:
 Loose connection or installation.
 Cracks.
 Corrosion or contamination.
 Distortion.
 Loose or missing rivets.
 Cuts or wear.
 Damaged or broken locks or fasteners.
 Loose pipeline clips or protective material. Obstruction of pipelines or
leaks from pipelines.
 Change of colour due to high temperature or fluid leaks.
Operate Make sure that an item or system functions correctly, without the use of
test equipment or reference to measurements.

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 Refill Add a material to a tank, bottle or other container to a known level or
quantity, and as necessary:
 Remove caps or covers from filler openings.
 Clear filler openings.
 Make sure that gaskets and caps or covers are not damaged.
 Refit caps or covers.
 Fit locks or fasteners as necessary.
Fit Correctly attach one item to another item.
Refit Fit an item that was previously removed.
Replace Remove an item and fit a serviced or new item.
Connect Join or attach electrical cables, pipelines or controls.
Disconnect Separate or remove electrical cables, pipelines or controls.
Reconnect Join or attach electrical cables, pipelines or controls that were previously
disconnected.

5.4.4 Antistatic precautions

The PCBs in Linx printers use some electrostatic-sensitive components that can be severely
damaged if these components are submitted to static discharge. Static electricity, which is
generated on a person through friction and movement, is discharged through the first route
to earth that is contacted. Damage caused by a static discharge is not always immediately
detected after the static discharge has occurred, and can cause component failure in the
future. It is very important that maintenance technicians use the following antistatic
precautions when PCBs are touched:
 Wear an antistatic wrist strap that is approved by industry and includes a resistive
component (greater than 2 M) in the lead. The antistatic wrist strap must be connected
to a good electrical earth. The continuity of the antistatic wrist strap and the electrical
earth must be checked at regular intervals.
 Always hold a PCB by its edges and do not touch the components or printed circuit
tracks. After a PCB is removed from a printer or its packaging, the PCB must be put on
a static-dissipative mat.
 Always use antistatic packaging when PCBs and software components are shipped or
moved between locations. All Linx PCBs are shipped in static shielding bags and
special PCB boxes, and this packaging must be used again for any further
transportation.

5.4.5 Recommended procedures

Refitting the top cover
When the top cover is refitted, make sure that the Display PCB ribbon cable is not trapped
between the IPM PCB bracket and the Display PCB.
As a standard procedure, maintenance technicians must make sure that all cables and pipes
are routed correctly before the top cover is refitted, to prevent the risk of damage.

Spectrum maximum Set Pressure

When the Set Pressure is manually adjusted on the 7900 Spectrum printer, Linx recommends
that a pressure no greater than 3.52 bar (50.98 p.s.i. or 200 bits) is set. A higher pressure can
cause the Ink Mixing valve to stick.

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 5.4.6 7900 CE approval checklist
CE approval for the Linx 7900 Continuous Ink Jet Printer depends on the conditions given
below. If the printer is not left in the correct condition, the CE approval for the printer may
be invalidated. All maintenance technicians must make sure that the printer meets the
following conditions after any maintenance task is completed, so that the CE approval and
general safety are maintained.

Electronics
 All IPM PCB and Display PCB securing screws must be fitted and correctly tightened.
 The fan must be connected to the LVPSU and must be operating.
 Links LK5, LK19, LK20, LK21, LK26 and LK27 must NOT be left fitted on the IPM PCB.

Ink system
 The ink spillage detector must be fitted and connected.
 Gland fittings from the printhead to the ink system enclosure, and from the ink system
enclosure to the electronics compartment, must be undamaged, correctly fitted and
tight.
 The ink and solvent filler cap/bottle O-ring and the filler tube profiled seal must be
present, undamaged and correctly fitted.
 The valves and valve gaskets must be correctly fitted, and the valve caps must be
tightly connected.
 The pressure transducer connector and protective boot must be correctly fitted.

Printhead
 The bonding wire between the printhead and the chassis must be tightly connected.
 The printhead cover tube must be correctly fitted and the thumb screw tightened.

Cabinet
 EMC gaskets on the top cover must not be damaged and be correctly fitted.
 The keyboard must be correctly and tightly fitted.
 There must not be any obstruction to the ventilation of the printer—for example, no
obstruction of the air filter.
 The external alarm connector (PL5 on the rear panel) earth stud and nut must be
connected.
 The protective earth (PE) connector of the mains electrical supply cable must be tightly
connected to the earth terminal in the cabinet. All of the other earth connections within
the cabinet must be tightly connected.
 The earth bonding wire between the top cover and the chassis must be tightly
connected.
 The top cover must be correctly engaged with the hinge bracket on the rear chassis, and
the cover latch must be correctly fastened.
 The ink and solvent caps must be correctly fitted.

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 5.4.7 Scheduled Maintenance Checklist
The Scheduled Maintenance Checklist is a summary of the ‘Scheduled Maintenance’
instruction and provides useful information about the history of the printer. An example of
the form is given at the end of the ‘Scheduled Maintenance’ instruction and the form is for
use by Distributor maintenance technicians. The form must be completed by the
maintenance technician on completion of a scheduled maintenance on a printer, then filed
with the history documents of the printer.
NOTE: Linx maintenance technicians must use the authorized Service Report form on
completion of a scheduled maintenance of a printer.
If Distributors use this form, Linx recommends that the form is created as a two-page,
carbon-copy document. The top copy is the Customer Copy and the bottom copy is the
Service Copy (printer history).

5.4.8 Maintenance instruction documents

The Maintenance Instructions that describe the correct procedures for different
maintenance tasks on 7900 printers are contained in the following pages. These instructions
are created as single documents, which can be removed and copied for separate use.

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7900 Maintenance Instruction
Scheduled Maintenance

Parts required

FA65026 Basic Scheduled Maintenance Kit

(4200CE/4800/4900/6800/6900/7300/7900/5900)
comprising:
FA13004 Ink Dip Tube (Pick-up Tube) Assembly
FA73044 Main Ink Filter 10 µm

FA74330 7900 Scheduled Maintenance Kit

comprising:
FA13004 Ink Dip Tube (Pick-up Tube) Assembly
FA73044 Main Ink Filter 10 µm
Feed Damper and Restrictor Assembly

FA74331 Scheduled Maintenance Kit—Spectrum

comprising:
FA73044 Main Ink Filter 10 µm
FA72050 Feed Damper Assembly
FA13179 Air Filter for IP65
FA74189 3-Way Connector Replacement Filter (Ultima plus and Midi plus
printheads)
FA74221 Mk7 Printhead Valve Filter Assembly 35 µm (Ultima plus and Midi plus)

Additional parts required

FA73014 O-ring 7.66 x 1.78 EPDM—Pack as required
FA74135 M3 x 28 Csk Poz SS Screw—Pack as required
FA74136 Gasket Fluid Connector 3-Way—Pack as required
FA74163 3-Way Connector Replacement Filter (Ultima, Midi, Mini, and Micro
printheads)
FA13178 Air Filter for IP55 (as necessary)
FA320019 In- Line Filter (DFC)

Equipment required

FA65016 Scheduled Maintenance Tool Kit

comprising:
FA65007 Blanking Set 1/8 Union Fitting
FA65022 Fluid Connector 3-Way—Service Accessories
FA65023 Pre-Pump Swage Tool
FA69012 Lubricant Small—Main Ink Filter
FA74005 Damper Drain Tube
FA65337 4800/6800 Dip Tube (Pick-up Tube) Removal Tool

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7900 Maintenance Instruction
Scheduled Maintenance

FA79018 Tube PTFE 1/8 OD x 1/16 ID, Natural, 5 metres

FA79019 Tube PTFE 1/8 OD x 1/16 ID, Blue, 5 metres
FA79020 Tube PTFE 1/8 OD x 1/16 ID, Red, 5 metres
FA79021 Tube PTFE 6 mm OD x 4 mm ID, Natural, 5 metres
FA79022 Tube PTFE 3/16 OD x 1/8 ID, Natural, 5 metres
FA900003 Solvent Cleaning Bottle
FA900005 Beaker 0.25 Litre
FA940003 Eyeglass x9 Magnification
FA940021 Syringe Polypropylene 50 ml
FA940029 Solvent Resistant Cleaning Brush
FA940067 Double-Ended Trim Tool
FA999058 Gloves Nitrile Large 8–8.5
FA999076 Safety Spectacles Blue
FA30054 Tygon 4040A Tube 1/4 in. OD x 1/8 in. ID (IJ600 only)
FA30058 Tygon 4040A Tube 3/16 in. OD x 3/32 in. ID (IJ600 only)

Additional equipment required

FA72150 Fluid Connector 3-Way—Service Accessories—Pigmented
FA74046 Nozzle Cleaning Service Accessory
FA16005 Cover Removal Tool
FA65339 Mandrel Extraction Tool
FA940052 Tube Cutter Plastic 4 mm–14 mm
FA100007 Tube PTFE 6 mm OD x 4 mm ID, Coil 25 mm ID, 5 metres (Spectrum
printer only)
FA999056 Gloves Nitrile Small 6–6.5 ) as required
FA999057 Gloves Nitrile Medium 7–7.5 ) as required
Antistatic Wrist Strap and Lead
DVM (Digital Voltmeter)
Tweezers
Waste ink container (at least 5 litres capacity)
Beaker, stainless steel or glass
Absorbent, lint-free paper towel

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

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Scheduled Maintenance

Procedures

WARNING: HAZARDOUS SUBSTANCES. THIS PRINTER USES SOLVENT AND

SOLVENT-BASED INKS THAT CAN BE HAZARDOUS. THESE INKS AND SOLVENTS ARE
HIGHLY FLAMMABLE, AND THE LIQUID, VAPOUR OR SPRAY CAN CAUSE IRRITATION TO
THE EYES AND SKIN.
WEAR SAFETY EYE GLASSES AND SOLVENT-RESISTANT PROTECTIVE GLOVES WHEN
THERE IS DIRECT CONTACT WITH THE INKS AND SOLVENTS, WHEN WORK IS DONE ON THE
PRINTER, AND WHEN THE PRINTER IS CLEANED.
THERE IS A RISK OF SEVERE IRRITATION AND TEMPORARY (REVERSIBLE) DAMAGE TO
THE EYES, AND IRRITATION OF THE SKIN IF THIS SAFETY WARNING IS IGNORED.

All 7900 printers

1 Speak to the operators and enquire if there are any problems with the printer’s
performance.
2 Record the printer model and serial number, and the printhead type and serial
number.
3 Record the printhead calibration code and Reference Modulation taken from the
printhead conduit label. Record these same parameters from the Printhead page
and the Monitor Jet page, respectively.
4 Shut down and turn off the printer. Turn off the mains electrical supply and
disconnect the mains electrical supply cable from the printer.
5 Examine the printhead conduit for damage and make sure that it is secured
correctly at the terminating bushes.
6 Examine the mains electrical supply cable for damage, and make sure that the
connector is in good condition and correctly connected. Replace as necessary.
7 Remove the printhead cover tube. Examine the printhead and components for
damage or obvious misalignment.
8 Clean the printhead using the correct solvent for the type of ink being used in the
printer. If the printer uses a pigmented ink, carry out the procedure described in
the ‘Printhead Cleaning for Pigmented Inks’ maintenance instruction.
9 Turn on the printer and start the jet. Record all of the required data from the
Monitor Jet and Maintenance Times pages (Print Monitor > Menu >
Maintenance). Monitor and record any fault or warning messages.
10 Shutdown the jet and turn off the printer.
11 Drain the ink from the ink system. Refer to the ‘Draining the Ink System’
maintenance instruction.

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Scheduled Maintenance

Standard 7900 and 7900 Food Grade printers only

12 Pigmented ink printers only (not the 7900 Spectrum printer):
(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.
13 Remove the mandrel and filter assemblies from the ink and solvent filler tubes
using the Mandrel Extraction Tool. Examine the filters and filler tubes for any
debris (for example, foil seals from ink or solvent bottles) and remove if found.
Refit the mandrel and filter assemblies.
14 Examine the filler cap/bottle O-ring and the filler tube O-ring (ink and solvent).
Replace any damaged O-rings.
15 Replace the ink pick-up tube, which includes the in-line filter. Refer to the ‘Ink Tank
Pick-up Tube Replacement’ maintenance instruction. This replacement must be
carried out at every Scheduled Maintenance.
16 Standard 7900 printer only. Replace the damper. When the scheduled maintenance
is completed, and the Maintenance Finished key is pressed, the printer requests an
Easi-Change® code. Enter the 12-character Easi-Change® code, which is printed on
a label attached to the damper assembly and the damper packaging.
NOTE: The Easi-Change® process does not apply to Linx 7900 Spectrum and Food
Grade printers.
16 7900 Food Grade printer only. Linx recommends that the damper is replaced every
12 months. If there is a 'damper replacement date' label attached to the damper,
examine the date. Consider how long the damper has been fitted and the
approximate time until the next Scheduled Maintenance visit, and replace the
damper if necessary.
If the damper is replaced, write the current date on the 'damper replacement date'
label that is attached to the new damper.
17 Examine the ink system tubing for trapping and kinks. Replace any damaged
tubing.
18 Replace the filter in the 3-way fluid connector (pigmented ink printers only). Refer
to the ‘3-Way Fluid Connector Filter Replacement’ maintenance instruction.
19 Solver printer only. Replace the DFC disc filter. Cut the pipes as close as possible to
the barb connections of the filter. Use the tube cutter to make sure that the pipes are
cut cleanly and straight.
20 Turn on the printer.
21 Enter the SureFill® code for the first bottle of new ink, and then refill the ink system
with two 0.5-litre bottles of new ink. (A SureFill® code is not required for the
second bottle of ink.) Make sure that the ink is the correct type for the printer
type.
22 Turn off the printer.

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Scheduled Maintenance

23 Replace the main ink filter. Refer to the ‘Main Ink Filter Replacement’ maintenance
instruction.
24 Purge the main ink filter. Refer to the ‘Main Ink Filter Purge’ maintenance
instruction.

7900 Spectrum printer only

12 Remove the ink tank lid and examine the inside of the tank for pigment build-up.
Clean the inside of the tank as necessary. Refer to the ‘Spectrum Ink Tank Removal’
maintenance instruction.
13 Replace the main ink filter. Refer to the ‘Main Ink Filter Replacement’ maintenance
instruction.
14 Remove the mandrel and filter assemblies from the ink and solvent filler tubes
using the Mandrel Extraction Tool. Examine the filters and filler tubes for any
debris (for example, foil seals from ink or solvent bottles) and remove if found.
15 Refit the mandrel and filter assemblies.
16 Examine the filler cap/bottle O-ring and the filler tube O-ring (ink and solvent).
Replace any damaged O-rings.
17 Linx recommends that the damper is replaced every 12 months. If there is a
'damper replacement date' label attached to the damper, examine the date.
Consider how long the damper has been fitted and the approximate time until the
next Scheduled Maintenance visit, and replace the damper if necessary.
If the damper is replaced, write the current date on the 'damper replacement date'
label that is attached to the new damper.
18 Examine the ink system tubing for trapping and kinks. Replace any damaged
tubing.
19 Replace the filter in the 3-way fluid connector. Refer to the ‘3-Way Fluid Connector
Filter Replacement’ maintenance instruction.
20 Replace the filter in the Printhead Feed valve. Refer to the ‘Printhead Feed Valve
Filter Replacement’ maintenance instruction.
21 Turn on the printer.
22 Enter the SureFill® code for the first bottle of new ink, and then refill the ink system
with two 0.5-litre bottles of new ink. (A SureFill® code is not required for the
second bottle of ink.) Make sure that the ink is the correct type for the printer
type.
23 Turn off the printer.
24 Purge the main ink filter. Refer to the ‘Main Ink Filter Purge’ maintenance
instruction.

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Scheduled Maintenance

All 7900 printers

25 Examine the wiring and connectors within the electronics compartment and to the
Display PCB for trapping and signs of abrasion. Replace any damaged cables.
26 Remove the air filter as shown in Figure 1 or Figure 2. The 7900 (IP65 version) filter
is disposable, that is, it must be replaced rather than cleaned and refitted.
The 7900 (IP55 version) filter can be cleaned, using compressed air blown through in
the reverse direction to the normal airflow, and refitted. Examine the 7900 (IP55
version) filter and replace it if it is severely blocked or damaged. Make sure that the
new filter is fitted with the metal side facing down.

79070

Figure 1. Removing the 7900 (IP65 version) air filter

79069

Figure 2. Removing the 7900 (IP55 version) air filter

27 Examine the printer for any loose hardware and secure as necessary.

CAUTION: Static-Sensitive Devices. The PCBs contain static-sensitive devices. Take the
following antistatic precautions when PCBs are touched. Wear an antistatic wrist strap and
connect the lead to a good electrical earth. Always hold PCBs by their edges and do not touch
the components, printed circuit tracks or connector pins.
28 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.

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Scheduled Maintenance

WARNING: LETHAL VOLTAGE HAZARD. DANGEROUS VOLTAGES EXIST IN THIS

EQUIPMENT WHEN ELECTRICAL POWER IS APPLIED.
MAXIMUM CARE MUST BE TAKEN WHEN WORK IS DONE ON THE PRINTER WHILE
ELECTRICAL POWER IS APPLIED AND THE COVER IS REMOVED. THE CORRECT,
STANDARD ELECTRICAL SAFETY PRECAUTIONS MUST BE TAKEN.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS SAFETY
WARNING IS IGNORED.
29 Calibrate the Charge Amplifier. Refer to the ‘Charge Amplifier Calibration’
maintenance instruction.
30 Perform printhead valves tests. Refer to the ‘Printhead Valves Tests’ maintenance
instruction.
31 Make sure that the jet is correctly aligned. Refer to the ‘Jet Alignment and Nozzle
Cleaning’ maintenance instruction.
32 Start the printer (if necessary) and record the parameters displayed on the Monitor
Jet page (Print Monitor > Menu > Maintenance).
33 While observing the printhead, shut down and then restart the jet using the [stop]
and [start] keys. Repeat the shutdown and startup operation four times, monitoring
the time taken to start up, and recording all the parameters and times taken. Both
the shutdown and startup should be clean. If any startup takes longer than
nominally 2 minutes, check for any associated fault or warning messages and
investigate the cause of the problem.
34 Take print samples using the standard test message and record the calculated Ref
Modulation on the Scheduled Maintenance Checklist. Refer to the ‘Modulation Range
Checks’ maintenance instruction.
35 Remove the printhead cover tube and reconfirm correct jet alignment. Refer to the
‘Jet Alignment and Nozzle Cleaning’ maintenance instruction.
36 Refit the printhead cover tube, making sure that the securing screw is fully
tightened.
37 On the Maintenance Times page (Print Monitor > Menu > Maintenance), reset the
Maintenance Due Within and Maintenance Due By values to the recommended
maintenance intervals for the ink type used in the printer and the environmental
conditions. To do this, select the Maintenance Finished option. Refer to
Maintenance Page > Maintenance Times earlier in this chapter.
38 Run the printer for 30 minutes, taking print samples every 10 minutes using the
standard test message. Record the calculated Reference Modulation on the
Scheduled Maintenance Checklist. Refer to the ‘Modulation Range Checks’
maintenance instruction.
39 Run the printer on the production line. Advise the operator or production manager
of any specific points relating to the operation of the printer, its location, or the
mounting of the printhead. Record any advice given on the Service Report form.
40 Make sure that the printer top cover is securely refitted.
41 Clean the printer top cover and base unit.

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Scheduled Maintenance

42 On completion of the scheduled maintenance, make sure that the customer signs
the Service Report form.
43 Make sure that all print samples are retained with the Service Report form.
44 The ‘Scheduled Maintenance’ maintenance instruction is now completed.

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7900 Maintenance Instruction
Scheduled Maintenance

SCHEDULED MAINTENANCE CHECKLIST

CUSTOMER DATE CALL NUMBER

PRINTER MODEL PRINTER SERIAL No.

PRINTHEAD TYPE PRINTHEAD SERIAL No.

PRINTHEAD CAL. CODE (CONDUIT) REF MOD PRINTHEAD CAL. CODE (PRINTER) REF MOD

POWER ON TIME (HRS) TOTAL JET RUNNING TIME (HRS) TOTAL

POWER ON TIME (HRS) PRESENT JET RUNNING TIME (HRS) PRESENT

ITEM  ITEM 
x Speak with Operators about any printer problems x Examine for loose hardware
x Record printer and printhead information (see above) x Remove, examine, clean and refit PCBs
x Examine conduit and mains electrical supply cable x Calibrate charge amplifier
x Examine and clean printhead x Perform printhead valves tests
x Start printer—record maint. times and jet parameters x Ensure correct jet alignment
Pressure TOF Phase Solvent Read Pressure TOF Phase Solvent Read
steady? Add Pressure steady? Add Pressure

x Drain ink system
x Clean pigmented ink tank (N/A* to Spectrum)
x Examine ink and solvent filler tubes for debris
x Examine O-rings in filler tubes and caps
x Replace pre-pump filter (N/A* to 49/68/69/73/59/7900)
x Replace ink pick-up tube (N/A* to 6200 & Spectrum)
x Replace damper
x Replace solv. pick-up filter (N/A* to 49/68/69/73/59/7900)
x Examine ink system tubing
x Replace 3-way fluid connector filter (pig. inks only)
x Replace Printhead Feed valve filter (Spectrum only)
x Replace DFC disk filter (Solver printer only)
x Refill ink system
x Replace and purge main ink filter
x Examine electronics wiring and connectors
x Clean or replace air filter
x Start printer and record jet parameters above
x Stop and start jet checks
x Perform modulation range checks with print samples
x Record calculated Ref. Modulation value: ·
x Reconfirm correct jet alignment
x Reset scheduled maintenance intervals
x Perform modulation range checks with print samples
x Record calculated Ref. Modulation value: ·
x Run printer ‘on line’ and advise operator
x Refit all screws and fasten top cover
x Clean printer top cover and base unit
x Complete paperwork

* N/A = not applicable CUSTOMER’S SIGNATURE

NAME
SIGNATURE

Issue 11 – Apr 2013

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Scheduled Maintenance

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7900 Maintenance Instruction
Printhead Cleaning for Pigmented Inks

Parts required
FA81505/5L General Purpose MEK Solvent 1505
FA91605/5L Solvent 1605 for Pigmented Inks 1305 and 1310
FA91606/5L Solvent 1606 for Pigmented Inks 1306 and 1311
FA900003 Solvent Cleaning Bottle
FA900005 Beaker 0.25 Litre
FA940029 Solvent Resistant Cleaning Brush
FA999056 Gloves Nitrile Small 6–6.5 )
FA999057 Gloves Nitrile Medium 7–7.5 ) as required
FA999058 Gloves Nitrile Large 8–8.5 )
FA999076 Safety Spectacles Blue
Absorbent, lint-free paper towel

Introduction
This maintenance instruction describes the procedure for cleaning Mk7 printheads fitted to
7900 printers that use the following pigmented inks:
 Black Pigmented Ink 1009
 Blue Pigmented Ink 1033
 Yellow Pigmented Ink 1039
 Opaque Blue ink 1043
 White Pigmented Ink 1059 and 1069
 Brilliant White Ink 1305 and 1306
 High-Opacity Grey Ink 1310 and 1311
Linx recommends that the printhead is checked daily for ink build-up and cleaned if
necessary. It should also be cleaned at intervals of 1 working week using a non-abrasive,
solvent resistant brush (FA940029).

WARNING: HAZARDOUS SUBSTANCES. THIS PRINTER USES SOLVENT AND

SOLVENT-BASED INKS THAT CAN BE HAZARDOUS. THESE INKS AND SOLVENTS ARE
HIGHLY FLAMMABLE, AND THE LIQUID, VAPOUR OR SPRAY CAN CAUSE IRRITATION TO
THE EYES AND SKIN.
WEAR SAFETY EYE GLASSES AND SOLVENT-RESISTANT PROTECTIVE GLOVES WHEN
THERE IS DIRECT CONTACT WITH THE INKS AND SOLVENTS, WHEN WORK IS DONE ON THE
PRINTER, AND WHEN THE PRINTER IS CLEANED.
THERE IS A RISK OF SEVERE IRRITATION AND TEMPORARY (REVERSIBLE) DAMAGE TO
THE EYES, AND IRRITATION OF THE SKIN IF THIS SAFETY WARNING IS IGNORED.
CAUTION: Contamination of the Printhead Nozzle Assembly. Blockages and print failures can
occur if contamination is allowed to enter the printhead nozzle assembly. Wear powder-free
protective gloves during the following procedure to prevent contamination of the printhead
nozzle assembly. If the standard protective gloves that contain powder are worn, powder
contamination can enter the printhead nozzle assembly.

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Printhead Cleaning for Pigmented Inks

Procedure
1 Stop the jet and wait for the following message to appear in the Printer Status area
of the Print Monitor page:
“IDLE”
or wait until the Auto Power Down facility switches the printer off.
2 Turn off the printer and disconnect it from the mains electrical supply.
3 Remove the printhead cover tube.
CAUTION: Solvent Precautions for the Printhead and Nozzle. The printhead and nozzle can be
damaged if important precautions are not taken. Make sure that the solvent used to wash the
printhead is the correct type for the ink used in the printer. Do not wash the nozzle with solvent
unless the nozzle has an ink obstruction or blockage. NEVER USE A BRUSH ON THE NOZZLE.
4 Hold the printhead over a beaker, as shown in Figure 1, and wash all of the
components and the circuit board with solvent.
68123

MIDI -PLUS

Figure 1. Correct area of the printhead to wash with solvent

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Printhead Cleaning for Pigmented Inks

5 Use the brush to gently remove any ink deposits that will not wash off at step 4,
paying particular attention to the deflector plates (Figure 2). Do not use the brush
to clean the nozzle.
68124

MIDI -PLUS

Figure 2. Correct area of the printhead to clean with the brush

CAUTION: Printhead Damage. Black pigmented ink 1009 contains carbon particles, which are
very conductive. It is most important to make sure that ALL traces of carbon are removed from
the printhead surface around the charge electrode and between the deflector plates. If these
areas are not cleaned completely, the remaining carbon can cause short circuits, which can
damage the printhead.
6 Alternately, wash and then gently brush the printhead components and the circuit
board (Figure 2), finishing with a wash when all the ink deposits have been
removed. Do not use the brush to clean the nozzle. Only use new solvent. Do not
recycle the solvent.
7 Allow the printhead to dry.

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Printhead Cleaning for Pigmented Inks

8 Wash the inside of the printhead cover tube with solvent, as shown in Figure 3,
until all ink has been removed. Use the brush, where possible, to remove ink
deposits that do not immediately wash off. Finish the cleaning with a wash and
allow the cover tube to dry.

Figure 3. Washing the printhead cover tube with solvent

9 Refit the printhead cover tube and firmly tighten the knurled securing screw.
10 The ‘Printhead Cleaning for Pigmented Inks’ maintenance instruction is now
completed.

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Draining the Ink System

Parts required
FA74005 Damper Drain Tube
FA16005 Cover Removal Tool
FA940052 Tube Cutter Plastic 4 mm–14 mm
FA79021 Tube PTFE 6 mm OD x 4 mm ID, Natural, 5 metres
FA65339 Mandrel Extraction Tool
FA999056 Gloves Nitrile Small 6–6.5 )
FA999057 Gloves Nitrile Medium 7–7.5 ) as required
FA999058 Gloves Nitrile Large 8–8.5 )
FA999076 Safety Spectacles Blue
Waste ink container (at least 5 litres capacity)
Absorbent, lint-free paper towel

Procedure

WARNING: HAZARDOUS SUBSTANCES. THIS PRINTER USES SOLVENT AND

SOLVENT-BASED INKS THAT CAN BE HAZARDOUS. THESE INKS AND SOLVENTS ARE
HIGHLY FLAMMABLE, AND THE LIQUID, VAPOUR OR SPRAY CAN CAUSE IRRITATION TO
THE EYES AND SKIN.
WEAR SAFETY EYE GLASSES AND SOLVENT-RESISTANT PROTECTIVE GLOVES WHEN
THERE IS DIRECT CONTACT WITH THE INKS AND SOLVENTS, WHEN WORK IS DONE ON THE
PRINTER, AND WHEN THE PRINTER IS CLEANED.
THERE IS A RISK OF SEVERE IRRITATION AND TEMPORARY (REVERSIBLE) DAMAGE TO
THE EYES, AND IRRITATION OF THE SKIN IF THIS SAFETY WARNING IS IGNORED.

All 7900 printers

1 Shut down and turn off the printer. Turn off the mains electrical supply and
disconnect the mains electrical supply cable from the printer.
2 Remove the ink and solvent filler caps.
3 Unlock the security latch on the front of the top cover and remove the cover.
Position the cover so that the keyboard and display can be accessed.

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Draining the Ink System

4 Switch the printer on and select the System Flush option on the Maintenance page
(Print Monitor > Menu > Maintenance). The first page of the System Flush
procedure is displayed with the instruction “Check solvent level.”.
69183

Figure 1. System Flush—first page

5 To continue with the System Flush procedure (and therefore the Empty Tank
sequence), it is necessary to perform a number of actions on the printer before the
flush cycles can begin. These required actions are displayed on each successive
System Flush page, and must be performed in accordance with the following
expanded explanations for each instruction. Once each action has been completed,
press the OK key, which displays the next instruction.
6 Check solvent level. This action is not applicable when draining the ink system; it
is only necessary to press the OK key to proceed to the next instruction.
7 Prop up the printer. (Not applicable to the 7900 Spectrum printer—see NOTE
below.) Before commencing the ink draining procedure, the printer must be raised
by approximately 50 mm at the front left side to aid drainage of the ink. This is
because the ink pick-up tube is situated at the rear right side of the tank.
NOTE: The 7900 Spectrum printer does not require propping up, but the OK key
must be pressed to continue the procedure.

WARNING: LETHAL VOLTAGE HAZARD. DANGEROUS VOLTAGES EXIST IN THIS

EQUIPMENT WHEN ELECTRICAL POWER IS APPLIED.
MAXIMUM CARE MUST BE TAKEN WHEN WORK IS DONE ON THE PRINTER WHILE
ELECTRICAL POWER IS APPLIED AND THE COVER IS REMOVED. THE CORRECT,
STANDARD ELECTRICAL SAFETY PRECAUTIONS MUST BE TAKEN.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS SAFETY
WARNING IS IGNORED.
8 Orientate filter and damper. Ignore the instruction regarding the filter. Carefully
lift the feed damper and cable tie off the hook on the side of the ink system
enclosure. Hold the feed damper in the vertical position with the drain cap
uppermost.

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Draining the Ink System

9 Connect bleed line to damper. Remove the damper drain cap and connect the
damper drain tube to the damper drain. Insert the other end of the drain tube into a
waste container of at least 5 litres capacity. Orientate the damper so that the drain is
at the bottom, that is, at its lowest position, as shown in the following two
illustrations.

79087

Drain tube

Figure 2. Damper orientation and drain tube—standard 7900

68050

Drain tube

Figure 3. Damper orientation and drain tube—7900 Food Grade and 7900 Spectrum

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Draining the Ink System

10 When the required actions have been completed, the following page is displayed.

69184

Figure 4. System Flush options page

11 Press the Empty Tank key, which displays the instruction “Turn on tap to bleed
line.”.
IMPORTANT: The bleed line tap is used in the Linx manufacturing process only.
There is no bleed line in the maintenance technician’s damper
drain tube kit, therefore, any action referring to the bleed line tap
should be ignored.
12 Due to the unique design of the 7900 Spectrum ink tank, it is not possible to drain all
of the ink with the Empty Tank function. Therefore, to enable all of the ink to be
removed, proceed with the following step 12 sub-items.

7900 Spectrum printer only

12a Disconnect and remove the ink pick-up pipe, which is connected between the ink
tank lid (Festo connection) and the pump/PRV (pressure relief valve) T-piece.
Discard the pipe but retain the Festo nut.
12b Connect a new 360 mm length of 6 mm OD tube to the pump/PRV T-piece.
12c Remove the mandrel and filter assembly from the ink filler tube using the Mandrel
Extraction Tool.
12d Insert the free end of the new length of pipe into the ink tank and push it down
until it reaches the base of the tank. Hold the pipe in place for the duration of the
Empty Tank sequence to make sure that all the ink is removed.

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Draining the Ink System

All 7900 printers

CAUTION: Pump Damage. Do not allow the ink system pump to run in a dry condition. Use the
Empty Tank sequence only the number of times required to empty the system of ink. The pump
must not be run for longer than 30 seconds after the change in the sound of the pump
indicates that cavitation (no ink in the pump) has occurred. Damage to the pump can occur if
the pump is allowed to run continuously in a dry condition.
13 Press the OK key to continue the procedure, which starts the pump. The pump
runs at maximum pressure for approximately 1 minute and 40 seconds, and then
automatically stops on completion of the Empty Tank sequence. During the
sequence a Progress bar gives an indication of how much of the sequence has been
completed. Press the Stop Sequence key if the audible pitch of the pump changes
indicating that the ink tank is empty.

69307

Figure 5. Empty Tank sequence in progress

14 At some point towards the end of the Empty Tank sequence the ‘ink low’ condition
will be reached. Make sure that the SureFill page is displayed with the System
Warning message “3.03 Ink Low”. Press the OK key on the SureFill page to accept
the warning.
15 If the tank is not empty after a single Empty Tank sequence, select the Empty Tank
option again to repeat the sequence. Press the Stop Sequence key when the audible
pitch of the pump changes, indicating that the ink tank is empty.
16 At this point the ink pick-up pipe on the 7900 Spectrum must be reconnected to the
ink pick-up connection on the tank lid. To do this, proceed with the following
step 16 sub-items.

7900 Spectrum printer only

16a Withdraw the drain pipe from the ink tank and wipe off any surplus ink from the
end.
16b Cut the pipe to a length of 55 mm using the tube cutter.
16c Fit the Festo nut (retained earlier) over the end of the newly cut pipe.
16d Insert the end of the pipe into the ink pick-up connection on the tank lid, and fit and
tighten the Festo nut.
16e Refit the mandrel and filter assembly to the ink filler tube using the Mandrel
Extraction Tool.

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Draining the Ink System

All 7900 printers

17 Disconnect the drain tube from the damper and refit the drain cap.
18 Refit the damper and cable tie to the hook on the side of the ink system enclosure.
19 The ‘Draining the Ink System’ maintenance instruction is now completed.

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7900 Maintenance Instruction
Spectrum Ink Tank Removal

Parts required
FA16005 Cover Removal Tool
FA900003 Solvent Cleaning Bottle
FA940029 Solvent Resistant Cleaning Brush
FA940052 Tube Cutter Plastic 4 mm–14 mm as required
FA999056 Gloves Nitrile Small 6–6.5 )
FA999057 Gloves Nitrile Medium 7–7.5 ) as required
FA999058 Gloves Nitrile Large 8–8.5 )
FA999076 Safety Spectacles Blue
Correct solvent for the ink used in the printer as required
Absorbent, lint-free paper towel

Introduction
This maintenance instruction describes the procedure for removing the 7900 Spectrum ink
tank for access to the main ink filter. It also details the procedure for removing the ink tank
lid to enable the tank to be cleaned, and includes the cleaning recommendations.

WARNING: HAZARDOUS SUBSTANCES. THIS PRINTER USES SOLVENT AND

SOLVENT-BASED INKS THAT CAN BE HAZARDOUS. THESE INKS AND SOLVENTS ARE
HIGHLY FLAMMABLE, AND THE LIQUID, VAPOUR OR SPRAY CAN CAUSE IRRITATION TO
THE EYES AND SKIN.
WEAR SAFETY EYE GLASSES AND SOLVENT-RESISTANT PROTECTIVE GLOVES WHEN
THERE IS DIRECT CONTACT WITH THE INKS AND SOLVENTS, WHEN WORK IS DONE ON THE
PRINTER, AND WHEN THE PRINTER IS CLEANED.
THERE IS A RISK OF SEVERE IRRITATION AND TEMPORARY (REVERSIBLE) DAMAGE TO
THE EYES, AND IRRITATION OF THE SKIN IF THIS SAFETY WARNING IS IGNORED.

Procedure

Removal for access

1 Make sure that the ink system has been drained before proceeding with this
procedure. Refer to the ‘Draining the Ink System’ maintenance instruction.
2 Shut down and turn off the printer. Turn off the mains electrical supply and
disconnect the mains electrical supply cable from the printer.
3 Remove the ink and solvent filler caps.
4 Unlock the security latch on the front of the top cover and remove the cover.
5 Temporarily refit the ink and solvent filler caps to reduce evaporation of the ink
and solvent.

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Spectrum Ink Tank Removal

6 Disconnect the ink tank float switch sensor cable. Gently pull the cable through the
grommet in the ink system enclosure wall until the connector is touching the
grommet. This makes sure that there is sufficient slack to enable the tank to be
removed.
7 Unclip the PRV (pressure relief valve) from its retaining clip located on the left side
of the tank.
8 Disconnect the ink pick-up and return pipes (connections shown in Figure 1) from
the tank lid using a 12 mm AF spanner.

69390
Ink tank vent pipe
and purge pipe
connections

Ink pick-up pipe

and ink return pipe
connections

Ink tank base

plate bracket

Figure 1. 7900 Spectrum ink tank

9 If there is insufficient slack in the ink tank vent and purge pipes to allow removal of
the tank, remove the pipes from the tank lid barb connections (shown in Figure 1)
using the tube cutter.
10 Loosen the four pump securing bolts using a 7 mm AF spanner and pull the pump
forward a few millimetres, away from the ink tank.
11 Pull the ink tank assembly forward until the tank is clear of the lip of the ink system
enclosure.
12 Lift the tank clear and suspend it from the right-hand side of the ink system
enclosure using the bracket formed in the ink tank base plate (shown in Figure 1).
13 The main ink filter can now be replaced if required. Refer to the ‘Main Ink Filter
Replacement’ maintenance instruction.

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Ink tank cleaning and refitting

14 Remove the ink filler cap.
15 Remove the six tank lid securing screws using a 3 mm hexagon key.
16 Remove the lid and rubber gasket.
NOTE: If the 7900 Spectrum printer is left idle for a period in excess of 4 weeks or there has
been a fault with the ink mixing circuit, the inside of the ink tank can become
heavily stained with pigment. This pigment build-up must be removed and the
tank thoroughly cleaned to make sure that the ink system can circulate and mix the
ink correctly, keeping the pigment in suspension.
17 To clean the ink tank, a combination of the correct solvent and a stiff brush must be
used to remove the pigment lining the inside of the tank. Do not use any other tools
that might scratch the stainless steel surface of the tank.
18 Refit the rubber gasket to the lid making sure that it is firmly seated in the gasket
recess. Hold the gasket in place with the lid securing screws to make sure that it
does not become trapped when the lid is refitted.
19 Refit the lid to the tank and secure with the six hexagon screws.
20 Temporarily refit the ink filler cap to reduce evaporation of the ink.
21 Remove any absorbent material from the ink system enclosure.
22 Unhook the tank from the side of the ink system enclosure and reposition it in the
ink system enclosure. Push the tank rearwards making sure that it fits under the lip
of the ink system enclosure.
23 Reposition the pump and tighten the four pump securing bolts.
24 If the ink tank vent and purge pipes were removed, reconnect them to the tank lid
barb connections.
25 Reconnect the ink pick-up and return pipes to the tank lid.
26 Refit the PRV (pressure relief valve) in its retaining clip.
27 Gently push the float switch sensor cable back through the grommet in the ink
system enclosure wall and reconnect it.
28 Remove the ink and solvent filler caps.
29 Refit the top cover and secure the locking latch.
30 Refit the ink and solvent filler caps.
31 The ‘Spectrum Ink Tank Removal’ maintenance instruction is now completed.

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Spectrum Ink Tank Removal

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7900 Maintenance Instruction
Ink Tank Pick-up Tube Replacement

Parts required
FA13004 Ink Dip Tube (Pick-up Tube) Assembly

Equipment required
FA69012 Lubricant Small—Main Ink Filter
FA16005 Cover Removal Tool
FA65337 4800/6800 Dip Tube (Pick-up Tube) Removal Tool
FA940052 Tube Cutter Plastic 4 mm–14 mm
FA999056 Gloves Nitrile Small 6–6.5 )
FA999057 Gloves Nitrile Medium 7–7.5 ) as required
FA999058 Gloves Nitrile Large 8–8.5 )
FA999076 Safety Spectacles Blue
Absorbent, lint-free paper towel
Abrasive paper

Introduction
This maintenance instruction describes the replacement procedure for the ink tank pick-up
tube and filter assembly, which must be done at every scheduled maintenance.
The procedure is applicable only to the standard 7900 printers (IP55 and IP65 versions) and
not the 7900 Spectrum printer.
The procedure can be used to replace the ink pick-up tube in the 7900 Food Grade printer,
but the ink pick-up pipe supplied in the kit must be cut to a length of 100 mm. This pipe is
connected between the ink pick-up tube and the primary pump inlet T-piece connector in a
7900 Food Grade printer.
The ink tank pick-up tube has an integral 40 µm, stainless steel, in-line filter fitted inside the
tube. The pick-up tube and filter, together with two O-rings are supplied as an assembled
part in the spare parts pack. A compression fitting, a length of 6 mm OD pipe and a pipe
elbow support are also included.
Compression fitting
48216

O-rings

Pick-up tube

In-line filter

Figure 1. Ink tank pick-up tube and filter assembly

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Ink Tank Pick-up Tube Replacement

Procedure

WARNING: HAZARDOUS SUBSTANCES. THIS PRINTER USES SOLVENT AND

SOLVENT-BASED INKS THAT CAN BE HAZARDOUS. THESE INKS AND SOLVENTS ARE
HIGHLY FLAMMABLE, AND THE LIQUID, VAPOUR OR SPRAY CAN CAUSE IRRITATION TO
THE EYES AND SKIN.
WEAR SAFETY EYE GLASSES AND SOLVENT-RESISTANT PROTECTIVE GLOVES WHEN
THERE IS DIRECT CONTACT WITH THE INKS AND SOLVENTS, WHEN WORK IS DONE ON THE
PRINTER, AND WHEN THE PRINTER IS CLEANED.
THERE IS A RISK OF SEVERE IRRITATION AND TEMPORARY (REVERSIBLE) DAMAGE TO
THE EYES, AND IRRITATION OF THE SKIN IF THIS SAFETY WARNING IS IGNORED.
1 Shut down and turn off the printer. Turn off the mains electrical supply and
disconnect the mains electrical supply cable from the printer.
2 Remove the ink and solvent filler caps.
3 Unlock the security latch on the front of the top cover and remove the cover.
Position the cover so that the keyboard can be accessed.
4 Temporarily refit the ink and solvent filler caps to reduce evaporation of the ink
and solvent.
5 Put absorbent, lint-free paper towel around the areas of the ink pick-up tube and
the pump to contain any ink spillage.
6 Use the pick-up tube removal tool to remove the pick-up tube from the ink tank.
Note that the pick-up tube is not threaded but is a push fit.
7 Remove the ink pick-up pipe Festo nut on the pump and disconnect the pipe. Keep
the Festo nut, but discard the ink pick-up pipe, pipe elbow support and pick-up
tube.
8 Slide the compression nut, olive and sleeve over the steel insert end of the new
length of pipe in the correct order, as shown in Figure 2.

Compression nut 73080

Olive

Sleeve

Steel insert

Figure 2. Correct assembly of the ink pick-up tube fluid connection

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Ink Tank Pick-up Tube Replacement

9 Apply two drops of thread assembly lubricant to the pick-up tube threads.
10 Insert the steel insert end of the pipe into the new pick-up tube outlet. Slide the
compression fitting components along the pipe to the pick-up tube connection, and
fit the compression nut firmly onto the pick-up tube.
11 Apply a small amount of thread assembly lubricant to the two O-rings fitted to the
neck of the new pick-up tube assembly.
12 Fit the pick-up tube to the ink tank and push firmly into place.
13 Slide the blue Festo nut that was removed from the pump in step 7 over the free
end of the new ink pick-up pipe.
14 Push the pipe onto the pump barb connection. (To help to connect the pipe, hold
the pipe with a piece of abrasive paper.)
15 Fit the Festo nut firmly onto the pump connection.
16 Fit the pipe elbow support to the ink pick-up pipe in the same position as on the
discarded pipe.

WARNING: LETHAL VOLTAGE HAZARD. DANGEROUS VOLTAGES EXIST IN THIS

EQUIPMENT WHEN ELECTRICAL POWER IS APPLIED.
MAXIMUM CARE MUST BE TAKEN WHEN WORK IS DONE ON THE PRINTER WHILE
ELECTRICAL POWER IS APPLIED AND THE COVER IS REMOVED. THE CORRECT,
STANDARD ELECTRICAL SAFETY PRECAUTIONS MUST BE TAKEN.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS SAFETY
WARNING IS IGNORED.
NOTE: If the ink tank pick-up tube replacement is being done as part of the Scheduled
Maintenance, there will be no ink in the tank at this point. Therefore, the following
leak check must be carried out at a later stage in the Scheduled Maintenance once
the tank has been refilled with ink.
17 Turn on the printer.
18 Start the jet and examine the pick-up tube compression fitting for leaks.
19 Shut down and turn off the printer.
20 Remove any absorbent material from the ink system.
21 Remove the ink and solvent filler caps.
22 Refit the top cover and secure the locking latch.
23 Refit the ink and solvent filler caps.
24 The ‘Ink Tank Pick-up Tube Replacement’ maintenance instruction is now
completed.

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Ink Tank Pick-up Tube Replacement

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7900 Maintenance Instruction
3-Way Fluid Connector Filter Replacement

Parts required
FA74163 3-Way Connector Replacement Filter (Ultima, Midi, Mini, and Micro
printheads)
or
FA74189 3-Way Connector Replacement Filter (Ultima plus and Midi plus
printheads)

Equipment required
FA16005 Cover Removal Tool
FA999056 Gloves Nitrile Small 6–6.5 )
FA999057 Gloves Nitrile Medium 7–7.5 ) as required
FA999058 Gloves Nitrile Large 8–8.5 )
FA999076 Safety Spectacles Blue
Tweezers
Absorbent, lint-free paper towel

Procedure

WARNING: HAZARDOUS SUBSTANCES. THIS PRINTER USES SOLVENT AND

SOLVENT-BASED INKS THAT CAN BE HAZARDOUS. THESE INKS AND SOLVENTS ARE
HIGHLY FLAMMABLE, AND THE LIQUID, VAPOUR OR SPRAY CAN CAUSE IRRITATION TO
THE EYES AND SKIN.
WEAR SAFETY EYE GLASSES AND SOLVENT-RESISTANT PROTECTIVE GLOVES WHEN
THERE IS DIRECT CONTACT WITH THE INKS AND SOLVENTS, WHEN WORK IS DONE ON THE
PRINTER, AND WHEN THE PRINTER IS CLEANED.
THERE IS A RISK OF SEVERE IRRITATION AND TEMPORARY (REVERSIBLE) DAMAGE TO
THE EYES, AND IRRITATION OF THE SKIN IF THIS SAFETY WARNING IS IGNORED.
1 Shut down and turn off the printer. Turn off the mains electrical supply and
disconnect the mains electrical supply cable from the printer.
2 Remove the ink and solvent filler caps.
3 Unlock the security latch on the front of the top cover and remove the cover.
Position the cover so that the keyboard 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 that might be spilt.

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3-Way Fluid Connector Filter Replacement

7 Unscrew and remove the 3-way fluid connector assembly screw and separate the
two parts of the connector (see Figure 1).

68053

Female part

O-ring gasket

Male part

Feed line Locating lug

Filter

Locating recess

Assembly screw
Figure 1. 3-way fluid connector disassembled
8 Remove and discard the old O-ring gasket from the fluid connector.
9 Remove and discard the old filter from inside the larger of the two parts of the fluid
connector, using the thicker, grooved end of the plastic insert/extract tool supplied
with the new filter.
CAUTION: Contamination of the 3-Way Fluid Connector Filter and O-Ring Gasket. Blockages
and print failures can occur if contamination is allowed to enter the 3-way fluid connector. The
following procedure must be performed in a clean, dust-free environment, and a special Clean
Room is recommended. Maximum care must be taken when the new filter and gasket are fitted.
Use tweezers to carefully hold and fit the components. The new filter and gasket must not
touch any fibres, and contact with the skin must be prevented. Wear powder-free protective
gloves during the procedure. If the standard protective gloves that contain powder are worn,
powder contamination can enter the nozzle assembly.
10 Remove the new filter from its protective bag and examine it for any damage and
contamination.
11 Insert the new filter fully into the fluid connector using the thinner, smooth end of
the insert/extract tool supplied with the new filter.
12 Remove the new O-ring gasket from its protective bag and examine it for any
damage and flash.
13 Using the tweezers, carefully position the new O-ring gasket in the shaped recess in
the larger part of the fluid connector.
14 Fit and hold the two parts of the fluid connector together, making sure that the
locating lug and recess are correctly aligned.

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3-Way Fluid Connector Filter Replacement

15 Refit and fully tighten the fluid connector assembly screw.

NOTE: If the 3-way fluid connector filter replacement is being done as part of the
Scheduled Maintenance, there will be no ink in the tank at this point. Therefore, the
following jet alignment, nozzle cleaning, and leak check must be carried out at a
later stage in the Scheduled Maintenance once the tank has been refilled with ink.
16 Carry out the ‘Jet Alignment and Nozzle Cleaning’ maintenance instruction,
checking the 3-way fluid connector for leaks at the same time.
17 Remove any absorbent material from the ink system enclosure and reposition the
3-way fluid connector back in its original location.
18 Remove the ink and solvent filler caps.
19 Refit the top cover and secure the locking latch.
20 Refit the ink and solvent filler caps.
21 The ‘3-Way Fluid Connector Filter Replacement’ maintenance instruction is now
completed.

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3-Way Fluid Connector Filter Replacement

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7900 Maintenance Instruction
Main Ink Filter Replacement

Parts required
FA73044 Main Ink Filter 10 µm

Equipment required
FA16005 Cover Removal Tool
FA940052 Tube Cutter Plastic 4 mm–14 mm
FA999056 Gloves Nitrile Small 6–6.5 )
FA999057 Gloves Nitrile Medium 7–7.5 ) as required
FA999058 Gloves Nitrile Large 8–8.5 )
FA999076 Safety Spectacles Blue
Absorbent, lint-free paper towel
Abrasive paper

Introduction
This maintenance instruction describes the replacement procedure for the main ink filter on
the standard 7900 printer (IP55 and IP65), the 7900 Food Grade printer and the 7900 Spectrum
printer. Where there are differences in the procedure for the 7900 Food Grade and 7900
Spectrum printers, these differences are stated at the applicable points in the instruction.

Procedure

WARNING: HAZARDOUS SUBSTANCES. THIS PRINTER USES SOLVENT AND

SOLVENT-BASED INKS THAT CAN BE HAZARDOUS. THESE INKS AND SOLVENTS ARE
HIGHLY FLAMMABLE, AND THE LIQUID, VAPOUR OR SPRAY CAN CAUSE IRRITATION TO
THE EYES AND SKIN.
WEAR SAFETY EYE GLASSES AND SOLVENT-RESISTANT PROTECTIVE GLOVES WHEN
THERE IS DIRECT CONTACT WITH THE INKS AND SOLVENTS, WHEN WORK IS DONE ON THE
PRINTER, AND WHEN THE PRINTER IS CLEANED.
THERE IS A RISK OF SEVERE IRRITATION AND TEMPORARY (REVERSIBLE) DAMAGE TO
THE EYES, AND IRRITATION OF THE SKIN IF THIS SAFETY WARNING IS IGNORED.
1 Shut down and turn off the printer. Turn off the mains electrical supply and
disconnect the mains electrical supply cable from the printer.
2 Remove the ink and solvent filler caps.
3 Unlock the security latch on the front of the top cover and remove the cover.
4 Temporarily refit the ink and solvent filler caps to reduce evaporation of the ink
and solvent.
5 7900 Spectrum printer only. Remove the ink tank to gain access to the main ink filter
(refer to the ‘Spectrum Ink Tank Removal’ maintenance instruction).
6 Carefully lift the main ink filter clear of the ink system enclosure.
7 Place absorbent, lint-free paper towel under the main ink filter and venturi
manifold to contain any ink that might be spilt.

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Main Ink Filter Replacement

Assembly of the new main ink filter

8 Remove the new filter, two lengths of pipe and two stainless steel inserts from their
packaging.
9 Cut the two lengths of pipe to the following printer-dependent lengths (if
necessary), using the tube cutter to make sure that they are cut cleanly and straight.

MAIN INK FILTER INLET AND OUTLET PIPE LENGTHS

Printer model Filter inlet pipe Filter outlet pipe
(mm) (mm)
Standard 7900 (IP55 & IP65) 120 185
7900 Food Grade 80 185
7900 Spectrum 75 300

Table 1. Main ink filter inlet and outlet pipe lengths

10 Push a stainless steel insert into one end of each of the two lengths of pipe, making
sure that the inserts are pushed in flush with the end of the pipes.
11 Remove the nuts, olives and sleeves from both sides of the new filter and fit them
over the steel insert ends of the pipes, in the correct order (see Figure 1).

Compression nut 6203

Olive
Sleeve
Pipe
Steel insert

Elbow

Figure 1. Correct assembly of the main ink filter fluid connections

12 Insert the correct length of pipe (refer to step 9 and Table 1) into the inlet port of the
new filter until it meets the pipe stop inside the elbow. Do not push the pipe past
the pipe stop.
13 Push the sleeve, olive and nut up to the elbow and screw the nut on until finger
tight.
14 Mark the nut on one face and, using a spanner, tighten it two full turns only. Note
that if the nut reaches the end of the threaded portion of the elbow, the nut has been
over tightened and there is a risk of the elbow shearing.

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Main Ink Filter Replacement

15 Repeat steps 12 to 14 for the outlet port of the new filter using the correct length of
pipe (refer to step 9 and Table 1).

Main ink filter removal

16 Remove the fluid connection from the inlet port (pump side) of the old filter and
disconnect the pipe.
17 Hold the disconnected end of the filter, and pull off the glove from the hand
holding the filter so that the glove turns inside out over the filter (see Figure 2). Fit a
new glove on the bare hand.

68051

Figure 2. One end of the main ink filter enclosed in a protective glove
18 Remove the fluid connection from the outlet port (venturi manifold side) of the old
filter and disconnect the pipe.

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Main Ink Filter Replacement

19 Hold the disconnected end of the filter, and pull off the glove from the hand
holding the filter so that the glove turns inside out over the filter. Both ends of the
filter are now enclosed in gloves (see Figure 3). Dispose of the old filter and fit a
new glove on the bare hand.
68052

Figure 3. Both ends of the main ink filter enclosed in protective gloves

Standard 7900 printer only

20 Remove the fluid connection (blue Festo nut) from the pump outlet and disconnect
the old filter pipe. Discard the pipe and the fluid connection parts for the old filter,
but retain the blue Festo nut and pipe elbow support.
21 Disconnect the old filter pipe from the venturi manifold inlet (cut the pipe off the
metal barb). Discard the pipe and the fluid connection parts for the old filter, but
retain the pipe elbow support.
22 Slide the blue Festo nut that was removed from the pump outlet in step 20 over the
end of the new filter inlet pipe. Push the pipe onto the pump connection (it may
help to grip the pipe with a piece of abrasive paper). Fit and tighten the Festo nut
firmly onto the pump connection.
23 Refit the pipe elbow support to the filter inlet pipe.
24 Connect the outlet pipe of the new filter to the metal barb on the venturi manifold
inlet (it may help to grip the pipe with a piece of abrasive paper).
25 Refit the pipe elbow support to the filter outlet pipe.

7900 Food Grade printer only

20 Disconnect the old filter pipe from the pump outlet T-piece connector (cut the pipe
off the metal barb). Discard the pipe and the fluid connection parts for the old filter,
but retain the pipe elbow support.
21 Disconnect the old filter pipe from the venturi manifold inlet (cut the pipe off the
metal barb). Discard the pipe and the fluid connection parts for the old filter, but
retain the pipe elbow support.

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Main Ink Filter Replacement

22 Connect the inlet pipe of the new filter to the metal barb on the pump outlet T-piece
connector (it may help to grip the pipe with a piece of abrasive paper).
23 Refit the pipe elbow support to the filter inlet pipe.
24 Connect the outlet pipe of the new filter to the metal barb on the venturi manifold
inlet (it may help to grip the pipe with a piece of abrasive paper).
25 Refit the pipe elbow support to the filter outlet pipe.

7900 Spectrum printer only

20 Disconnect the old filter pipe from the pipe size adaptor (cut the pipe off the metal
barb). Discard the pipe and the fluid connection parts for the old filter.
21 Remove the fluid connection (blue Festo nut) from the venturi manifold inlet and
disconnect the old filter pipe. Discard the pipe and the fluid connection parts for
the old filter, but retain the blue Festo nut.
22 Connect the inlet pipe of the new filter to the metal barb on the pipe size adaptor (it
may help to grip the pipe with a piece of abrasive paper).
23 Slide the blue Festo nut that was removed from the venturi manifold inlet in
step 21 over the end of the new filter outlet pipe.
24 Push the pipe onto the venturi manifold connection (it may help to grip the pipe
with a piece of abrasive paper). Fit and tighten the Festo nut firmly onto the venturi
manifold connection.
25 Refit the Spectrum ink tank (refer to the ‘Spectrum Ink Tank Removal’ maintenance
instruction).

All 7900 printers

26 Remove any absorbent material from the ink system enclosure and position the
new main ink filter in its original location.
27 Remove the ink and solvent filler caps.
28 Refit the top cover and secure the locking latch.
29 Refit the ink and solvent filler caps.
30 The ‘Main Ink Filter Replacement’ maintenance instruction is now completed.

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Main Ink Filter Replacement

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7900 Maintenance Instruction
Main Ink Filter Purge

Parts required
0.5 litres of the appropriate ink as required

Procedure

WARNING: HAZARDOUS SUBSTANCES. THIS PRINTER USES SOLVENT AND

SOLVENT-BASED INKS THAT CAN BE HAZARDOUS. THESE INKS AND SOLVENTS ARE
HIGHLY FLAMMABLE, AND THE LIQUID, VAPOUR OR SPRAY CAN CAUSE IRRITATION TO
THE EYES AND SKIN.
WEAR SAFETY EYE GLASSES AND SOLVENT-RESISTANT PROTECTIVE GLOVES WHEN
THERE IS DIRECT CONTACT WITH THE INKS AND SOLVENTS, WHEN WORK IS DONE ON THE
PRINTER, AND WHEN THE PRINTER IS CLEANED.
THERE IS A RISK OF SEVERE IRRITATION AND TEMPORARY (REVERSIBLE) DAMAGE TO
THE EYES, AND IRRITATION OF THE SKIN IF THIS SAFETY WARNING IS IGNORED.

WARNING: LETHAL VOLTAGE HAZARD. DANGEROUS VOLTAGES EXIST IN THIS

EQUIPMENT WHEN ELECTRICAL POWER IS APPLIED.
MAXIMUM CARE MUST BE TAKEN WHEN WORK IS DONE ON THE PRINTER WHILE
ELECTRICAL POWER IS APPLIED AND THE COVER IS REMOVED. THE CORRECT,
STANDARD ELECTRICAL SAFETY PRECAUTIONS MUST BE TAKEN.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS SAFETY
WARNING IS IGNORED.
1 Turn on the printer.
2 Access the Jet Sequences page (Print Monitor > Menu > Maintenance).
3 Highlight the Filter Purge sequence in the list.
4 Press the Start Sequence key to initiate the Filter Purge sequence. During the
sequence, ink is circulated through the ink system primary circuit at a Set Pressure
of 2.11 bar (30.59 p.s.i.) for 5 minutes.
5 While the Filter Purge sequence is running, check for leaks at the main ink filter and
all other fluid connections. If any leaks are observed from the filter connections,
press the Stop Sequence key to stop the pump, and then tighten the appropriate
elbow nut by half a turn. Remember to hold the elbow with a spanner (wrench) to
avoid damage to the filter, and use only fingers to tighten the nut. Repeat the Filter
Purge sequence after tightening the connections.
6 If the System Warning message “3.03 Ink Low” is reported, add another 0.5 litre
bottle of ink to the tank.
7 Turn off the printer.
8 The ‘Main Ink Filter Purge’ maintenance instruction is now completed.

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Main Ink Filter Purge

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7900 Maintenance Instruction
Charge Amplifier Calibration

Parts required
FA16005 Cover Removal Tool
FA940067 Double-Ended Trim Tool
DVM (Digital Voltmeter)

Introduction
Calibration of the Charge Amplifier is required only when the IPM PCB is replaced and
during scheduled maintenance. The Charge Amplifier must not be calibrated when a new
printer is commissioned.
If the software alone is changed, the non-volatile RAM is initialized, which causes the
calibration values to be reset to the default values. Therefore, before the software is
changed, the XCAL125, XCAL255, CALCHG1 and EHTPSU1 values must be noted from
the Charge Calibration page (Print Monitor > Menu > Maintenance) and then entered
again after the software is changed.

Procedure

WARNING: LETHAL VOLTAGE HAZARD. DANGEROUS VOLTAGES EXIST IN THIS

EQUIPMENT WHEN ELECTRICAL POWER IS APPLIED.
MAXIMUM CARE MUST BE TAKEN WHEN WORK IS DONE ON THE PRINTER WHILE
ELECTRICAL POWER IS APPLIED AND THE COVER IS REMOVED. THE CORRECT,
STANDARD ELECTRICAL SAFETY PRECAUTIONS MUST BE TAKEN.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS SAFETY
WARNING IS IGNORED.
1 Make sure that the printer is switched off at the mains electrical supply.
2 Remove the ink and solvent filler caps.
3 Unlock the security latch on the front of the top cover and remove the cover.
Position the cover so that the 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.
5 Turn on the mains electrical supply to the printer and turn on the printer.
IMPORTANT: Leave the printer switched on for at least 30 minutes before proceeding
with the following calibration.
6 Connect the DVM negative lead to a convenient 0 V test point (for example, TP17 or
TP18) and the positive lead to test point TP29 (CHARGE).

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Charge Amplifier Calibration

WARNING: LETHAL VOLTAGE HAZARD. WHEN THE CALIBRATION MODE IS SET TO

‘CALIBRATION’, A MAXIMUM OF 300 V DC IS APPLIED TO THE PRINTHEAD CHARGE
ELECTRODE.
MAKE SURE THAT THE PRINTHEAD COVER TUBE IS CORRECTLY FITTED AND THE
SECURING SCREW IS FIRMLY TIGHTENED BEFORE THE CHARGE CALIBRATION
PROCEDURE IS PERFORMED. DO NOT REMOVE THE PRINTHEAD COVER TUBE DURING THE
CHARGE CALIBRATION PROCEDURE.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS SAFETY
WARNING IS IGNORED.
7 Access the Charge Calibration page (Print Monitor > Menu > Maintenance) and set
the Calibration Mode option to Zero.

69321

Figure 1. Calibration Mode page

8 Adjust VR3 on the IPM PCB to give a reading of 0 volts ±100 mV. Leave the DVM
connected to these test points.
9 Set the Calibration Mode option to Calibration.
10 Enter a value (for example, 30) on the Calibration Value page. Change this value as
necessary to obtain a DVM reading of 125 volts ±0.5 volts. Press the Apply key after
each value change to update the DVM reading.
11 Note the value now displayed on the Calibration Value page.
12 Continue to change the value on the Calibration Value page until the DVM reads
255 volts ±0.5 volts. Press the Apply key after each value change to update the
DVM reading.
13 Note the new value now displayed on the Calibration Value page and press the
OK key.
14 Open the XCAL125 page and enter the value that was noted at step 11, and then
press the OK key.
15 Open the XCAL255 page and enter the value that was noted at step 13, and then
press the OK key.

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Charge Amplifier Calibration

16 Set the Calibration Mode option to Off.

17 Check that the value displayed next to the EHTPSU1 option is the same as the
EHTPSU calibration voltage that is printed on a label attached to the PSU. If the
value is different, open the EHTPSU1 page and enter the correct value.
18 Check that the value displayed next to the CALCHG1 option is the same as the
charge calibration voltage on the printhead conduit label. The charge calibration
voltage is the final three digits of the CAL. CODE on the label. If the value is
different, open the CALCHG1 page and enter the correct value.
19 Turn off the printer.
20 Disconnect the DVM leads from the IPM PCB.
21 Remove the ink and solvent filler caps.
22 Refit the top cover and secure the locking latch.
23 Refit the ink and solvent filler caps.
24 The ‘Charge Amplifier Calibration’ maintenance instruction is now completed.

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Charge Amplifier Calibration

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Pressure Transducer Calibration

Parts required
FA16005 Cover Removal Tool
FA940067 Double-Ended Trim Tool
DVM (Digital Voltmeter)

Introduction
Calibration of the Pressure Transducer is required only when the IPM PCB or Pressure
Transducer is replaced. The Pressure Transducer must not be calibrated when a new
printer is commissioned or during scheduled maintenance.
IMPORTANT: This maintenance instruction describes a static calibration procedure.
During manufacturing a dynamic calibration procedure is used, therefore,
there can be a difference in calibration settings between printers when new
printers are received. New printers must not be calibrated when
commissioned.
See Service Bulletin SB0675 Issue 2 or later for more information.

Procedures

WARNING: LETHAL VOLTAGE HAZARD. DANGEROUS VOLTAGES EXIST IN THIS

EQUIPMENT WHEN ELECTRICAL POWER IS APPLIED.
MAXIMUM CARE MUST BE TAKEN WHEN WORK IS DONE ON THE PRINTER WHILE
ELECTRICAL POWER IS APPLIED AND THE COVER IS REMOVED. THE CORRECT,
STANDARD ELECTRICAL SAFETY PRECAUTIONS MUST BE TAKEN.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS SAFETY
WARNING IS IGNORED.
1 Make sure that the printer is switched off at the mains electrical supply.
2 Remove the ink and solvent filler caps.
3 Unlock the security latch on the front of the top cover and remove the cover.
Position the cover so that the 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.
5 Turn on the mains electrical supply to the printer and turn on the printer.
6 Set the digital volt meter (DVM) to DC Volts. Connect the DVM negative lead to a
convenient 0 V test point (for example, TP17 or TP18) and the positive lead to TP11
(READPRESS) on the IPM PCB.
7 Turn VR2 on the IPM PCB anticlockwise (using the double-ended trim tool) until
the DVM reading is greater than 1 volt.
8 Slowly turn VR2 clockwise until the calibration value shown on the pressure
transducer label is indicated on the DVM, with a tolerance of ±2 millivolts.
9 Turn off the printer.
10 Disconnect the DVM.
11 The ‘Pressure Transducer Calibration’ maintenance instruction is now completed.

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Printhead Valves Tests

Parts required
FA999056 Gloves Nitrile Small 6–6.5 )
FA999057 Gloves Nitrile Medium 7–7.5 ) as required
FA999058 Gloves Nitrile Large 8–8.5 )
FA999076 Safety Spectacles Blue

Procedures

WARNING: HAZARDOUS SUBSTANCES. THIS PRINTER USES SOLVENT AND

SOLVENT-BASED INKS THAT CAN BE HAZARDOUS. THESE INKS AND SOLVENTS ARE
HIGHLY FLAMMABLE, AND THE LIQUID, VAPOUR OR SPRAY CAN CAUSE IRRITATION TO
THE EYES AND SKIN.
WEAR SAFETY EYE GLASSES AND SOLVENT-RESISTANT PROTECTIVE GLOVES WHEN
THERE IS DIRECT CONTACT WITH THE INKS AND SOLVENTS, WHEN WORK IS DONE ON THE
PRINTER, AND WHEN THE PRINTER IS CLEANED.
THERE IS A RISK OF SEVERE IRRITATION AND TEMPORARY (REVERSIBLE) DAMAGE TO
THE EYES, AND IRRITATION OF THE SKIN IF THIS SAFETY WARNING IS IGNORED.

Testing for a leaking Printhead Feed valve

1 Make sure that the printer is switched on.
2 Access the Edit Pressure page (Print Monitor > Menu > Maintenance > Monitor Jet)
and enter the maximum Set Pressure of 4.49 bar (65.00 p.s.i.).

69329

3.37 4.49 3.24 0.00

90 0

Off 0 0

0
0
24

Figure 1. Entering a Set Pressure of 4.49 bar on the Edit Pressure page

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3 Access the Valves page (Print Monitor > Menu > Maintenance).
4 Open the ink system Feed valve by highlighting Feed in the Valves list and pressing
the Open/Close key.

69332

Figure 2. Feed Valve open on the Valves page

5 Remove the printhead cover tube and observe the printhead nozzle for 2 to 3
minutes for leakage. If leakage is not observed, proceed to step 6.
If there is leakage from the nozzle, proceed with the following sub-items:
(a) Close the ink system Feed valve by pressing the Open/Close key.
(b) On the Edit Pressure page, enter a Set Pressure of 0.
(c) Turn off the printer.
(d) Replace the Printhead Feed valve.
(e) Repeat the test from step 1.
6 Close the ink system Feed valve by pressing the Open/Close key.
7 On the Edit Pressure page, enter a Set Pressure of 0.
8 Turn off the printer.
9 Refit and secure the printhead cover tube.
10 The ‘Testing for a Leaking Printhead Feed Valve’ procedure is now completed.

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Printhead Valves Tests

Testing for a leaking Printhead Purge valve

1 Make sure that the printer is switched on.
2 Remove the printhead cover tube.
3 Access the Jet Functions page (Print Monitor > Menu > Maintenance) and start the
jet by pressing the Jet Test – Start key.

69171

Figure 3. Jet Test – Start option on the Jet Functions page

4 While the jet is running, turn off the printer using the mains power supply switch
on the rear panel. The jet should stop abruptly. If the jet decays slowly, the
Printhead Purge valve is leaking. Therefore, the printhead must be replaced, and
the test repeated from step 1.
5 Observe the printhead nozzle for 1 minute for signs of leakage. If leakage is not
observed, proceed to step 6.
If there are signs of leakage, replace the printhead, and then repeat the test from
step 1.
6 Refit and secure the printhead cover tube.
7 The ‘Testing for a Leaking Printhead Purge Valve’ procedure is now completed.

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Ink System Feed Valve Test

Parts required
FA999056 Gloves Nitrile Small 6–6.5 )
FA999057 Gloves Nitrile Medium 7–7.5 ) as required
FA999058 Gloves Nitrile Large 8–8.5 )
FA999076 Safety Spectacles Blue

Procedure

WARNING: HAZARDOUS SUBSTANCES. THIS PRINTER USES SOLVENT AND

SOLVENT-BASED INKS THAT CAN BE HAZARDOUS. THESE INKS AND SOLVENTS ARE
HIGHLY FLAMMABLE, AND THE LIQUID, VAPOUR OR SPRAY CAN CAUSE IRRITATION TO
THE EYES AND SKIN.
WEAR SAFETY EYE GLASSES AND SOLVENT-RESISTANT PROTECTIVE GLOVES WHEN
THERE IS DIRECT CONTACT WITH THE INKS AND SOLVENTS, WHEN WORK IS DONE ON THE
PRINTER, AND WHEN THE PRINTER IS CLEANED.
THERE IS A RISK OF SEVERE IRRITATION AND TEMPORARY (REVERSIBLE) DAMAGE TO
THE EYES, AND IRRITATION OF THE SKIN IF THIS SAFETY WARNING IS IGNORED.

Testing for a leaking Ink System Feed valve (closed)

1 Make sure that the printer is switched on.
2 Access the Edit Pressure page (Print Monitor > Menu > Maintenance > Monitor Jet)
and enter the maximum Set Pressure of 4.49 bar (65.00 p.s.i.).

69329

3.37 4.49 3.24 0.00

90 0

Off 0 0

0
0
24

Figure 1. Entering a Set Pressure of 4.49 bar on the Edit Pressure page

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Ink System Feed Valve Test

3 Access the Valves page (Print Monitor > Menu > Maintenance).
4 Open the Printhead Feed valve by highlighting Printhead Feed in the Valves list
and pressing the Open/Close key.

69345

Figure 2. Printhead Feed valve open on the Valves page

5 Remove the printhead cover tube and observe the printhead nozzle for 2 to 3
minutes for leakage. If leakage is not observed, proceed to step 1.
If there is leakage from the nozzle, proceed with the following sub-items:
(a) Close the Printhead Feed valve by pressing the Open/Close key.
(b) On the Edit Pressure page, enter a Set Pressure of 0.
(c) Turn off the printer.
(d) Replace the ink system Feed valve.
(e) Repeat the test from step 1.
6 Close the Printhead Feed valve by pressing the Open/Close key.
7 On the Edit Pressure page, enter a Set Pressure of 0.
8 Turn off the printer.
9 Refit and secure the printhead cover tube.
10 The ‘Ink System Feed Valve Test’ maintenance instruction is now completed.

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Purge and Gutter Valves Tests

Parts required
FA65022 Fluid Connector 3-Way—Service Accessories
or
FA72150 Fluid Connector 3-Way—Service Accessories—Pigmented
FA74135 M3 x 28 Csk Poz SS Screw—Pack as required
FA74136 Gasket Fluid Connector 3-Way—Pack as required

Equipment required
FA16005 Cover Removal Tool
FA999056 Gloves Nitrile Small 6–6.5 )
FA999057 Gloves Nitrile Medium 7–7.5 ) as required
FA999058 Gloves Nitrile Large 8–8.5 )
FA999076 Safety Spectacles Blue
Absorbent, lint-free paper towel

Procedures

WARNING: HAZARDOUS SUBSTANCES. THIS PRINTER USES SOLVENT AND

SOLVENT-BASED INKS THAT CAN BE HAZARDOUS. THESE INKS AND SOLVENTS ARE
HIGHLY FLAMMABLE, AND THE LIQUID, VAPOUR OR SPRAY CAN CAUSE IRRITATION TO
THE EYES AND SKIN.
WEAR SAFETY EYE GLASSES AND SOLVENT-RESISTANT PROTECTIVE GLOVES WHEN
THERE IS DIRECT CONTACT WITH THE INKS AND SOLVENTS, WHEN WORK IS DONE ON THE
PRINTER, AND WHEN THE PRINTER IS CLEANED.
THERE IS A RISK OF SEVERE IRRITATION AND TEMPORARY (REVERSIBLE) DAMAGE TO
THE EYES, AND IRRITATION OF THE SKIN IF THIS SAFETY WARNING IS IGNORED.

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Purge and Gutter Valves Tests

Testing for a leaking Purge or Gutter valve (closed)

1 Turn on the printer.
2 Access the Jet Functions page (Print Monitor > Menu > Maintenance) and start the
jet by pressing the Jet Test – Start key.

69171

Figure 1. Jet Test – Start option on the Jet Functions page

3 Access the Monitor Jet page (Print Monitor > Menu > Maintenance).
4 Observe the jet parameters. Wait until the Actual TOF reading is within ±0.3% of
the Reference TOF reading, and the Set Pressure reading has stabilized. Note the
Set Pressure reading.
5 Shut down and turn off the printer. Turn off the mains electrical supply and
disconnect the mains electrical supply cable from the printer.
6 Remove the ink and solvent filler caps.
7 Unlock the security latch on the front of the top cover and remove the cover.
Position the cover so that the keyboard can be accessed.
8 Temporarily refit the ink and solvent filler caps to reduce evaporation of the ink
and solvent.
9 Carefully lift the 3-way fluid connector clear of the ink system enclosure.
10 Place absorbent, lint-free paper towel under the 3-way fluid connector to contain
any ink that might be spilt.
11 Unscrew and remove the 3-way fluid connector assembly screw and separate the
two parts of the connector.

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Purge and Gutter Valves Tests

12 Connect the Purge/Gutter Test fluid connector between the printhead and the ink
system parts of the 3-way fluid connector, using the extra screw supplied with the
assembly (Figure 2). Make sure that the O-ring gaskets are fitted to both
connections before assembly to avoid the possibility of leaks. Make sure that the
assembly screws are tight.
NOTE: The purpose of the Purge /Gutter Test fluid connector is to blank off the
purge line.

O-ring gasket
68094
Assembly
screw

O-ring gasket
d
thea
Assembly he Prin
screw To t

Purge line tube

Locating
lug

Locating
m recess
Syste
Ink
m the
Fro
Figure 2. Purge/Gutter Test fluid connector fitted in the 3-way fluid connector
13 Turn on the printer.
14 Access the Jet Functions page (Print Monitor > Menu > Maintenance) and start the
jet by pressing the Jet Test – Start key.
15 Observe the jet parameters. Wait until the Actual TOF reading is within ±0.3% of
the Reference TOF reading, and the Set Pressure reading has stabilized. Note the
Set Pressure reading.
16 If the Set Pressure reading is less than the reading noted at step 4 minus 0.05 bar
(0.77 p.s.i.), the Purge or Gutter valve is leaking. To determine which valve is
leaking, continue from step 18.
17 Otherwise, proceed with the following sub-items:
(a) Shut down the printer.
(b) Disconnect and remove the Purge/Gutter Test fluid connector.
(c) Reconnect the 3-way fluid connector using a new O-ring gasket (supplied in
FA74136 Gasket Fluid Connector 3-way—Pack). Make sure that the assembly
screw is tight.
(d) Proceed to step 21.

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Purge and Gutter Valves Tests

CAUTION: Printhead Damage and Print Failures. The printhead can be damaged or the printer
can fail if the wrong solvent is allowed to enter the ink or solvent tanks. Make sure that the
solvent used during the following procedure is the correct type for the ink and solvent used in
the printer. Use only Linx solvents.
18 Place the free end of the purge line tube in a container of clean solvent (Figure 3). If
solvent is seen to be drawn up the tube, the Gutter valve is leaking and must be
replaced. If solvent is not drawn up the tube, and the Set Pressure values from
step 16 are different, the Purge valve is leaking and must be replaced.

68095

Purge/Gutter Test
fluid connector

Purge line of the

Purge/Gutter Test
fluid connector inserted
in a beaker of solvent

Figure 3. Testing for a leaking Purge or Gutter valve (closed)

19 Repeat this instruction from the beginning after replacing either valve as both
valves may have been leaking.
20 On completion of the test, proceed with the following sub-items:
(a) Shut down the printer.
(b) Disconnect and remove the Purge/Gutter Test fluid connector.
(c) Reconnect the 3-way fluid connector using a new O-ring gasket (supplied in
FA74136 Gasket Fluid Connector 3-way—Pack). Make sure that the assembly
screw is tight.

Testing for a leaking or inoperative Gutter valve (open)

21 Remove the printhead cover tube.
22 Access the Jet Sequences page (Print Monitor > Menu > Maintenance).

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Purge and Gutter Valves Tests

23 Initiate a Nozzle Clear sequence by highlighting Nozzle Clear in the Jet Sequences
list and pressing the Start Sequence key.
69346

Figure 4. Nozzle Clear option on the Jet Sequences page

CAUTION: Printhead Damage and Print Failures. The printhead can be damaged or the printer
can fail if the wrong solvent is allowed to enter the ink or solvent tanks. Make sure that the
solvent used during the following procedure is the correct type for the ink and solvent used in
the printer. Use only Linx solvents.
24 While the Nozzle Clear 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 into the gutter 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 repair either fault, replace the
Gutter valve and repeat the test.
25 Carry out the ‘Jet Alignment and Nozzle Cleaning’ maintenance instruction,
checking the 3-way fluid connector for leaks at the same time.
26 Remove any absorbent material from the ink system enclosure and reposition the
3-way fluid connector back in its original location.
27 Remove the ink and solvent filler caps.
28 Refit the top cover and secure the locking latch.
29 Refit the ink and solvent filler caps.
30 The ‘Purge and Gutter Valves Tests’ maintenance instruction is now completed.

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Purge and Gutter Valves Tests

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Solvent Flush Valve Tests

Parts required
FA16005 Cover Removal Tool
FA999056 Gloves Nitrile Small 6–6.5 )
FA999057 Gloves Nitrile Medium 7–7.5 ) as required
FA999058 Gloves Nitrile Large 8–8.5 )
FA999076 Safety Spectacles Blue

Procedures

WARNING: HAZARDOUS SUBSTANCES. THIS PRINTER USES SOLVENT AND

SOLVENT-BASED INKS THAT CAN BE HAZARDOUS. THESE INKS AND SOLVENTS ARE
HIGHLY FLAMMABLE, AND THE LIQUID, VAPOUR OR SPRAY CAN CAUSE IRRITATION TO
THE EYES AND SKIN.
WEAR SAFETY EYE GLASSES AND SOLVENT-RESISTANT PROTECTIVE GLOVES WHEN
THERE IS DIRECT CONTACT WITH THE INKS AND SOLVENTS, WHEN WORK IS DONE ON THE
PRINTER, AND WHEN THE PRINTER IS CLEANED.
THERE IS A RISK OF SEVERE IRRITATION AND TEMPORARY (REVERSIBLE) DAMAGE TO
THE EYES, AND IRRITATION OF THE SKIN IF THIS SAFETY WARNING IS IGNORED.

Testing for an inoperative Solvent Flush valve

IMPORTANT: Only perform this test after having successfully completed the ‘Purge and
Gutter Valves’ Tests’ maintenance instruction, steps 21 to 30.
1 Shut down and turn off the printer. Turn off the mains electrical supply and
disconnect the mains electrical supply cable from the printer.
2 Remove the ink and solvent filler caps.
3 Unlock the security latch on the front of the top cover and remove the cover.
Position the cover so that the keyboard can be accessed.
4 Temporarily refit the ink and solvent filler caps to reduce evaporation of the ink
and solvent.
5 Turn on the printer.

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Solvent Flush Valve Tests

6 Access the Jet Functions page (Print Monitor > Menu > Maintenance) and start the
jet by pressing the Jet Test – Start key.
69171

Figure 1. Jet Test – Start option on the Jet Functions page

7 When the jet has successfully started, press the red [stop] key on the control panel
to cause a full normal shutdown to occur. During the shutdown sequence, observe
the feed line (red striped pipe) and make sure that it is drained of ink and then
refilled with solvent. Note that the solvent in the tank may not be clear but coloured
slightly with ink. If the feed line is not drained, the Solvent Flush valve may not be
operating. This symptom could be caused by a faulty Solvent Flush valve, but is
more likely to be no solenoid energizing voltage from the IPM PCB.
8 Access the Valves page (Print Monitor > Menu > Maintenance).
9 Test for an audible click when the Solvent Flush valve is opened and closed. To do
this, highlight Solvent Flush in the Valves list and press the Open/Close key twice.
69347

Figure 2. Solvent Flush valve open on the Valves page

10 If the Solvent Flush valve is heard to operate (audible click), the fault is more likely
to be elsewhere in the solvent pick-up circuit. For example, no solvent in the tank; a
blocked solvent pick-up tube filter; inefficient venturi; blocked in-line feed filter. All
possibilities must be investigated before deciding to replace the Solvent Flush valve.
11 Repeat the test after investigating and repairing either fault.

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Solvent Flush Valve Tests

Testing for a leaking Solvent Flush valve

12 Access the Valves page (Print Monitor > Menu > Maintenance).
13 Open the Printhead Feed valve by highlighting Printhead Feed in the Valves list
and pressing the Open/Close key.
14 Access the Jet Sequences page (Print Monitor > Menu > Maintenance).
15 Initiate a Nozzle Clear sequence by highlighting Nozzle Clear in the Jet Sequences
list and pressing the Start Sequence key.
69346

Figure 3. Nozzle Clear option on the Jet Sequences page

16 While the Nozzle Clear sequence is in operation (20 seconds), use a finger to gently
flick the pipe connecting the solvent tank to the Solvent Add and Solvent Flush
valves to cause bubbles to appear (Figure 4). Observe the bubbles, and if movement
is seen in the direction of the Solvent Flush valve, the valve is leaking and must be
replaced.

68104

Solvent Flush
valve

From solvent tank

pick-up tube

Figure 4. Creating bubbles to test the Solvent Flush valve for leaks

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Solvent Flush Valve Tests

17 Turn off the printer.

18 Remove the ink and solvent filler caps.
19 Refit the top cover and secure the locking latch.
20 Refit the ink and solvent filler caps.
21 The ‘Solvent Flush Valve Tests’ maintenance instruction is now completed.

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7900 Maintenance Instruction
Solvent Add Valve Tests

Parts required
FA16005 Cover Removal Tool
FA999056 Gloves Nitrile Small 6–6.5 )
FA999057 Gloves Nitrile Medium 7–7.5 ) as required
FA999058 Gloves Nitrile Large 8–8.5 )
FA999076 Safety Spectacles Blue

Procedures

WARNING: HAZARDOUS SUBSTANCES. THIS PRINTER USES SOLVENT AND

SOLVENT-BASED INKS THAT CAN BE HAZARDOUS. THESE INKS AND SOLVENTS ARE
HIGHLY FLAMMABLE, AND THE LIQUID, VAPOUR OR SPRAY CAN CAUSE IRRITATION TO
THE EYES AND SKIN.
WEAR SAFETY EYE GLASSES AND SOLVENT-RESISTANT PROTECTIVE GLOVES WHEN
THERE IS DIRECT CONTACT WITH THE INKS AND SOLVENTS, WHEN WORK IS DONE ON THE
PRINTER, AND WHEN THE PRINTER IS CLEANED.
THERE IS A RISK OF SEVERE IRRITATION AND TEMPORARY (REVERSIBLE) DAMAGE TO
THE EYES, AND IRRITATION OF THE SKIN IF THIS SAFETY WARNING IS IGNORED.

Testing for a leaking Solvent Add valve

1 Shut down and turn off the printer. Turn off the mains electrical supply and
disconnect the mains electrical supply cable from the printer.
2 Remove the ink and solvent filler caps.
3 Unlock the security latch on the front of the top cover and remove the cover.
Position the cover so that the keyboard can be accessed.
4 Temporarily refit the ink and solvent filler caps to reduce evaporation of the ink
and solvent.
5 Turn on the printer.

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Solvent Add Valve Tests

6 Using a finger, gently flick the pipe connecting the solvent tank to the Solvent Add
and Solvent Flush valves to cause bubbles to appear (Figure 1).

68104

Solvent Flush
valve

From solvent tank

pick-up tube

Figure 1. Creating bubbles to test the Solvent Add valve for leaks
7 Access the Edit Pressure page (Print Monitor > Menu > Maintenance > Monitor Jet)
and enter the maximum Set Pressure of 4.49 bar (65.00 p.s.i.).
69329

3.37 4.49 3.24 0.00

90 0

Off 0 0

0
0
24

Figure 2. Entering a Set Pressure of 4.49 bar on the Edit Pressure page
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, the Solvent Add valve is leaking and must be replaced.

Testing for an inoperative Solvent Add valve

IMPORTANT: Only perform the following test if the ‘Solvent Flush Valve Tests’
maintenance instruction has been successfully completed proving that the
Solvent Flush valve is serviceable.
9 Using a finger, gently flick the pipe connecting the solvent tank to the Solvent Add
and Solvent Flush valves to cause bubbles to appear (Figure 1).

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Solvent Add Valve Tests

10 Access the Edit Pressure page (Print Monitor > Menu > Maintenance > Monitor Jet)
and enter a Set Pressure of 0.9 bar (12.75 p.s.i.).
11 Access the Valves page (Print Monitor > Menu > Maintenance).
12 Open the Solvent Add valve by highlighting Solvent Add in the Valves list and
pressing the Open/Close key.

69348

Figure 3. Solvent Add valve open on the Valves page

13 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 Add valve is
not heard to operate when opened (no audible click), the Solvent Add valve is not
operating. This symptom could be caused by a faulty Solvent Add valve, but is
more likely to be no solenoid energizing voltage from the IPM PCB.
If the bubbles do not move but the Solvent Add valve is heard to operate (audible
click), the fault is more likely to be elsewhere in the solvent pick-up circuit. For
example, no solvent in the tank; a blocked solvent pick-up tube filter; inefficient
venturi. All possibilities must be investigated before deciding to replace the Solvent
Add valve.
14 Repeat the test after investigating and repairing either fault.
15 On the Edit Pressure page, set the Set Pressure to 0.
16 Make sure that the Solvent Add valve is closed by pressing the Open/Close key on
the Valves page to display Closed next to the Solvent Add option.
17 Turn off the printer.
18 Remove the ink and solvent filler caps.
19 Refit the top cover and secure the locking latch.
20 Refit the ink and solvent filler caps.
21 The ‘Solvent Add Valve Tests’ maintenance instruction is now completed.

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Solvent Add Valve Tests

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Jet Alignment and Nozzle Cleaning

Parts required
FA73051 Screw M2 x 6 Pan Poz SS—Pack
FA73052 Washer Shakeproof M2 SS—Pack

Equipment required
FA74046 Nozzle Cleaning Service Accessory
FA900003 Solvent Cleaning Bottle
FA900005 Beaker 0.25 Litre
FA940003 Eyeglass x9 Magnification
FA999056 Gloves Nitrile Small 6–6.5 )
FA999057 Gloves Nitrile Medium 7–7.5 ) as required
FA999058 Gloves Nitrile Large 8–8.5 )
FA999076 Safety Spectacles Blue
Ultrasonic bath
Empty 0.5 litre ink bottle
Beaker, stainless steel or glass
Correct solvent for the printer as required
Clean hot water (preferably deionized)
between 55 °C and 100 °C as required
Absorbent, lint-free paper towel

Procedures

WARNING: HAZARDOUS SUBSTANCES. THIS PRINTER USES SOLVENT AND

SOLVENT-BASED INKS THAT CAN BE HAZARDOUS. THESE INKS AND SOLVENTS ARE
HIGHLY FLAMMABLE, AND THE LIQUID, VAPOUR OR SPRAY CAN CAUSE IRRITATION TO
THE EYES AND SKIN.
WEAR SAFETY EYE GLASSES AND SOLVENT-RESISTANT PROTECTIVE GLOVES WHEN
THERE IS DIRECT CONTACT WITH THE INKS AND SOLVENTS, WHEN WORK IS DONE ON THE
PRINTER, AND WHEN THE PRINTER IS CLEANED.
THERE IS A RISK OF SEVERE IRRITATION AND TEMPORARY (REVERSIBLE) DAMAGE TO
THE EYES, AND IRRITATION OF THE SKIN IF THIS SAFETY WARNING IS IGNORED.
CAUTION: Printhead Damage. Extended contact with solvent can damage the printhead. Do
not put the printhead into solvent to clean it and do not use an ultrasonic bath. These incorrect
methods can cause damage to the printhead and can make your warranty invalid.

Correct jet alignment

1 Turn on the printer.

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Jet Alignment and Nozzle Cleaning

2 Access the Jet Functions page (Print Monitor > Menu > Maintenance) and start the
jet by pressing the Jet Test – Start key.
69171

Figure 1. Jet Test – Start option on the Jet Functions page

3 Remove the printhead cover tube.
4 Examine the alignment of the jet with an eyeglass. The jet should pass exactly
through the centre of the charge electrode and enter the gutter as shown in the
following illustration.

Vertical 50% 50%

gutter alignment
Mk7
Midi 50% The jet must enter
Midi plus the horizontal centre
Ultima 50% of the gutter
Ultima plus

68055

70% 30%

Mk7 50%
Mini
Micro 50%

The jet must pass exactly

through the centre of
the charge electrode
Figure 2. Correct alignment of the jet into the gutter

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Jet Alignment and Nozzle Cleaning

5 Examine the jet to make sure that it is perpendicular to the nozzle face (Figure 3).

Misaligned jet

For correct jet alignment,

this angle must be
90 degrees
6219

Figure 3. Correct alignment of the jet from the nozzle

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

Nozzle Clear sequence

1 Shutdown the jet by pressing the Jet Test – Stop key.
2 Invert the printhead and wrap absorbent, lint-free paper towel around the area
below the nozzle (Figure 5).
3 Access the Jet Sequences page (Maintenance menu).
4 Initiate a Nozzle Clear sequence by highlighting Nozzle Clear in the Jet Sequences
list and pressing the Start Sequence key.
69346

Figure 4. Nozzle Clear option on the Jet Sequences page

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CAUTION: Printhead Damage and Print Failures. The printhead can be damaged or the printer
can fail if the wrong solvent is allowed to enter the ink or solvent tanks. Make sure that the
solvent used during the following procedure is the correct type for the ink and solvent used in
the printer. Use only Linx solvents.
5 While the Nozzle Clear sequence is in operation (20 seconds), apply small amounts
of solvent to the inverted nozzle face. Observe that the solvent is drawn in through
the nozzle (Figure 5).

68056

Take care to build up MIDI

a good coating of
solvent on the nozzle
face, as shown here

Figure 5. Nozzle Clear sequence—applying solvent to the nozzle face

6 When the Nozzle Clear sequence has finished, access the Jet Functions page (Print
Monitor > Menu > Maintenance) and attempt to start the jet by pressing the Jet
Test – Start key.
7 Observe the alignment of the jet. If the jet is misaligned or the nozzle is still blocked,
press the Jet Test – Stop key to stop the jet.
8 Repeat steps 3 to 7 until the jet is perpendicular to the nozzle face, but no more
than a further seven times (that is, a Nozzle Clear sequence with an attempt to
start the jet carried out after each sequence). The Nozzle Clear sequence must not
be performed more than a total of eight times.

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Jet Alignment and Nozzle Cleaning

9 If the jet is now correctly aligned, this maintenance instruction can be terminated.
Shut down and turn off the printer, and refit the printhead cover tube.
10 If after eight Nozzle Clear sequences the jet is still misaligned due to a partial
nozzle blockage or is non-existent, continue with the ‘Nozzle Soaking’ procedure. If
the jet is now perpendicular to the nozzle face (Figure 3) but is misaligned with the
gutter, proceed to the ‘Nozzle Realignment’ part of this maintenance instruction.

Nozzle soak
CAUTION: Contamination of the Printhead Nozzle Assembly. Blockages and print failures can
occur if contamination is allowed to enter the printhead nozzle assembly. The following
procedure must be performed in a clean, dust-free environment, and a special Clean Room is
recommended. Maximum care must be taken when the nozzle assembly is fitted. The pipe on
the rear of the nozzle assembly must not touch any fibres, and contact with the skin must be
prevented. Wear powder-free protective gloves during the following procedure to prevent
contamination of the printhead nozzle assembly. If the standard protective gloves that contain
powder are worn, powder contamination can enter the nozzle assembly.
CAUTION: Printhead Damage and Print Failures. The printhead can be damaged or the printer
can fail if the wrong solvent is allowed to enter the ink or solvent tanks. Make sure that the
solvent used during the following procedure is the correct type for the ink and solvent used in
the printer. Use only Linx solvents.
1 Shut down and turn off the printer.
2 Remove the securing screw from the printhead nozzle protection cover and remove
the cover.
3 Clean the printhead thoroughly with the correct solvent type, paying particular
attention to the nozzle and surrounding area.
4 Remove the two securing screws and shakeproof washers from the nozzle
assembly plate and remove the nozzle assembly. Remove the nozzle O-ring from
the nozzle assembly and retain it 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 6).

6220

Figure 6. Suspending the nozzle in a beaker of solvent

6 Place the beaker in an ultrasonic bath partly filled with water for 20 minutes.
7 Refit the nozzle O-ring to the nozzle assembly, and then refit the nozzle assembly to
the printhead using new securing screws and shakeproof washers. While doing
this, avoid touching the nozzle assembly pipe with fingers.

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Jet Alignment and Nozzle Cleaning

8 Turn on the printer.

9 Access the Jet Functions page (Print Monitor > Menu > Maintenance) and start the
jet by pressing the Jet Test – Start key.
10 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 the jet is now
correctly aligned, this maintenance instruction can be terminated by carrying out
the following sub-items:
(a) Carefully refit the nozzle protection cover making sure that the jet alignment is
not disturbed.
(b) Shut down and turn off the printer.
(c) Refit the printhead cover tube.
11 If the jet is still not perpendicular to the nozzle face (Figure 3), 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.
12 If the jet is perpendicular to the nozzle face but is not correctly aligned into the
gutter, use the procedure described in ‘Nozzle Realignment’.

Nozzle wash
This procedure is intended for use on nozzles that 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: Contamination of the Printhead Nozzle Assembly. Blockages and print failures can
occur if contamination is allowed to enter the printhead nozzle assembly. The following
procedure must be performed in a clean, dust-free environment, and a special Clean Room is
recommended. Maximum care must be taken when the nozzle assembly is fitted. The pipe on
the rear of the nozzle assembly must not touch any fibres, and contact with the skin must be
prevented. Wear powder-free protective gloves during the following procedure to prevent
contamination of the printhead nozzle assembly. If the standard protective gloves that contain
powder are worn, powder contamination can enter the nozzle assembly.
CAUTION: Printhead Damage and Print Failures. The printhead can be damaged or the printer
can fail if the wrong solvent is allowed to enter the ink or solvent tanks. Make sure that the
solvent used during the following procedure is the correct type for the ink and solvent used in
the printer. Use only Linx solvents.

Solvent wash
1 Shut down and turn off the printer.
2 Remove the securing screw from the printhead nozzle protection cover and remove
the cover (if not previously removed).
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 it in a safe place.
4 Wash the nozzle assembly with the same type of solvent that is used in the printer.

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Jet Alignment and Nozzle Cleaning

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
the same type of solvent that is used in the printer.
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
syringe plunger and withdraw it 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 Lift the nozzle assembly out of the solvent, and empty the syringe and nozzle
assembly into the beaker by depressing the plunger to the bottom of the syringe.
10 Dry the nozzle assembly by withdrawing the syringe plunger to suck only air into
the syringe through the nozzle. Depress the syringe plunger again to force air
through the nozzle assembly. Repeat this drying process three times.

Hot water wash

11 Fill a clean beaker or similar container (stainless steel or glass, not plastic) with hot
water (preferably deionized and between 55 °C and 100 °C).
12 Position the nozzle assembly in the water and withdraw the syringe plunger to
draw water back through the nozzle assembly and into the syringe. Depress the
syringe plunger and withdraw it again, with the nozzle assembly remaining in the
water in the beaker. Repeat this operation three times.
13 Lift the nozzle assembly out of the water, and empty the syringe and nozzle
assembly into the beaker 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 must be repeated
until the blockage is cleared.
14 Dry the nozzle assembly by withdrawing the syringe plunger to suck only air into
the syringe through the nozzle. Depress the syringe 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 steps 7 to 10
inclusive.
16 Before refitting the nozzle assembly, the gun assembly must be flushed with ink.
Place the printhead in an empty 0.5 litre ink bottle, making sure 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 Turn on the printer.
18 Access the Edit Pressure page (Print Monitor > Menu > Maintenance > Monitor Jet)
and enter a Set Pressure of 2.11 bar (30.59 p.s.i.).
19 Access the Valves page (Print Monitor > Menu > Maintenance).

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Jet Alignment and Nozzle Cleaning

20 Open the Feed and Printhead Feed valves by highlighting Feed and Printhead
Feed in the Valves list and pressing the Open/Close key for each. Leave the valves
open for 5 seconds, during which time ink is ejected from the nozzle.
69350

Figure 7. Feed and Printhead Feed valves open on the Valves page
21 Press the Valve Reset key to close the valves after 5 seconds.
22 On the Edit Pressure page, set the Set Pressure to 0.
23 Turn off the printer.
24 Remove the printhead from the ink bottle and thoroughly wash the printhead with
the correct solvent type. Pay particular attention to the nozzle assembly and
surrounding area.
25 Disconnect the syringe from the PTFE tube and remove the tube from the pipe at
the rear of the nozzle assembly.
26 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.
27 Turn on the printer
28 Access the Jet Functions page (Print Monitor > Menu > Maintenance) and start the
jet by pressing the Jet Test – Start key.
29 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.
30 If the jet alignment is correct, carefully refit the nozzle protection cover making sure
that the jet alignment is not disturbed.
31 Shut down and turn off the printer.
32 Refit the printhead cover tube.

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Jet Alignment and Nozzle Cleaning

Nozzle realignment
1 Remove the securing screw from the printhead nozzle protection cover and remove
the cover (if not previously removed).
2 The best method to realign the nozzle is to use 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 return to its original position.
Apply a little more force so that the nozzle is deflected, but when released does not
return completely to its original position. Continue to use this method until the jet
is correctly aligned into the gutter, as described in ‘Correct Jet Alignment’ at the
beginning of this maintenance instruction.
3 Shut down the printer and then restart the jet using the [start] key on the control
panel. Repeat this four times to make sure that the jet alignment is maintained, the
jet is stable during the start and stop sequences, and that no warning or fault
messages are reported.
4 Carefully refit the nozzle protection cover and securing screw, making sure that the
jet alignment is not disturbed.
5 Shut down and turn off the printer.
6 Refit the printhead cover tube.
7 The ‘Jet Alignment and Nozzle Cleaning’ maintenance instruction is now
completed.

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7900 Maintenance Instruction
Modulation Range Checks

Parts required
This maintenance instruction checks the quality of the printed message and makes sure that
the Reference Modulation value is set so that optimum print quality is maintained with
varying ink viscosity. It can also be used to assess the relative viscosity of the ink.

Procedure
1 Turn on the printer.
2 Access the Test Message page (Print Monitor > Menu > Maintenance).
3 Create a test message by highlighting the biggest available message type (raster) in
the Test Message list and pressing the Create key.
69352

Figure 1. Creating a test message on the Test Message page

4 Select the test message on the Message Store page (Print Monitor).

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Modulation Range Checks

5 Access the Jet Functions page (Print Monitor > Menu > Maintenance) and start the
jet by pressing the Jet Test – Start key, and then press the Start Print key.
69171

69650

Figure 2. Jet Test – Start and Start Print options on the Jet Functions page
6 Access the Monitor Jet page (Print Monitor > Menu > Maintenance) and note the
Reference Modulation value (circled in Figure 3). Also note the Actual Modulation
value (displayed in the box to the right of the Reference Modulation) so that it can
be reset to this at the end of the procedure.
69354

3.37 3.04 3.24 3.04

90 67

1262 1261

15
0
24

Figure 3. Reference Modulation value on the Monitor Jet page

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Modulation Range Checks

7 Access the Edit Modulation page (Print Monitor > Menu > Maintenance > Monitor
Jet).
69176

3.37 3.04 3.24 3.04

90 67

1262 1261

15
0
24

Figure 4. Changing the Actual Modulation value on the Edit Modulation page
8 Carry out a modulation range analysis using the following method. Produce a
series of print samples, starting at the original Reference Modulation value and
then decreasing the Actual Modulation value in steps of 10 volts on the Edit
Modulation page. Press the Back key after each value change. Continue to decrease
the Actual Modulation until the print quality just starts to deteriorate (see Figure 5),
and record the value (Vm1). Then increase the Actual Modulation from the original
Reference Modulation value in steps of 10 volts. Continue to increase the Actual
Modulation until the print quality just starts to deteriorate (see Figure 6), or until
the maximum of 255 is reached, and record the value (Vm2).
NOTE: It may be that the maximum setting for Vm2 is reached without there being
evidence of over modulation. In this case record Vm2 as the maximum
value. The same applies to under modulation.
48168

Figure 5. Under modulation—expected deterioration when Reference Mod is < Vm1

48169

Figure 6. Over modulation—expected deterioration when Reference Mod is > Vm2

9 Check that the original Reference Modulation value is approximately equal to the
calculated modulation, as follows:
68092

Vmc = Vm1 + (Vm2 – Vm1)

3

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Modulation Range Checks

10 Record the calculated value (Vmc) on the Scheduled Maintenance Checklist.

11 On the Edit Modulation page, reset the Actual Modulation to the original value
noted in step 6 and press the Automatic Tracking key.

Evaluating the relative viscosity

12 Compare the Reference Modulation with the calculated modulation (Vmc):
(Vmc) = Ref Modulation viscosity is correct.
(Vmc) < Ref Modulation viscosity is low but no action is required.
(Vmc) << Ref Modulation viscosity is too low. If the printer is failing,
change the ink.
(Vmc) > Ref Modulation viscosity is high but no action is required.
(Vmc) >> Ref Modulation viscosity is too high. If the printer is failing,
change the ink.

13 If the printer has been failing because the ink viscosity is too low or too high,
appropriate action must be taken to determine the root cause of the viscosity
problem.
14 The ‘Modulation Range Checks’ maintenance instruction is now completed.

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Blocked Gutter Clearance

Parts required
FA65022 Fluid Connector 3-Way—Service Accessories
or
FA72150 Fluid Connector 3-Way—Service Accessories—Pigmented
FA74135 M3 x 28 Csk Poz SS Screw—Pack as required
FA74136 Gasket Fluid Connector 3-Way—Pack as required

Equipment required
FA16005 Cover Removal Tool
FA900003 Solvent Cleaning Bottle
FA999056 Gloves Nitrile Small 6–6.5 )
FA999057 Gloves Nitrile Medium 7–7.5 ) as required
FA999058 Gloves Nitrile Large 8–8.5 )
FA999076 Safety Spectacles Blue
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 forces ink out of the gutter (that
is, 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.
IMPORTANT: The Linx 7900 Solver printer is fitted with the Dynamic Flow Control (DFC)
device. Two fluid pipes connect the DFC module to the printhead gutter
line instead of the gutter restrictor. Because the DFC module is part of the
gutter line, additional steps must be performed if this ‘Blocked Gutter
Clearance’ procedure is done on a 7900 Solver printer. These additional
steps are included in the following procedure at the applicable point. If
these additional steps are ignored, the DFC will be damaged.

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Blocked Gutter Clearance

Procedure

WARNING: HAZARDOUS SUBSTANCES. THIS PRINTER USES SOLVENT AND

SOLVENT-BASED INKS THAT CAN BE HAZARDOUS. THESE INKS AND SOLVENTS ARE
HIGHLY FLAMMABLE, AND THE LIQUID, VAPOUR OR SPRAY CAN CAUSE IRRITATION TO
THE EYES AND SKIN.
WEAR SAFETY EYE GLASSES AND SOLVENT-RESISTANT PROTECTIVE GLOVES WHEN
THERE IS DIRECT CONTACT WITH THE INKS AND SOLVENTS, WHEN WORK IS DONE ON THE
PRINTER, AND WHEN THE PRINTER IS CLEANED.
THERE IS A RISK OF SEVERE IRRITATION AND TEMPORARY (REVERSIBLE) DAMAGE TO
THE EYES, AND IRRITATION OF THE SKIN IF THIS SAFETY WARNING IS IGNORED.

WARNING: HIGH-PRESSURE INK JET HAZARD. DURING THE FOLLOWING PROCEDURE INK
IS EJECTED FROM THE PRINTHEAD GUTTER AT MAXIMUM PRESSURE.
WHEN THE PROCEDURE IS BEING PERFORMED, ENCLOSE THE PRINTHEAD IN AN
ACCEPTABLE CONTAINER TO CONTAIN THE INK JET. WEAR SAFETY EYE GLASSES AND
SOLVENT-RESISTANT PROTECTIVE GLOVES.
THERE IS A RISK OF SEVERE IRRITATION AND TEMPORARY (REVERSIBLE) DAMAGE TO
THE EYES, AND IRRITATION OF THE SKIN IF THIS SAFETY WARNING IS IGNORED.
1 Shut down and turn off the printer. Turn off the mains electrical supply and
disconnect the mains electrical supply cable from the printer.
2 Remove the ink and solvent filler caps.
3 Unlock the security latch on the front of the top cover and remove the cover.
Position the cover so that the keyboard 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 that might be spilt.
7 Unscrew and remove the 3-way fluid connector assembly screw and separate the
two parts of the connector.

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Blocked Gutter Clearance

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). Make sure that the O-ring gaskets are fitted to both
connections before assembly to avoid the possibility of leaks. Make sure that the
assembly screws are tight.
O-ring gasket
68096
Assembly
screw

O-ring gasket

ead
Assembly eP rinth
screw T o th

Ink system feed line

Locating connected to the
lug printhead gutter line

Locating
recess
System
e Ink
Fro m th

Figure 1. Gutter Clear fluid connector fitted in the 3-way fluid connector

7900 Solver printer only

8a Cut the pipes off the barb connectors as shown in Figure 2 to remove the DFC from
the gutter line. Use a tube cutter to make sure that the pipes are cut cleanly and
straight.

69644

Printhead In-line A1
conduit barb connector

Cut the pipe here

P/HD CONNECTOR

DFC Module
Cut the
GUTTER
pipe here

Figure 2. Removal of the DFC pipe connections

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Blocked Gutter Clearance

8b Connect the pipe from the 3-way fluid connector to the A1 barb connector, as
shown in Figure 3. The DFC is now removed from the gutter line.

69645

Printhead
conduit Connect
this pipe to the
A1 barb connector

P/HD CONNECTOR

DFC Module
GUTTER

Figure 3. Gutter line connection

All 7900 printers

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 Turn on the printer.
12 Access the Edit Pressure page (Print Monitor > Menu > Maintenance > Monitor Jet)
and enter the maximum Set Pressure of 4.49 bar (65.00 p.s.i.).
69329

3.37 4.49 3.24 0.00

90 0

Off 0 0

0
0
24

Figure 4. Entering a Set Pressure of 4.49 bar on the Edit Pressure page
13 Access the Valves page (Print Monitor > Menu > Maintenance).

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14 Open the ink system Feed valve by highlighting Feed in the Valves list and pressing
the Open/Close key. The full force of the maximum running pressure is now
applied to the gutter.
69332

Figure 5. Feed Valve open on the Valves page

15 Leave the Feed valve open until ink is ejected from the gutter or for a maximum of
1 minute. As soon as ink pours from the gutter or 1 minute has elapsed, press the
Valve Reset key to close the valve.
16 On the Edit Pressure page, set the Set Pressure to 0.
17 If the gutter is still blocked after 1 minute, repeat steps 12 to 16. If after this the
gutter is still blocked, the printhead must be replaced.
18 Turn off the printer.
19 Remove the printhead and sealing material from the ink bottle.
CAUTION: Printhead Damage and Print Failures. The printhead can be damaged or the printer
can fail if the wrong solvent is allowed to enter the ink or solvent tanks. Make sure that the
solvent used during the following procedure is the correct type for the ink and solvent used in
the printer. Use only Linx solvents.
20 Thoroughly wash the printhead with the correct solvent type. Pay particular
attention to the gutter assembly area on the printhead.

7900 Solver printer only

20a Cut the pipe at the A1 barb connector and reconnect the pipe to the DFC P/HD
CONNECTOR barb. Use a tube cutter to make sure that the pipe is cut cleanly and
straight.
20b Reconnect the DFC GUTTER pipe to the A1 barb connector.
NOTE: Replacement pipes will be required if this procedure is performed many times,
because the existing pipes can become too short to reconnect to the DFC.

All 7900 printers

21 Disconnect and remove the Gutter Clear fluid connector, and reconnect the 3-way
fluid connector using a new O-ring gasket (supplied in FA74136 Gasket Fluid
Connector 3-Way—Pack). Make sure that the assembly screw is tight.

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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 making sure that the securing screw is fully
tightened.
25 Remove the ink and solvent filler caps.
26 Refit the top cover and secure the locking latch.
27 Refit the ink and solvent filler caps.
28 The ‘Blocked Gutter Clearance’ maintenance instruction is now completed.

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7900 Maintenance Instruction
System Flush

Parts required
FA74005 Damper Drain Tube
FA16005 Cover Removal Tool
FA900005 Beaker 0.25 Litre
FA900003 Solvent Cleaning Bottle
FA940021 Syringe Polypropylene 50 ml as required
FA999056 Gloves Nitrile Small 6–6.5 )
FA999057 Gloves Nitrile Medium 7–7.5 ) as required
FA999058 Gloves Nitrile Large 8–8.5 )
FA999076 Safety Spectacles Blue
Correct solvent for the ink used in the printer as required
Absorbent, lint-free paper towel
Waste container—15 litres capacity
Empty solvent bottle—base removed

Introduction
This maintenance instruction provides the procedures to completely flush a 7900 printer in
the following three circumstances:
 To prepare the printer to be shipped or for storage.
2. To remove contaminated ink.
3. To change an ‘in use’ printer to a new ink, in preparation for calibration.
The detailed ‘System Flush Procedure’ referred to within the individual procedures for the
above circumstances, is provided separately in Part B of this maintenance instruction.
The procedure for purging the main ink filter is referred out to the ‘Main Ink Filter Purge’
maintenance instruction, which is provided earlier in this section of Chapter 5.
It is important to make sure that the procedures outlined in this maintenance instruction are
followed carefully to achieve reliable printer operation.

Printer conditions during the Flush 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 is checked at each stage of the cycle, and the cycle
terminates if the level is low. If this error is detected, the advisory message “Flush Cycle
Stopped” is displayed.
 The cycle terminates with all valves off and zero system pressure.
 The cycle can be terminated by the operator at any stage by pressing the Stop Sequence
key on the System Flush page. This action takes immediate effect, so no advisory message,
such as “Stopping Cycle : Please Wait”, is displayed. It is used for speed in preference to
the mains power supply switch in situations, for example, where a pressurized leak has
occurred. Use of the Stop Sequence key may leave the ink system in an undefined state. If
the cycle is terminated for any reason, the sequence counter is not incremented.

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System Flush

Procedures

WARNING: HAZARDOUS SUBSTANCES. THIS PRINTER USES SOLVENT AND

SOLVENT-BASED INKS THAT CAN BE HAZARDOUS. THESE INKS AND SOLVENTS ARE
HIGHLY FLAMMABLE, AND THE LIQUID, VAPOUR OR SPRAY CAN CAUSE IRRITATION TO
THE EYES AND SKIN.
WEAR SAFETY EYE GLASSES AND SOLVENT-RESISTANT PROTECTIVE GLOVES WHEN
THERE IS DIRECT CONTACT WITH THE INKS AND SOLVENTS, WHEN WORK IS DONE ON THE
PRINTER, AND WHEN THE PRINTER IS CLEANED.
THERE IS A RISK OF SEVERE IRRITATION AND TEMPORARY (REVERSIBLE) DAMAGE TO
THE EYES, AND IRRITATION OF THE SKIN IF THIS SAFETY WARNING IS IGNORED.

Part A—System Flush Circumstances

1. To prepare the printer to be shipped or stored

CAUTION: Printhead Damage and Print Failures. The printhead can be damaged or the printer
can fail if the wrong solvent is allowed to enter the ink or solvent tanks. Make sure that the
solvent used during the following procedure is the correct type for the ink and solvent used in
the printer. Use only Linx solvents.
1 Shut down and turn off the printer. Turn off the mains electrical supply and
disconnect the mains electrical supply cable from the printer.
2 Remove the ink and solvent filler caps.
3 Unlock the security latch on the front of the top cover and remove the cover.
Position the cover so that the keyboard and display can be accessed.
4 Carry out the ‘System Flush Procedure’ described in Part B of this maintenance
instruction (that is, ‘Empty Ink Tank’, ‘Flush Cycle’ and’ Solvent Drain’).
5 Repeat step 4 two more times before proceeding to step 6.
6 Carry out the ‘Empty Ink Tank’ part of the ‘System Flush Procedure’ once more.
The solvent tank should be empty, but if it is not, syphon off any remaining solvent.
7 Reposition the damper back in its original location in the ink system enclosure.
8 Refit the top cover and secure the locking latch.
9 Refit the ink and solvent filler caps.
10 The printer is now flushed ready for packing.

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2. To remove contaminated ink

CAUTION: Printhead Damage and Print Failures. The printhead can be damaged or the printer
can fail if the wrong solvent is allowed to enter the ink or solvent tanks. Make sure that the
solvent used during the following procedure is the correct type for the ink and solvent used in
the printer. Use only Linx solvents.
1 Shut down and turn off the printer. Turn off the mains electrical supply and
disconnect the mains electrical supply cable from the printer.
2 Remove the ink and solvent filler caps.
3 Unlock the security latch on the front of the top cover and remove the cover.
Position the cover so that the keyboard and display can be accessed.
4 Carry out the ‘System Flush Procedure’ described in Part B of this maintenance
instruction (that is, ‘Empty Ink Tank’, ‘Flush Cycle’ and’ Solvent Drain’).
5 Repeat step 4 two more times before proceeding to step 6.
6 Carry out the ‘Empty Ink Tank’ part of the ‘System Flush Procedure’ once more.
The solvent tank should be empty, but if it is not, syphon off any remaining solvent.
7 Replace the main ink filter, ink pick-up tube, feed filter in the 3-way fluid
connector, and printhead Feed valve filter. Maintenance instructions for these
procedures are provided in this section of Chapter 5. Also replace the solvent
pick-up tube, damper, and DFC in-line filter (Solver printer only).
8 The printer can now be recommissioned with fresh ink (one or two bottles, until the
‘ink low’ warning has cleared) and fresh solvent (one or two bottles, until the
‘solvent low’ warning has cleared).
9 Carry out the ‘Main Ink Filter Purge’ maintenance instruction.
NOTE: If the main ink filter or damper do not fill with ink, the pump must be
primed. This must be done with the printer switched off. Insert the nozzle
of the syringe (Linx part number FA940021—Syringe Polypropylene 50 ml)
into the Luer fitting on the damper. Withdraw the syringe plunger to draw
ink through the pump. Continue withdrawing the plunger until ink is
present in the pipe on the outlet side of the pump. Note that the syringe is a
disposable item, with a limited functional life of approximately two
applications when used with solvent-based inks.
10 Carry out at least six Nozzle Clear sequences (refer to the ‘Jet Alignment and
Nozzle Cleaning’ maintenance instruction).
11 Reposition the damper back in its original location in the ink system enclosure.
12 Refit the top cover and secure the locking latch.
13 Refit the ink and solvent filler caps.
14 Press the [start] key to start the jet.
15 The printer is now clear of contaminated ink and ready for use.

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3. To change an ‘in use’ printer to a new ink, in preparation for calibration

1 Shut down and turn off the printer. Turn off the mains electrical supply and
disconnect the mains electrical supply cable from the printer.
2 Remove the ink and solvent filler caps.
3 Unlock the security latch on the front of the top cover and remove the cover.
Position the cover so that the keyboard and display can be accessed.
CAUTION: Printhead Damage and Print Failures. Make sure that the solvent added to the ink
tank during the following process is the correct type for the ink type that is cleared from the
printer.
4 Carry out the ‘System Flush Procedure’ described in Part B of this maintenance
instruction (that is, ‘Empty Ink Tank’, ‘Flush Cycle’ and’ Solvent Drain’).
5 Repeat step 4 two more times before proceeding to step 6.
6 Carry out the ‘Empty Ink Tank’ part of the ‘System Flush Procedure’ once more.
The solvent tank should be empty, but if it is not, syphon off any remaining solvent.
7 Replace the main ink filter and the ink tank pick-up tube. Maintenance instructions
for these tasks can be found earlier in this section of Chapter 5.
CAUTION: Printhead Damage and Print Failures. Make sure that the solvent added to the ink
tank during the following process is the correct type for the ink type that will be added when
the printer is recommissioned.
8 Carry out the ‘System Flush Procedure’ again (that is, ‘Empty Ink Tank’, ‘Flush
Cycle’ and’ Solvent Drain’).
9 Repeat step 8 two more times before proceeding to step 10.
10 Carry out the ‘Empty Ink Tank’ part of the ‘System Flush Procedure’ once more.
The solvent tank should be empty, but if it is not, syphon off any remaining solvent.
11 The printer may now be recommissioned with the new ink (one or two bottles, until
the ‘ink low’ warning has cleared) and the new solvent (one or two bottles, until the
‘solvent low’ warning has cleared).
12 Carry out the ‘Main Ink Filter Purge’ maintenance instruction.
NOTE: If the main ink filter or damper do not fill with ink, the pump must be
primed. This must be done with the printer switched off. Insert the nozzle
of the syringe (Linx part number FA940021—Syringe Polypropylene 50 ml)
into the Luer fitting on the damper. Withdraw the syringe plunger to draw
ink through the pump. Continue withdrawing the plunger until ink is
present in the pipe on the outlet side of the pump. Note that the syringe is a
disposable item, with a limited functional life of approximately two
applications when used with solvent-based inks.
13 Carry out at least six Nozzle Clear sequences (refer to the ‘Jet Alignment and
Nozzle Cleaning’ maintenance instruction).
14 Access the Jet Functions page (Print Monitor > Menu > Maintenance) and start the
jet by pressing the Jet Test – Start key.
15 Run the jet for 10 minutes.
16 Stop the jet.

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17 Carry out the ‘Empty Ink Tank’ part of the ‘System Flush Procedure’ once more.
NOTE: It is important to make sure that the ink tank, damper, and main ink filter
are drained completely of ink.
18 The printer may now be recommissioned with fresh, new ink (one or two bottles,
until the ‘ink low’ warning has cleared), which must be of the same batch and
viscosity, as marked on the ink bottle label.
NOTE: Steps 11 to 18 must be carried out, despite the apparent duplication of ink
commissioning. These steps help to remove traces of solvent that remain
from the flushing process, which could decrease the viscosity of the ink and
cause incorrect calibration.
19 Repeat the ‘Main Ink Filter Purge’ maintenance instruction.
NOTE: If the main ink filter or damper do not fill with ink, the pump must be
primed. This must be done with the printer switched off. Insert the nozzle
of the syringe (Linx part number FA940021—Syringe Polypropylene 50 ml)
into the Luer fitting on the damper. Withdraw the syringe plunger to draw
ink through the pump. Continue withdrawing the plunger until ink is
present in the pipe on the outlet side of the pump. Note that the syringe is a
disposable item, with a limited functional life of approximately two
applications when used with solvent-based inks.
20 Place an earthed container under the printhead because solvent will be present in
the pipes.
21 Reposition the damper back in its original location in the ink system enclosure.
22 Refit the top cover and secure the locking latch.
23 Refit the ink and solvent filler caps.
24 The printer is now ready for calibration. Refer to the ‘Ink Conversion Calibration
(Offset Calibration)’ maintenance instruction.

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Part B—System Flush Procedure

Precautions
During the system flush, the solvent tank must contain only enough solvent (approximately
600 ml) to successfully complete the task. Too much solvent in the solvent tank may result
in the ink tank overflowing during the cycle, due to solvent being dumped into the ink tank
as solvent is used to fill the system. Therefore, fill the solvent tank just until the System
Warning message “3.04 Solvent Low” is cleared. This may require drawing off some
solvent first to see the warning message appear, and then refilling with solvent until the
warning message clears.
As a precaution, fit an empty solvent bottle (with its base removed) to the ink tank filler
tube during the flush cycles in case the tank overflows. Also, it is advisable to put the
printhead in a beaker to contain any spillage from the nozzle.
NOTE: The ‘Flush Cycle’ part of the ‘System Flush Procedure’ thoroughly flushes all the
valves and pipework with solvent.

Empty Tank
1 Turn on the printer.
2 Select the System Flush option on the Maintenance page (Print Monitor > Menu >
Maintenance). The first page of the System Flush procedure is displayed with the
instruction “Check solvent level.”.
69183

Figure 1. System Flush—first page

3 To continue with the System Flush procedure, it is necessary to perform a number
of actions on the printer before the flush cycles can begin. These required actions
are displayed on each successive System Flush page, and must be performed in
accordance with the following expanded explanations for each instruction. Once
each action has been completed, press the OK key, which displays the next
instruction.
4 Check solvent level. Carry out the actions described in ‘Precautions’ at the
beginning of this ‘Part B—System Flush Procedure’.

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5 Prop up the printer. (Not applicable to the 7900 Spectrum printer—see NOTE
below.) Before commencing the ink draining procedure, the printer must be raised
by approximately 50 mm at the front left side to aid drainage of the ink. This is
because the ink pick-up tube is situated at the rear right side of the tank.
NOTE: The 7900 Spectrum printer does not require propping up, but the OK key
must be pressed to continue the procedure.

WARNING: LETHAL VOLTAGE HAZARD. DANGEROUS VOLTAGES EXIST IN THIS

EQUIPMENT WHEN ELECTRICAL POWER IS APPLIED.
MAXIMUM CARE MUST BE TAKEN WHEN WORK IS DONE ON THE PRINTER WHILE
ELECTRICAL POWER IS APPLIED AND THE COVER IS REMOVED. THE CORRECT,
STANDARD ELECTRICAL SAFETY PRECAUTIONS MUST BE TAKEN.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS SAFETY
WARNING IS IGNORED.
6 Orientate filter and damper. Ignore the instruction regarding the filter. Carefully
lift the feed damper and cable tie off the hook on the side of the ink system
enclosure. Hold the feed damper in the vertical position with the drain cap
uppermost.
7 Connect bleed line to damper. Remove the damper drain cap and connect the
damper drain tube to the damper drain. Insert the other end of the drain tube into a
waste container of at least 5 litres capacity. Orientate the damper so that the drain is
at the bottom, that is, at its lowest position, as shown in the following two
illustrations.

79087

Drain tube

Figure 2. Damper orientation and drain tube—standard 7900

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68050

Drain tube

Figure 3. Damper orientation and drain tube—7900 Food Grade and 7900 Spectrum
8 When the required actions have been completed, the following page is displayed.
69184

Figure 4. System Flush options page

9 Press the Empty Tank key, which displays the instruction “Turn on tap to bleed
line.”.
IMPORTANT: The bleed line tap is used in the Linx manufacturing process only.
There is no bleed line in the maintenance technician’s damper
drain tube kit, therefore, any action referring to the bleed line tap
should be ignored.
10 Due to the unique design of the 7900 Spectrum ink tank, it is not possible to drain all
of the ink with the Empty Tank function. Therefore, to enable all of the ink to be
removed, proceed with the following step 10 sub-items.

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7900 Spectrum printer only

10a Disconnect and remove the ink pick-up pipe, which is connected between the ink
tank lid (Festo connection) and the pump/PRV (pressure relief valve) T-piece.
Discard the pipe but retain the Festo nut.
10b Connect a new 360 mm length of 6 mm OD tube to the pump/PRV T-piece.
10c Remove the mandrel and filter assembly from the ink filler tube using the Mandrel
Extraction Tool.
10d Insert the free end of the new length of pipe into the ink tank and push it down
until it reaches the base of the tank. Hold the pipe in place for the duration of the
Empty Tank sequence to make sure that all the ink is removed.

All 7900 printers

CAUTION: Pump Damage. Do not allow the ink system pump to run in a dry condition. Use the
Empty Tank sequence only the number of times required to empty the system of ink. The pump
must not be run for longer than 30 seconds after the change in the sound of the pump
indicates that cavitation (no ink in the pump) has occurred. Damage to the pump can occur if
the pump is allowed to run continuously in a dry condition.
11 Press the OK key to continue the procedure, which starts the pump and increments
the sequence count by 1. The pump runs at maximum pressure for approximately 1
minute and 40 seconds, and then automatically stops on completion of the Empty
Tank sequence. During the sequence a Progress bar gives an indication of how
much of the sequence has been completed. Press the Stop Sequence key if the
audible pitch of the pump changes indicating that the ink tank is empty.
69307

Figure 5. Empty Tank sequence in progress

12 At some point towards the end of the Empty Tank sequence the ‘ink low’ condition
will be reached. Make sure that the SureFill page is displayed with the System
Warning message “3.03 Ink Low”. Press the Exit key on the SureFill page.
13 Make sure that the ink tank is empty before continuing with the following Flush
Cycle sequence. If the tank is not empty after a single Empty Tank sequence, select
the Empty Tank option again to repeat the sequence. Press the Stop Sequence key
when the audible pitch of the pump changes, indicating that the ink tank is empty.
14 At this point the ink pick-up pipe on the 7900 Spectrum must be reconnected to the
ink pick-up connection on the tank lid. To do this, proceed with the following
step 14 sub-items.

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7900 Spectrum printer only

14a Withdraw the drain pipe from the ink tank and wipe off any surplus ink from the
end.
14b Cut the pipe to a length of 55 mm using the tube cutter.
14c Fit the Festo nut (retained earlier) over the end of the newly cut pipe.
14d Insert the end of the pipe into the ink pick-up connection on the tank lid, and fit and
tighten the Festo nut.
14e Refit the mandrel and filter assembly to the ink filler tube using the Mandrel
Extraction Tool.

All 7900 printers

15 Disconnect the drain tube from the damper and refit the drain cap.
16 Refit the damper and cable tie to the hook on the side of the ink system enclosure.

Flush Cycle
69355

Figure 6. System Flush options page—Empty Tank sequence count of 1

17 Press the Flush Cycle key, which displays the instruction “Turn off bleed tap.”.
18 Ignore the “Turn off bleed tap.” instruction and press the OK key, which displays
the instruction “Fill ink tank with 0.5 litres of solvent”.
CAUTION: Printhead Damage and Print Failures. The printhead can be damaged or the printer
can fail if the wrong solvent is allowed to enter the ink or solvent tanks. Make sure that the
solvent used during the following procedure is the correct type for the ink and solvent used in
the printer. Use only Linx solvents.
19 It is necessary to add solvent to the ink tank before the Flush Cycle can begin. Add
1.0 litre of solvent to the ink tank. If this is the first time the Flush Cycle has been
run (sequence count is 0) and a “3.04 Solvent Low” warning message is displayed,
the Flush Cycle cannot proceed. If necessary, fill the solvent tank just until the “3.04
Solvent Low” warning message is cleared.

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20 Press the OK key to continue, which starts the pump and increments the sequence
count by 1. The pump runs at maximum pressure for approximately 1 minute and
40 seconds, and then automatically stops on completion of the Flush Cycle
sequence. During the sequence a Progress bar gives an indication of how much of
the sequence has been completed. The Flush Cycle sequence can be terminated at
any time by pressing the Stop Sequence key.
NOTE: The “3.04 Solvent Low” warning message may be reported during the
Flush Cycle as solvent is used to fill the system. This warning can be
ignored, except when the software does not allow the sequence to continue
and action is required, as described in step 19.

Solvent Drain
69356

Figure 7. System Flush options page—Flush Cycle sequence count of 1

21 Make sure that the drain tube from the damper is disconnected and the damper
drain cap is refitted before proceeding.
22 Press the Solvent Drain key, which displays the instruction “Turn off bleed tap.”.
23 Ignore the “Turn off bleed tap.” instruction and press the OK key, which starts the
pump and increments the sequence count by 1. The pump runs at maximum
pressure for approximately 10 minutes, and then automatically stops on
completion of the Solvent Drain sequence. During the sequence a Progress bar
gives an indication of how much of the sequence has been completed. The Solvent
Drain sequence can be terminated at any time by pressing the Stop Sequence key.
24 When the ‘System Flush Procedure’ is completed, it is necessary to flush the gutter
line (from the gutter through the gutter valve). To do this, first press the Exit key on
the System Flush page to return to the Maintenance page.

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25 Access the Edit Pressure page (Print Monitor > Menu > Maintenance > Monitor Jet)
and enter the maximum Set Pressure of 4.49 bar (65.00 p.s.i.).
69329

3.37 4.49 3.24 0.00

90 0

Off 0 0

0
0
24

Figure 8. Entering a Set Pressure of 4.49 bar on the Edit Pressure page
26 Apply solvent to the gutter using the solvent cleaning bottle until the solvent in the
gutter line flows clear. Note that a minimum of 250 ml of solvent must be used.
27 On the Edit Pressure page, set the Set Pressure to 0.
28 Return to Part A of this maintenance instruction.

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7900 Maintenance Instruction
Ink Conversion Calibration (Offset Calibration)

Parts required
FA20012 Printhead Calibration Label–Pack

Introduction
This maintenance instruction describes the calibration procedure for a 7900 printer fitted
with a Mk7 printhead, following a conversion from one ink type to another. Ink Conversion
tables that show which ink conversions are allowed for each printhead type are available to
Distributors on ExtraLinx. UK customers can contact Linx International Technical Support
for this information.
New printheads and new nozzles are supplied with a calibration sheet, and Reference
Pressure and Reference Modulation Offset Tables, which give offset values for conversion to
(printhead specific) approved inks.
IMPORTANT: It is most important that the Reference Pressure and Reference Modulation
Offset Tables sheet supplied with each individual printhead or nozzle is
retained and filed. If it is required to convert a printer to a different ink in
the future, the offset values from the original sheet for the printhead or
nozzle must be used. However, if the original offset values are not
available or were not supplied, they must be obtained from the Linx
International Technical Support department before a recalibration is done.

Preparation
NOTE: The ‘System Flush’ part of this procedure (referred to below) is not applicable to
new ‘dry’ printers received from Linx when they are first commissioned with ink.
The ‘System Flush’ procedure is only applicable to ‘in use’ printers that have the
ink changed to a different ink in preparation for calibration.
Before this calibration is begun, the printer must be flushed and recommissioned with the
new ink according to the ‘System Flush’ maintenance instruction, which can be found
earlier in this section of Chapter 5.
The procedures described in the following maintenance instruction must be understood
fully and followed carefully to make sure that printer operation is reliable.

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Procedure
1 Carry out the ‘Preparation’ instructions detailed above.
2 Access the Ink/Solvent Type page (Print Monitor > Menu > Setup > Installation >
Ink/Solvent) and select the correct ink type for the ink that the printer is to be
converted to.
3 Access the Printhead Code page (Print Monitor > Menu > Setup > Installation >
Printhead).
4 Adjust the existing Reference Pressure (circled in Figure 1) in accordance with the
‘Reference Pressure Offset (bits)’ value given for the new ink in the offset table
supplied with the printhead or nozzle.
69359

Figure 1. Reference Pressure value on the Printhead Code page

An example of the offset table is shown below.
PRESSURE AND MODULATION OFFSET TABLES
FROM 3103 TO DYE BASED OR PIGMENTED INK TYPES 68723

MkVII ULTIMA (Table Issue No: )

Machine Ink Type 3103 1010 1014 1016 1018 1065 1070 1075 1085 1121 1240 1243 1248 1270 1405 2030 2035 2250 3123 3124 3160 3240 3401

Reference Pressure
– 0 1 13 4 11 –1 7 11 –1 1 1 –8 2 3 1 1 –4 0 0 0 1 8
Offset (bits)

Reference Modulation
– 10 –10 –15 0 –10 –10 0 10 –10 10 10 0 20 5 –22 –22 –10 0 0 0 10 20
Offset (VM + offset) (V)

Modulation Slope 2.5 2.0 2.0 1.0 2.0 1.0 1.5 2.3 1.2 2.0 2.0 2.0 3.5 1.0 1.3 1.4 1.4 2.0 2.5 2.5 2.5 2.0 2.5

4900 Ink Type B B B B B B B B B B B B B B A C C C B B B C B

Table 1. Example of a Reference Pressure and Reference Modulation offset table

NOTE: The Reference Pressure offset is relative to 3103 ink for all Mk7 printheads
except the Mini, where it is relative to 2035 ink.

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The following are two examples of the method:

1. When calibrating a printer fitted with a Mk7 Ultima printhead, after converting
from 3103 to 1270 ink, add 2 bits to the existing 3103 Reference Pressure value.
2. When calibrating a printer fitted with a Mk7 Ultima printhead, after converting
from 1290 to 1240 ink, subtract 6 bits from the existing 1290 Reference Pressure
to obtain the 3103 value, and then add 1 bit to obtain the new 1240 Reference
Pressure value.
5 Adjust the existing Reference Modulation (circled in Figure 2) in accordance with
the ‘Reference Modulation Offset (VM + offset) (V)’ value given for the new ink in
the offset table supplied with the printhead or nozzle.
69360

Figure 2. Reference Modulation value on the Printhead Code page

NOTE: The Reference Modulation offset is relative to 3103 ink for all Mk7
printheads except the Mini, where it is relative to 2035 ink.
The following are two examples of the method:
1. When calibrating a printer fitted with a Mk7 Ultima printhead, after converting
from 3103 to 1270 ink, add 20 volts to the existing 3103 Reference Modulation
value.
2. When calibrating a printer fitted with a Mk7 Ultima printhead, after converting
from 1290 to 1240 ink, add 30 volts to the existing 1290 Reference Modulation to
obtain the 3103 value, and then add 10 volts to obtain the new 1240 Reference
Modulation value.
6 Check the new Reference Modulation value by carrying out a modulation range
analysis in accordance with the ‘Modulation Range Checks’ maintenance
instruction.

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Fitting the flag label

7 Write the following information on a new printhead calibration label:
 The printhead serial number (in the SERIAL NO box).
 The new Reference Pressure followed by the Charge Calibration Factor (in the
CODE box).
 The new Reference Modulation (in the MODULATION box).
 The new ink type (in the INK TYPE box).
 The date of the ink conversion calibration (in the FITTED ON box).
8 Use a damp cloth to remove any dust or dirt from the printhead conduit adjacent to
the existing conduit label, and then dry the conduit with paper towel. Do not use
any solvents to clean the conduit.
9 Remove the backing paper from the completed printhead calibration label and
attach the label to the printhead conduit (as shown in Figure 3) adjacent to the
existing conduit label. The label must be wrapped around the conduit so that it
extends out at 90 degrees, and all written information is covered by the transparent
tail.
6318

Figure 3. Correct fitting of the printhead calibration label on the conduit

10 The ‘Ink Conversion Calibration (Offset Calibration)’ maintenance instruction is
now completed and the printer is now calibrated for use with the new ink.

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Calibrated Nozzle Replacement (Offset Calibration)

Parts required
FA74194 Calibrated Nozzle Assembly 75 µm (for use with non-food grade inks)
or
FA74070 Calibrated Nozzle Assembly 62 µm (for use with non-food grade inks)
or
FA74218 Calibrated Nozzle Assembly 50 µm (for use with non-food grade inks)
or
FA74241 Calibrated Nozzle Assembly 40 µm (for use with non-food grade inks)
plus
FA20012 Printhead Calibration Label–Pack

Equipment required
FA900003 Solvent Cleaning Bottle
FA940003 Eyeglass x9 Magnification
FA999056 Gloves Nitrile Small 6–6.5 )
FA999057 Gloves Nitrile Medium 7–7.5 ) as required
FA999058 Gloves Nitrile Large 8–8.5 )
FA999076 Safety Spectacles Blue
Tweezers
Correct solvent for the printer as required

Introduction
The procedure in this maintenance instruction is primarily used to replace a nozzle on a
Mk7 printhead, in circumstances where it has not been possible to clear a nozzle blockage
after carrying out the full ‘Jet Alignment and Nozzle Cleaning’ maintenance instruction.
This instruction also contains information for recalibrating a 7900 printer to operate with a
new printhead/nozzle combination after a printhead or nozzle replacement.
New printheads and nozzles are supplied with a calibration sheet, and Reference Pressure
and Reference Modulation Offset Tables, which give offset values to be used when the
printhead or nozzle is replaced.
IMPORTANT: It is most important that the Reference Pressure and Reference Modulation
Offset Tables sheet supplied with each individual printhead or nozzle is
retained and filed. If it is required to convert a printer to a different ink in
the future, the offset values from the original sheet for the printhead or
nozzle must be used. However, if the original offset values are not
available or were not supplied, they must be obtained from the Linx
International Technical Support department before a recalibration is done.

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Procedure

WARNING: HAZARDOUS SUBSTANCES. THIS PRINTER USES SOLVENT AND

SOLVENT-BASED INKS THAT CAN BE HAZARDOUS. THESE INKS AND SOLVENTS ARE
HIGHLY FLAMMABLE, AND THE LIQUID, VAPOUR OR SPRAY CAN CAUSE IRRITATION TO
THE EYES AND SKIN.
WEAR SAFETY EYE GLASSES AND SOLVENT-RESISTANT PROTECTIVE GLOVES WHEN
THERE IS DIRECT CONTACT WITH THE INKS AND SOLVENTS, WHEN WORK IS DONE ON THE
PRINTER, AND WHEN THE PRINTER IS CLEANED.
THERE IS A RISK OF SEVERE IRRITATION AND TEMPORARY (REVERSIBLE) DAMAGE TO
THE EYES, AND IRRITATION OF THE SKIN IF THIS SAFETY WARNING IS IGNORED.

Nozzle replacement
1 Shut down and turn off the printer. Turn off the mains electrical supply and
disconnect the mains electrical supply cable from the printer.
2 Remove the printhead cover tube.
3 Remove the securing screw from the printhead nozzle protection cover and remove
the cover.
CAUTION: Contamination of the Printhead Nozzle Assembly. Blockages and print failures can
occur if contamination is allowed to enter the printhead nozzle assembly. The following
procedure must be performed in a clean, dust-free environment, and a special Clean Room is
recommended. Maximum care must be taken when the nozzle assembly is fitted. The pipe on
the rear of the nozzle assembly must not touch any fibres, and contact with the skin must be
prevented. Wear powder-free protective gloves during the following procedure to prevent
contamination of the printhead nozzle assembly. If the standard protective gloves that contain
powder are worn, powder contamination can enter the nozzle assembly.
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.
CAUTION: Nozzle O-Ring Quality. Blockages and print failures can occur if rubber particles
from the new O-ring are allowed to enter the nozzle plate or the gun assembly. Examine the
new O-ring before it is fitted to make sure that the part is clean and not damaged.
6 Carefully remove the new calibrated nozzle assembly and O-ring from the
packaging, and examine them for cleanliness and damage.
CAUTION: Printhead Damage and Print Failures. The printhead can be damaged or the printer
can fail if the wrong solvent is allowed to enter the ink or solvent tanks. Make sure that the
solvent used during the following procedure is the correct type for the ink and solvent used in
the printer. Use only Linx solvents.
7 Thoroughly clean the nozzle assembly plate location and the gun body recess with
solvent.
8 Using the tweezers, carefully place the new O-ring into the recess of the gun body.
9 Position the nozzle assembly on the printhead and loosely refit the two securing
screws and shakeproof washers.

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Calibrated Nozzle Replacement (Offset Calibration)

CAUTION: Nozzle Damage. Damage to the nozzle can occur if tools are used to adjust the
nozzle position. Do not use pliers or any other tool to adjust the nozzle. Use only fingers to
adjust the nozzle until the alignment is correct.
10 Adjust the nozzle alignment until the jewel is visible through the slot in the charge
electrode when viewed from the gutter.
11 Fully tighten the two nozzle assembly securing screws.
12 Turn on the printer.
13 Access the Printhead Code page (Print Monitor > Menu > Setup > Installation >
Printhead).
14 Adjust, if necessary, the existing Reference Pressure (circled in Figure 1) according
to the ‘Reference Pressure Offset (bits)’ value for the ink in use, that is shown in the
offset table supplied with the nozzle.
69359

Figure 1. Reference Pressure value on the Printhead Code page

An example of the offset table is shown below.
PRESSURE AND MODULATION OFFSET TABLES
FROM 3103 TO DYE BASED OR PIGMENTED INK TYPES 68723

MkVII ULTIMA (Table Issue No: )

Machine Ink Type 3103 1010 1014 1016 1018 1065 1070 1075 1085 1121 1240 1243 1248 1270 1405 2030 2035 2250 3123 3124 3160 3240 3401

Reference Pressure
– 0 1 13 4 11 –1 7 11 –1 1 1 –8 2 3 1 1 –4 0 0 0 1 8
Offset (bits)

Reference Modulation
– 10 –10 –15 0 –10 –10 0 10 –10 10 10 0 20 5 –22 –22 –10 0 0 0 10 20
Offset (VM + offset) (V)

Modulation Slope 2.5 2.0 2.0 1.0 2.0 1.0 1.5 2.3 1.2 2.0 2.0 2.0 3.5 1.0 1.3 1.4 1.4 2.0 2.5 2.5 2.5 2.0 2.5

4900 Ink Type B B B B B B B B B B B B B B A C C C B B B C B

Table 1. Example of a Reference Pressure and Reference Modulation offset table

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15 Adjust, if necessary, the existing Reference Modulation (circled in Figure 2)

according to the ‘Reference Modulation Offset (VM + offset) (V)’ value for the ink
in use, that is shown in the offset table supplied with the nozzle.
69360

Figure 2. Reference Modulation value on the Printhead Code page

Jet realignment
16 Access the Jet Functions page (Print Monitor > Menu > Maintenance) and start the
jet by pressing the Jet Test – Start key.
69171

Figure 3. Jet Test – Start option on the Jet Functions page

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17 Examine the alignment of the jet with an eyeglass. The jet should pass exactly
through the centre of the charge electrode and enter the gutter as shown in the
following illustration.

Vertical 50% 50%

gutter alignment
Mk7
Midi 50% The jet must enter
Midi plus the horizontal centre
Ultima 50% of the gutter
Ultima plus

68055

70% 30%

Mk7 50%
Mini
Micro 50%

The jet must pass exactly

through the centre of
the charge electrode
Figure 4. Correct alignment of the jet into the gutter
18 If the jet is not correctly aligned, the nozzle may require adjustment to realign the
jet. The best method to realign the nozzle is to use 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 return to its original position.
Apply a little more force so that the nozzle is deflected, but when released does not
return completely to its original position. Continue to use this method until the jet
is correctly aligned into the gutter, as shown in Figure 4.
19 Shut down the printer and then restart the jet using the [start] key on the control
panel. Repeat this four times to make sure that the jet alignment is maintained, the
jet is stable during the start and stop sequences, and that no warning or fault
messages are reported.
20 Carefully refit the nozzle protection cover and securing screw, making sure that the
jet alignment is not disturbed.
21 Refit the printhead cover tube.
22 Check the new Reference Modulation value by carrying out a modulation range
analysis in accordance with the ‘Modulation Range Checks’ maintenance
instruction.
23 Shut down and turn off the printer.

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Fitting the flag label

24 Write the following information on a new printhead calibration label:
 The printhead serial number (in the SERIAL NO box).
 The new Reference Pressure followed by the Charge Calibration Factor (in the
CODE box).
 The new Reference Modulation (in the MODULATION box).
 The new ink type (in the INK TYPE box).
 The date of the ink conversion calibration (in the FITTED ON box).
25 Use a damp cloth to remove any dust or dirt from the printhead conduit adjacent to
the existing conduit label, and then dry the conduit with paper towel. Do not use
any solvents to clean the conduit.
26 Remove the backing paper from the completed printhead calibration label and
attach the label to the printhead conduit (as shown in Figure 5) adjacent to the
existing conduit label. The label must be wrapped around the conduit so that it
extends out at 90 degrees, and all written information is covered by the transparent
tail.
6318

Figure 5. Correct fitting of the printhead calibration label on the conduit

27 The ‘Calibrated Nozzle Replacement (Offset Calibration)’ maintenance instruction
is now completed.

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Positive Air Pump Installation

Parts required
FA67050 Positive Air Upgrade Internal

Equipment required
FA16005 Cover Removal Tool
FA940052 Tube Cutter Plastic 4 mm–14 mm

Introduction
The printhead positive air pump assembly is fitted in different positions in the 7900 IP65
and IP55 printers. This maintenance instruction describes how to fit the positive air pump
to both types of printer.

Procedure

WARNING: LETHAL VOLTAGE HAZARD. DANGEROUS VOLTAGES EXIST IN THIS

EQUIPMENT WHEN ELECTRICAL POWER IS APPLIED.
TURN OFF AND DISCONNECT THE PRINTER FROM THE MAINS ELECTRICAL SUPPLY
BEFORE THE COVER IS OPENED.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS SAFETY
WARNING IS IGNORED.

7900 IP65 printer

1 Shut down and turn off the printer. Turn off the mains electrical supply and
disconnect the mains electrical supply cable from the printer.
2 Remove the ink and solvent filler caps.
3 Unlock the security latch on the front of the top cover and remove the cover.

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4 Temporarily refit the ink and solvent filler caps to reduce evaporation of the ink
and solvent.

79068

Yellow-striped
positive air pipe

To PL9 on the
IPM PCB

Positive
air pump

A1–C1 barb

Securing nut (x2)

Figure 1. Connecting and fitting the printhead positive air pump—IP65 printer
5 Fit the pump assembly onto the two posts on the side of the air filter housing below
the cooling fan, in the orientation shown in Figure 1. Fit the two M3 Nyloc nuts
supplied in the kit.
6 Locate the coiled, yellow-striped positive air pipe, which is part of the printhead
conduit. This pipe is routed through the ink system enclosure, and then out
through the middle grommet in the front side of the ink system enclosure (refer to
Figure 1).
7 Remove and discard the cable tie that holds the coiled pipe, and then use the tube
cutter to accurately cut off the protective end cap from the pipe.
8 Connect the pipe to the A1-C1 barb that is fitted to the short pipe on the pump
assembly (refer to the magnified view in Figure 1).
9 Remove the protective dust cap from the inlet port of the pump.

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10 Connect the electrical supply cable for the pump to PL9 on the IPM PCB.
11 Use the cable tie supplied in the kit to attach the electrical cable for the pump to the
cable loom that goes to the IPM PCB. Make sure that the electrical cable is routed
clear of the pump assembly body.
12 Turn on the printer.
13 Remove the printhead cover tube and check for airflow from the positive air pipe
outlet on the printhead (see Figure 2).

68144

Positve air pipe outlet

Figure 2. Printhead positive air pipe outlet

14 Turn off the printer.
15 Refit the printhead cover tube.
16 Remove the ink and solvent filler caps.
17 Refit the top cover and secure the locking latch.
18 Refit the ink and solvent filler caps.
19 The ‘Positive Air Pump Installation’ maintenance instruction is now completed.

7900 IP55 printer

1 Shut down and turn off the printer. Turn off the mains electrical supply and
disconnect the mains electrical supply cable from the printer.
2 Remove the ink and solvent filler caps.
3 Unlock the security latch on the front of the top cover and remove the cover.

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4 Temporarily refit the ink and solvent filler caps to reduce evaporation of the ink
and solvent.

79080

Yellow-striped
positive air pipe

A1–C1
barb

Positive
air pump

Washers and
securing screw (x2)
Figure 3. Connecting and fitting the printhead positive air pump—IP55 printer
5 Put the pump assembly in position on the top of the air filter housing, between the
cooling fan and the EHTPSU, in the orientation shown in Figure 3.
6 Put a spring washer followed by a plain washer onto each of the two M3x10 screws
supplied in the kit.
7 Fit the screws and pump assembly to the air filter housing.
8 Locate the coiled, yellow-striped positive air pipe, which is part of the printhead
conduit. This pipe is routed through the ink system enclosure, and then out
through the middle grommet in the front side of the ink system enclosure (refer to
Figure 1).
9 Remove and discard the cable tie that holds the coiled pipe, and then use the tube
cutter to accurately cut off the protective end cap from the pipe.
10 Connect the pipe to the A1–C1 barb that is fitted to the short pipe on the pump
assembly (refer to Figure 3).
11 Remove the protective dust cap from the inlet port of the pump.
12 Connect the electrical supply cable for the pump to PL9 on the IPM PCB.
13 Use the cable tie supplied in the kit to attach the electrical cable for the pump to the
cable loom that goes to the IPM PCB. Make sure that the electrical cable is routed
clear of the pump assembly body.
14 Turn on the printer.
15 Remove the printhead cover tube and check for airflow from the positive air pipe
outlet on the printhead (see Figure 2).
16 Turn off the printer.
17 Refit the printhead cover tube.

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18 Remove the ink and solvent filler caps.

19 Refit the top cover and secure the locking latch.
20 Refit the ink and solvent filler caps.
21 The ‘Positive Air Pump Installation’ maintenance instruction is now completed.

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Printhead Feed Valve Replacement

Parts required
FA74160 Printhead Valve Assembly Mk7
comprising:
1 x 6800 Micro Valve Body
1 x O-ring
FA74219 Mk7 Printhead Valve Filter Assembly 15 µm (Ultima, Midi, Mini, and
Micro)
comprising:
1 x Feed Filter 15 µm
1 x O-ring
OR
FA74221 Mk7 Printhead Valve Filter Assembly 35 µm (Ultima plus and Midi plus)
comprising:
1 x Feed Filter 35 µm
1 x O-ring

Equipment required
FA940052 Tube Cutter Plastic 4 mm–14 mm
FA999056 Gloves Nitrile Small 6–6.5 )
FA999057 Gloves Nitrile Medium 7–7.5 ) as required
FA999058 Gloves Nitrile Large 8–8.5 )

Procedure

CAUTION: Contamination of the Printhead Feed Valve Components. Blockages and print
failures can occur if contamination is allowed to enter the printhead feed line. The following
procedure must be performed in a clean, dust-free environment, and a special Clean Room is
recommended. Maximum care must be taken when the feed valve assembly, filter and O-ring
are fitted. These components must not touch any fibres, and contact with the skin must be
prevented. Wear powder-free protective gloves during the procedure. If the standard protective
gloves that contain powder are worn, powder contamination can enter the nozzle assembly.
1 Shut down and turn off the printer. Turn off the mains electrical supply and
disconnect the mains electrical supply cable from the printer.

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2 Remove the one or two small cross head securing screw(s) from the printhead
upper cover (see Figure 1 below), and slide the cover back along the conduit to
expose the feed valve assembly.

Printhead upper cover

68800

MIDI

Cross-head
securing screw(s) (x1 or x2)
Figure 1. Printhead upper cover and securing screw(s)
3 Refer to Figure 2 and Figure 3 below for identification of the valve assembly parts
referred to in this procedure.
68801

Pipe
elbow supports
Valve assembly
knurled
connecting nut

Valve assembly Feed Valve

hexagonal-drive solenoid
securing screws
Feed Valve
body

Figure 2. Printhead Feed valve assembly

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Valve assembly
knurled connecting nut Barb connection
68803
Valve solenoid

Valve body

Valve assembly
hexagonal-drive
securing screws

O-ring Filter

Filter housing Valve mounting block

Figure 3. Printhead Feed valve component parts

4 Remove the two hexagonal-drive securing screws from the front face of the feed
valve assembly and carefully ease the assembly away from the valve mounting
block.
5 Carefully remove and discard the O-ring from the valve mounting block.
6 Remove the elbow supports from the ink feed pipe, and carefully cut the pipe off
the barb connection as close as possible to the barb.
7 Unscrew the valve assembly knurled connecting nut from the top of the valve
solenoid, being careful to retain the metal washer, and separate the valve body
from the solenoid.
8 Fit the new valve body from the spare parts pack (FA74160) to the solenoid. Secure
with the knurled nut, making sure that the retained metal washer is in place and
the two parts of the valve assembly are squarely in line with each other.
9 Prepare the end of the ink feed pipe using the tube cutter to make sure that the pipe
is cut cleanly and straight.
10 Connect the ink feed pipe to the valve barb connection.
NOTE: At this stage it is recommended that the feed filter in the valve mounting block is
replaced.

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CAUTION: Contamination from Dried Ink Deposits. Blockages and print failures can occur if
dried ink deposits are allowed to enter the filter housing. During the following process, be very
careful to make sure that ink deposits or build-up do not enter the filter housing.
11 Carefully remove the filter from its housing and discard it.
12 Carefully insert the new filter into its housing and make sure that the notches on
the filter are facing the inside of the valve mounting block. Take care not to damage
the filter when inserting it fully.
13 Refit the elbow supports to the ink feed pipe.
14 Fit the new O-ring (supplied in the spare parts pack FA74160) to the valve
mounting block.
15 Position the valve assembly onto the valve mounting block, and make sure that the
filter and O-ring are correctly seated. Secure the valve assembly using the two
hexagonal-drive screws. Tighten the screws until firm resistance is felt, and then
tighten a further ¼ turn.
16 Slide the printhead upper cover back down the conduit into position, and make
sure that the cover does not trap any wires or pipes. Secure the cover using the one
or two small cross head screw(s).
17 The ‘Printhead Feed Valve Replacement’ maintenance instruction is now
completed.

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Printhead Feed Valve Filter Replacement

Parts required
FA74219 Mk7 Printhead Valve Filter Assembly 15 µm (Ultima, Midi, Mini, and
Micro)
comprising:
1 x Feed Filter 15 µm
1 x O-ring
OR
FA74221 Mk7 Printhead Valve Filter Assembly 35 µm (Ultima plus and Midi plus)
comprising:
1 x Feed Filter 35 µm
1 x O-ring

Equipment required
FA999056 Gloves Nitrile Small 6–6.5 )
FA999057 Gloves Nitrile Medium 7–7.5 ) as required
FA999058 Gloves Nitrile Large 8–8.5 )

Procedure

CAUTION: Contamination of the Printhead Feed Valve Components. Blockages and print
failures can occur if contamination is allowed to enter the printhead feed line. The following
procedure must be performed in a clean, dust-free environment, and a special Clean Room is
recommended. Maximum care must be taken when the feed valve assembly, filter and O-ring
are fitted. These components must not touch any fibres, and contact with the skin must be
prevented. Wear powder-free protective gloves during the procedure. If the standard protective
gloves that contain powder are worn, powder contamination can enter the nozzle assembly.
1 Shut down and turn off the printer. Turn off the mains electrical supply and
disconnect the mains electrical supply cable from the printer.
2 Remove the one or two small cross head securing screw(s) from the printhead
upper cover (see Figure 1 below), and slide the cover back along the conduit to
expose the feed valve assembly.

Printhead upper cover

68800
MIDI

Cross-head
securing screw(s) (x1 or x2)
Figure 1. Printhead upper cover and securing screw(s)

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3 Refer to Figure 2 and Figure 3 below for identification of the valve assembly parts
referred to in this procedure.
68801

Pipe
elbow supports
Valve assembly
knurled
connecting nut

Valve assembly Feed Valve

hexagonal-drive solenoid
securing screws
Feed Valve
body

Figure 2. Printhead Feed valve assembly

Valve assembly
knurled connecting nut Barb connection
68803
Valve solenoid

Valve body

Valve assembly
hexagonal-drive
securing screws

O-ring Filter

Filter housing Valve mounting block

Figure 3. Printhead Feed valve component parts

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4 Remove the two hexagonal-drive securing screws from the front face of the feed
valve assembly and carefully ease the assembly away from the valve mounting
block.
5 Carefully remove and discard the O-ring from the valve mounting block.
CAUTION: Contamination from Dried Ink Deposits. Blockages and print failures can occur if
dried ink deposits are allowed to enter the filter housing. During the following process, be very
careful to make sure that ink deposits or build-up do not enter the filter housing.
6 Carefully remove the filter from its housing and discard it.
7 Carefully insert the new filter into its housing and make sure that the notches on
the filter are facing the inside of the valve mounting block. Take care not to damage
the filter when inserting it fully.
8 Fit the new O-ring (supplied in the spare parts pack FA74219) to the valve
mounting block.
9 Position the valve assembly onto the valve mounting block, and make sure that the
filter and O-ring are correctly seated. Secure the valve assembly using the two
hexagonal-drive screws. Tighten the screws until firm resistance is felt, and then
tighten a further ¼ turn.
10 Slide the printhead upper cover back down the conduit into position, and make
sure that the cover does not trap any wires or pipes. Secure the cover using the one
or two small cross head screw(s).
11 The ‘Printhead Feed Valve Filter Replacement’ maintenance instruction is now
completed.

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Printer Installation

Parts required
FA69446 Linx 7900 Maintenance Manual
MP65317 CIJ Commissioning Procedure (supplied with printer)
FA69315 Linx 5900 & 7900 Quick Start Guide
Linx 5900 & 7900 How To ... guides
FA999056 Gloves Nitrile Small 6–6.5 )
FA999057 Gloves Nitrile Medium 7–7.5 ) as required
FA999058 Gloves Nitrile Large 8–8.5 )
FA999076 Safety Spectacles Blue
Service/Install Report

Procedure

WARNING: HAZARDOUS SUBSTANCES. THIS PRINTER USES SOLVENT AND

SOLVENT-BASED INKS THAT CAN BE HAZARDOUS. THESE INKS AND SOLVENTS ARE
HIGHLY FLAMMABLE, AND THE LIQUID, VAPOUR OR SPRAY CAN CAUSE IRRITATION TO
THE EYES AND SKIN.
WEAR SAFETY EYE GLASSES AND SOLVENT-RESISTANT PROTECTIVE GLOVES WHEN
THERE IS DIRECT CONTACT WITH THE INKS AND SOLVENTS, WHEN WORK IS DONE ON THE
PRINTER, AND WHEN THE PRINTER IS CLEANED.
THERE IS A RISK OF SEVERE IRRITATION AND TEMPORARY (REVERSIBLE) DAMAGE TO
THE EYES, AND IRRITATION OF THE SKIN IF THIS SAFETY WARNING IS IGNORED.

1 Configuration
Configure the printer by entering the supplied Configuration Code on the ID page
(Print Monitor > Menu > Setup > Installation). Also enter the printer serial number
on the ID page.
Refer to the Linx 7900 Maintenance Manual, Chapter 4: ‘System Options’.
2 Installation Parameters
Enter the required parameters on the Installation pages (Date & Time, ID,
Printhead, Ink/Solvent, and Locale pages).
Refer to the Linx 7900 Maintenance Manual, Chapter 4: ‘System Options’.
3 Commissioning
Commission the printer in accordance with the Commissioning Procedure.
4 Installation on the Line
Position the printer on the production line and install the relevant accessories (for
example, cabinet, gantry, product sensor, and line speed detector). Refer also to the
‘Correct Installation of Mk7 Printheads’ maintenance instruction.

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5 Line Parameters
Enter the required parameters on the Line Setup pages (Trigger, Speed, Alarm,
and Power Down pages).
Refer to the Linx 7900 Maintenance Manual, Chapter 4: ‘System Options’.
6 Message Creation
Set the message defaults. Create a template and adjust the print parameters as
necessary.
Refer to the Linx 5900 & 7900 Quick Start Guide and the Linx 5900 & 7900 How To ...
guides.
7 Operator/Supervisor Training
Carry out operator training.
Refer to the Linx 7900 Maintenance Manual, Chapter 8: ‘Training Course Guides’.
8 Password
Set the required password level.
Refer to the ‘Linx 5900 & 7900 How To Change the System Setup’.
9 Documentation
Complete the Service/Install Report making sure that the customer signs the
report.
10 The ‘Printer Installation’ maintenance instruction is now completed.

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Correct Installation of Mk7 Printheads

Parts required
Correct installation and routing is critical to the life and reliability of the conduit. By
adhering to the following basic installation guidelines, the life of the conduit is significantly
increased.
The most important factor limiting the life of a conduit is the minimum bend radius it is
subjected to in an application. The recommendations are therefore to install the printhead
in a manner that maximizes this radius, and to make sure that the bend radius is never less
than the minimum.
This document is divided into three main topics, namely:
 Printhead Choice (for a particular application)
2. Conduit Routing (for particular applications)
3. Printer Position
Topics 1 and 2 are further sub-divided into two categories, dealing with the dynamics of the
application, namely:
 Static applications. The printhead is fixed in position relative to the printer or product
line, and the product moved relative to it. A conveyor line is a typical example.
 Dynamic applications. The printhead is moved relative to a stationary product. A
printhead installed on a traversing system to cross a multi-lane indexing line is a typical
example.

1 Printhead Choice
Linx Mk7 printheads are available in both straight and right-angled designs—it is
important to specify the correct one for the installation. The following diagrams illustrate
some of the factors to consider.

1.1 Printhead choice for static applications

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

The conduit is strained if a There is very little strain if a

straight printhead is used right-angled printhead is used

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AS168

The conduit is strained if a There is very little strain if a

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

AS169

The conduit is strained if a There is very little strain if a

right-angled printhead is used straight printhead is used

AS170

The conduit is strained if a There is very little strain if a

straight printhead is used right-angled printhead is used

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AS171

The conduit is strained if a There is very little strain if a

right-angled printhead is used straight printhead is used

1.2 Printhead choice for dynamic installations

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

The conduit is repeatedly tugged if a The conduit is gently flexed if a

right-angled printhead is used straight printhead is used

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

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2.1 Conduit routing for static applications

The conduit must never be bent to a radius less than 75 mm (measured to the inside of the
conduit). Always select the route to give the most gentle curves on the conduit, supporting
it where necessary.
AS173

The conduit is left to hang down The conduit is supported out of the
towards the production line way of the production line

AS174

The conduit will be crushed when the The conduit lies in a cut-out to prevent it
machine guard is closed being crushed when the guard is closed

AS175

The conduit is forced into a tight bend A conduit support prevents the conduit
over a sharp edge being bent over a sharp edge

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AS176

The conduit is forced into a tight bend A conduit support prevents the conduit
round a sharp edge being bent round a sharp edge

2.2 Conduit routing for dynamic applications

AS177

The conduit is bent tighter than necessary Use a loop of conduit to take up the motion
when the printhead moves. This reduces over the greatest length of conduit. This
reliability improves reliability

AS178

The conduit is pulled tight to prevent it hitting The conduit is supported on rollers to prevent
the web below as the printhead moves it hitting the web below as the printhead moves

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AS179

The conduit is twisted as the printhead The conduit is only bent as the printhead
moves. This reduces reliability moves. This improves reliability

3 Printer Position
The printer must be installed so that the conduit is not bent sharply at the rear of the
printer. Always allow 150 mm clearance for the conduit to bend.
AS180

<150 mm >150 mm

The conduit will be unreliable if it is The conduit will be more reliable if

bent tight, because there is less than there is more than 150 mm behind the
150 mm behind the printer printer for it to bend

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Changing the Orientation of Mk7 Right-Angled P/HDs

Parts required
2.5 mm hexagon key

Introduction
The 2-metre and 4-metre Mk7 right-angled printheads have the facility to orientate the right
angle in any one of eight positions through 360° (that is, at 45° intervals). This allows the
printhead to be correctly installed in any given application, with the minimum strain on the
conduit due to bending. (See also the ‘Correct Installation of Mk7 Printheads’ maintenance
instruction).
This maintenance instruction details the procedure for changing the orientation of the right
angle on Mk7 right-angled printheads.

Procedure
1 Support the printhead in the vertical position, preferably in a Linx Printhead
Mounting Assembly.
Referring to Figure 1
2 Remove the two conduit collar securing screws.
3 Unscrew and remove the four securing screws from the right-angle adaptor top
section, and remove the top section.

Right-angle adaptor
—top section
securing screws

Right-angle adaptor
top section

Gasket

O-ring

Conduit collar

Conduit collar
securing screws

Right-angle
orientation
screw

AS181

Figure 1. Removing the right-angle adaptor top section

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Changing the Orientation of Mk7 Right-Angled P/HDs

Referring to Figure 2
4 Lift the conduit clear of the right-angle adaptor bottom section and hold it in the
vertical position.
5 Unscrew and remove the orientation location screw.

Orientation location screw

Orientation location screw hole

O-ring Right-angle adaptor

bottom section

8 x orientation location
holes at 45° intervals

AS182

Figure 2. Changing the orientation of the right-angle adaptor bottom section

6 Whilst holding the conduit firmly to make sure that it does not twist, rotate the
right-angle adaptor bottom section to the desired position.
7 Align the orientation location screw hole with the nearest of the eight orientation
holes in the printhead body and refit the orientation location screw, making sure
that the O-ring is correctly seated.

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Referring to Figure 1
8 Lay the conduit straight back down in the right-angle adaptor bottom section
making sure that it does not twist.
9 Refit the right-angle adaptor top section and loosely refit the four securing screws,
making sure that the gasket is correctly seated.
10 Refit and tighten the two conduit collar securing screws, making sure that the
O-ring is correctly seated.
11 Fully tighten the four securing screws on the right-angle adaptor top section.
12 The ‘Changing the Orientation of Mk7 Right-Angled Printheads’ maintenance
instruction is now completed.

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Auto Mains Power-Off Bypass Kit Installation

Parts required
FA67058 Auto Mains Power-Off Bypass Kit

Equipment required
FA16005 Cover Removal Tool

Introduction
The purpose of the Auto Mains Power-Off Bypass Kit is to remove the auto Power-Off
facility from the printer to allow it to be integrated into original equipment manufacturer
(OEM) applications. This means that the power control for the printer is provided solely by
the mains power supply switch on the rear panel of the printer.

Procedure

WARNING: LETHAL VOLTAGE HAZARD. DANGEROUS VOLTAGES EXIST IN THIS

EQUIPMENT WHEN ELECTRICAL POWER IS APPLIED.
TURN OFF AND DISCONNECT THE PRINTER FROM THE MAINS ELECTRICAL SUPPLY
BEFORE THE COVER IS OPENED.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS SAFETY
WARNING IS IGNORED.
1 Shut down and turn off the printer. Turn off the mains electrical supply and
disconnect the mains electrical supply cable from the printer.
2 Remove the ink and solvent filler caps.
3 Unlock the security latch on the front of the top cover and remove the cover.
4 Disconnect the Display PCB ribbon cable connectors from PL17 and PL21 on the
IPM PCB.
5 Disconnect the top cover’s earth lead from the push-on blade connector in the base
of the cabinet, and place the top cover safely to one side.
6 Temporarily refit the ink and solvent filler caps to reduce evaporation of the ink
and solvent.

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Auto Mains Power-Off Bypass Kit Installation

Removing the existing auto power on/off cableform

7 Disconnect the Auto Power On/Off Cableform connector PL20 on the IPM PCB,
which is located at the top-left corner of the PCB as viewed from the component
side (see Figure 1, and item ‘A’ in Figure 2 and Figure 3).
NOTE: Figure 2 and Figure 3 show a 6900 printer, but the fitting procedure for the
auto mains power-off bypass kit is the same on 7900 printers.
Auto Power On/Off
connector PL20

69366

Figure 1. Location of the auto power on/off connector PL20 on the IPM PCB
8 Disconnect the four connections on the power on switch at the front of the printer
(labelled ‘B’ in Figure 2 and Figure 3).

69387
B
C
D

A
KEY
A Auto Power On/Off Cableform connector PL20
B Power On Switch
C Low Voltage Power Supply Unit connector
D Mains Power Supply Switch
Figure 2. Printer rear view showing the auto power on/off cableform connections

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Auto Mains Power-Off Bypass Kit Installation

KEY 69388 A
A Auto Power On/Off Cableform connector PL20
B Power On Switch
C Low Voltage Power Supply Unit connector
D Mains Power Supply Switch
D

B
Figure 3. Printer front view showing the auto power on/off cableform connections
9 Disconnect the cableform’s two earth connections from the push-on blade
connectors adjacent to the Power On Switch.
10 Disconnect the cableform connector on the Low Voltage Power Supply Unit
(labelled ‘C’ in Figure 2 and Figure 3).
11 Disconnect the cableform’s four connections (2 x brown and 2 x blue) on the Mains
Power Supply Switch at the rear of the printer, noting the colour coding of these
connections (labelled ‘D’ in Figure 2 and Figure 3).
12 Disconnect the cableform’s three connections (brown, blue, and yellow and green)
from the Mains Filter located below the Mains Power Supply Switch, noting the
colour coding of these connections.
13 Remove the Auto Power On/Off cableform from the printer.
14 Remove the Power On Switch from the front of the printer by unscrewing its
retaining nut.
15 Insert the blanking plug supplied in the spares kit into the vacant hole and secure
with its retaining nut.

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Auto Mains Power-Off Bypass Kit Installation

Connecting the new auto mains power-off bypass cableform (refer to Figure 4)

D
69389

KEY
C To Low Voltage Power Supply Unit connector
D To Mains Power Supply Switch
E To Mains Filter
F To push-on blade earth connectors adjacent to Power On Switch
G Power On Switch blanking plug and retaining nut
Figure 4. Auto mains power-off bypass kit
16 Connect the Auto Mains Power-Off Bypass Cableform’s three connections (brown,
blue, and yellow and green) to the Mains Filter (labelled ‘E’ in Figure 4), making
sure that the colour-coded wires are connected in the same sequence as those
removed.
17 Connect the cableform’s four connections (2 x brown and 2 x blue) to the Mains
Power Supply Switch at the rear of the printer (labelled ‘D’ in Figure 4), making
sure that the colour-coded wires are connected in the same sequence as those
removed.
18 Connect the cableform connector to the Low Voltage Power Supply Unit (labelled
‘C’ in Figure 4).
19 Connect the cableform’s two earth connections to the push-on blade connectors
adjacent to the redundant Power On Switch location (labelled ‘F’ in Figure 4).
20 Fit link LK20 (Power-Off Override) on the IPM PCB.
21 Reconnect the Display PCB ribbon cable connectors to PL17 and PL21 on the IPM
PCB.
22 Reconnect the top cover’s earth lead to the push-on blade connector in the base of
the cabinet.

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23 Remove the ink and solvent filler caps.

24 Refit the top cover and secure the locking latch.
25 Refit the ink and solvent filler caps.
NOTE: Make sure that the customer is made aware that this mains power modification has
been embodied on this printer, which means that the Auto Power-Off facility has
been removed.
26 The ‘Auto Mains Power-Off Bypass Kit Installation’ maintenance instruction is now
complete.

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MidiEC Printhead Cleaning

Parts required
FA69034 Cleaning Swab Pack
FA900003 Solvent Cleaning Bottle
FA900005 Beaker 0.25 Litre
FA999004 Hand Cleaner Reinolen, 100 ml Tube
FA999056 Gloves Nitrile Small 6–6.5 )
FA999057 Gloves Nitrile Medium 7–7.5 ) as required
FA999058 Gloves Nitrile Large 8–8.5 )
FA999076 Safety Spectacles Blue
Food Grade Solvent, 5L

Introduction
For trouble-free operation, the printhead must be kept free of any ink build-up or moisture.
The following cleaning procedure is intended to be used for weekly cleaning, and after any
uncontrolled shutdown (for example, power failure while the jet is running).
A cleaning kit is available from Linx—order as FA69035, 6800EC and 6900 FG Cleaning Kit.
This contains a cleaning swab pack, solvent cleaning bottle, beaker for waste solvent, hand
cleaning cream, nitrile gloves and safety spectacles.

About the cleaning procedure

 The cleaning procedure described in this maintenance instruction applies only to Linx
food grade inks.
 Food grade solvent can take up to 20 minutes to dry completely. The printhead must be
completely dry before starting the printer.
 To minimize startup delays, printhead cleaning should be carried out at the end of the
working shift.
 If ink build-up is observed on the nozzle, use the Nozzle Clear procedure. (Refer to the
‘Nozzle Clear Sequence’ part of the ‘Jet Alignment and Nozzle Cleaning’ maintenance
instruction in this chapter.)

Procedure

WARNING: HAZARDOUS SUBSTANCES. THIS PRINTER USES SOLVENT AND

SOLVENT-BASED INKS THAT CAN BE HAZARDOUS. THESE INKS AND SOLVENTS ARE
HIGHLY FLAMMABLE, AND THE LIQUID, VAPOUR OR SPRAY CAN CAUSE IRRITATION TO
THE EYES AND SKIN.
WEAR SAFETY EYE GLASSES AND SOLVENT-RESISTANT PROTECTIVE GLOVES WHEN
THERE IS DIRECT CONTACT WITH THE INKS AND SOLVENTS, WHEN WORK IS DONE ON THE
PRINTER, AND WHEN THE PRINTER IS CLEANED.
THERE IS A RISK OF SEVERE IRRITATION AND TEMPORARY (REVERSIBLE) DAMAGE TO
THE EYES, AND IRRITATION OF THE SKIN IF THIS SAFETY WARNING IS IGNORED.

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MidiEC Printhead Cleaning

CAUTION: Printhead Damage. Extended contact with solvent can damage the printhead. Do
not put the printhead into solvent to clean it and do not use an ultrasonic bath. These incorrect
methods can cause damage to the printhead and can make your warranty invalid.
CAUTION: Printhead Damage. Only the correct Linx food grade solvent for the ink must be
used with the cleaning swabs supplied with the cleaning kit. The use of any other materials or
fluid can cause damage to the printer and make the Food Grade status invalid.
CAUTION: Print Obstructions. Do not dry the printhead with a cloth or any other material,
because these items can leave fibres that can cause obstructions to the ink jet.
1 Shut down and turn off the printer. Turn off the mains electrical supply and
disconnect the mains electrical supply cable from the printer.
2 Remove the printhead cover tube.
3 Mount the printhead on a washstation, or hold the printhead over a beaker or
suitable container.
4 Remove the dried ink by gently squirting the correct Linx food grade solvent onto
the printhead area shown in Figure 1. Use short bursts, allowing the ink to dissolve
between bursts. Repeat the solvent application until all (or most) of the ink is
removed.

68754

MIDI 62 EC

WASH THIS
AREA ONLY

Figure 1. Area of the printhead to wash with solvent

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MidiEC Printhead Cleaning

5 Squirt more solvent onto the components shown circled in Figure 1. While they are
still wet, use the foam cleaning swabs to gently remove any ink deposits from the
components, as shown in Figure 2.

68780

MIDI 62 EC

THOROUGHLY
CLEAN
ALL THESE
COMPONENTS

Figure 2. Printhead components to clean with the swabs

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MidiEC Printhead Cleaning

6 Pay particular attention to the printhead components and parts that are identified
in Figure 3.

A
68711

D E
Figure 3. Identification of the printhead components
 Charge Electrode (A).
 EHT plate (C)—paying particular attention to the underside of the EHT plate.
 EHT plate mounting pillars (B).
 Deflector and Phase Plate (E)—paying particular attention to the blue face plate
(D).
 Deflector and Phase Plate mounting pillars (F)—paying particular attention to
the sides facing the EHT plate.
 PCB—clean only the area circled in Figure 2.
7 Continue using the solvent and cleaning swabs until any remaining ink deposits
are removed and the components and PCB are clean.
8 Allow a minimum of 10 minutes for the printhead to dry completely before starting
the printer (this may take up to 20 minutes on a cold day). This is important as the
printer may fail on startup if the printhead is not completely dry.

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9 Wash the inside of the printhead cover tube with the correct Linx food grade
solvent, as shown in Figure 4, until all ink is removed. Use the cleaning swabs,
where possible, to remove ink deposits that do not immediately wash off.

Figure 4. Washing the printhead cover tube with solvent

10 Allow a minimum of 10 minutes for the printhead cover tube to dry completely
before refitting it (this may take up to 20 minutes on a cold day).
11 Refit the printhead cover tube and firmly tighten the knurled securing screw.
12 The ‘MidiEC Printhead Cleaning’ maintenance instruction is now completed.

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7900 Maintenance Instruction
Dynamic Flow Control Module Replacement

Parts required
FA67081 Dynamic Flow Control Assembly

Equipment required
FA16005 Cover Removal Tool
FA940052 Tube Cutter Plastic 4 mm–14 mm
FA999056 Gloves Nitrile Small 6–6.5 )
FA999057 Gloves Nitrile Medium 7–7.5 ) as required
FA999058 Gloves Nitrile Large 8–8.5 )
FA999076 Safety Spectacles Blue

Introduction
The Dynamic Flow Control (DFC) option is a factory-fit module that is installed in the ink
system enclosure. The module replaces the function of the standard gutter restrictor in the
printhead gutter line.
This maintenance instruction describes only the replacement procedure for a DFC module
that has a fault. The DFC option cannot be retrofitted, because a Configuration Code is
required to enable the DFC software control, which is entered during manufacturing.
When the DFC module is replaced, the printer venturi also must be replaced with the
venturi supplied in the Dynamic Flow Control Assembly spare part kit.
If the printhead is replaced on a printer that has the DFC module fitted (a 7900 Solver
printer), refer to the replacement procedure in the ‘Printhead Replacement (Printer with
DFC)’ maintenance instruction.

Procedure

WARNING: HAZARDOUS SUBSTANCES. THIS PRINTER USES SOLVENT AND

SOLVENT-BASED INKS THAT CAN BE HAZARDOUS. THESE INKS AND SOLVENTS ARE
HIGHLY FLAMMABLE, AND THE LIQUID, VAPOUR OR SPRAY CAN CAUSE IRRITATION TO
THE EYES AND SKIN.
WEAR SAFETY EYE GLASSES AND SOLVENT-RESISTANT PROTECTIVE GLOVES WHEN
THERE IS DIRECT CONTACT WITH THE INKS AND SOLVENTS, WHEN WORK IS DONE ON THE
PRINTER, AND WHEN THE PRINTER IS CLEANED.
THERE IS A RISK OF SEVERE IRRITATION AND TEMPORARY (REVERSIBLE) DAMAGE TO
THE EYES, AND IRRITATION OF THE SKIN IF THIS SAFETY WARNING IS IGNORED.
1 Shut down and turn off the printer. Turn off the mains electrical supply and
disconnect the mains electrical supply cable from the printer.
2 Remove the ink and solvent filler caps.
3 Unlock the security latch on the front of the top cover and remove the cover.
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 in-line A1 barb connector in the
gutter return line and the 3-way fluid connector to contain any ink that might be
spilt during the following process.

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6 Identify the pipe labelled “GUTTER” on the DFC module. Cut the pipe off the
in-line barb connection in the gutter return line from the printhead, as shown in
Figure 1. Cut the pipe as close as possible to the barb connection and use the tube
cutter to make sure that the pipe is cut cleanly and straight. The gutter line must be
cut on the printhead side of the in-line A1 barb connector, leaving the barb
connector in the end of the gutter line to the DFC module.
69626

Cut the pipe here

Printhead
conduit
In-line A1
barb connector

P/HD CONNECTOR

DFC Module
Cut the
pipe here GUTTER

Figure 1. DFC module removal

7 Identify the pipe labelled “P/HD CONNECTOR” on the DFC module. Cut the pipe
off the barb connector of the gutter return line on the 3-way fluid connector, as
shown in Figure 1.
8 Disconnect the DFC in-line electrical connectors labelled ‘A’, ‘B’ and ‘C’ in Figure 2,
and disconnect the DFC earth blade connector.
NOTE: Figure 2 and Figure 3 show a 6900 printer, but the replacement procedure for the
DFC module is the same on 7900 printers.
(Connector A carries the control signal for the DFC module. Connector B carries the 24
volts supply to the fan. Connector C carries the 24 volts fan supply from the LVPSU.)

69627

DFC module
cableform
B

Location
C of the coiled
positive air pipe
A

Figure 2. DFC module cableform and connectors

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Dynamic Flow Control Module Replacement

9 Uncoil the positive air pipe and remove the pipe from the grommet in the wall of
the ink system enclosure.
10 Remove the DFC module cableform and the grommet from the wall of the ink
system enclosure.
11 Remove the DFC module from the ink system enclosure.
12 Fit the replacement DFC module in its correct location in the ink system enclosure.
13 Route the DFC module cableform as shown in Figure 3 and feed the cableform
through the grommet hole in the wall of the ink system enclosure.
14 Insert the positive air pipe through the grommet, and then fit the DFC module
cableform and the grommet to the wall of the ink system enclosure.

Correct DFC
cableform routing DFC module
69628

Figure 3. DFC module cableform routing

15 Coil the positive air pipe, fit a cable tie and reposition the pipe as shown in Figure 2.
16 Reconnect the DFC in-line electrical connectors labelled ‘A’, ‘B’ and ‘C’ in Figure 2,
and reconnect the DFC earth blade connector.
17 Identify the pipe labelled “P/HD CONNECTOR” on the DFC module. Connect the
pipe to the barb connector for the gutter return line on the 3-way fluid connector.
18 Identify the pipe labelled “GUTTER” on the DFC module (this pipe has an in-line
barb connector inserted in the end). Connect the pipe to the gutter return line from
the printhead.
19 Replace the printer venturi with the venturi supplied in the spare part kit.
20 Remove any absorbent material from the ink system enclosure and put the 3-way
fluid connector back in its original location.
21 Turn on the printer and make sure that the fan operates.

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22 Make sure that the green LED on the DFC module illuminates (that is, in the ‘Idle’
jet state).
23 Start the jet and make sure that the red LED on the DFC module is illuminated
during the jet start sequence (that is, in the ‘Jet Starting’ state).
24 When the jet has started (‘Jet Running’ state) and is running normally, make sure
that the green LED is illuminated. (The green LED illuminates provided that the Set
Pressure is between Reference Pressure and Solvent Add Pressure + 1 bit.)
25 Turn off the printer.
26 Remove the ink and solvent filler caps.
27 Refit the top cover and secure the locking latch.
28 Refit the ink and solvent filler caps.
29 The ‘Dynamic Flow Control Module Replacement’ maintenance instruction is now
completed.

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Printhead Replacement (Printer with DFC)

Parts required
FA74275 DFC/Printhead Signal Wire Connector

Equipment required
FA16005 Cover Removal Tool
FA940052 Tube Cutter Plastic 4 mm–14 mm
FA999056 Gloves Nitrile Small 6–6.5 )
FA999057 Gloves Nitrile Medium 7–7.5 ) as required
FA999058 Gloves Nitrile Large 8–8.5 )
FA999076 Safety Spectacles Blue

Introduction
The Dynamic Flow Control (DFC) option is a factory-fit module that is installed in the ink
system enclosure. The module replaces the function of the standard gutter restrictor in the
printhead gutter line.
If the printhead is replaced on a printer that has the DFC module fitted (a 7900 Solver
printer), the spare part DFC/Printhead Signal Wire Connector (FA74275) is required. This
spare part is an in-line connector with a single wire connected to it and a single pin
connector on the other end.
This maintenance instruction describes only the replacement procedure for a standard
printhead on a printer that has the DFC module fitted.

Procedure

WARNING: HAZARDOUS SUBSTANCES. THIS PRINTER USES SOLVENT AND

SOLVENT-BASED INKS THAT CAN BE HAZARDOUS. THESE INKS AND SOLVENTS ARE
HIGHLY FLAMMABLE, AND THE LIQUID, VAPOUR OR SPRAY CAN CAUSE IRRITATION TO
THE EYES AND SKIN.
WEAR SAFETY EYE GLASSES AND SOLVENT-RESISTANT PROTECTIVE GLOVES WHEN
THERE IS DIRECT CONTACT WITH THE INKS AND SOLVENTS, WHEN WORK IS DONE ON THE
PRINTER, AND WHEN THE PRINTER IS CLEANED.
THERE IS A RISK OF SEVERE IRRITATION AND TEMPORARY (REVERSIBLE) DAMAGE TO
THE EYES, AND IRRITATION OF THE SKIN IF THIS SAFETY WARNING IS IGNORED.
1 Shut down and turn off the printer. Turn off the mains electrical supply and
disconnect the mains electrical supply cable from the printer.
2 Remove the ink and solvent filler caps.
3 Unlock the security latch on the front of the top cover and remove the cover.
4 Temporarily refit the ink and solvent filler caps to reduce evaporation of the ink
and solvent.

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Printhead Replacement (Printer with DFC)

5 Place absorbent, lint-free paper towel under the in-line A1 barb connector in the
gutter return line and the 3-way fluid connector to contain any ink that might be
spilt during the following process.
6 Remove the printhead using the normal procedure for non-DFC printers.
Important additional points are:
(a) Cut the pipes off the two barb connectors as shown in Figure 1.
(b) Cut the pipes as close as possible to the barb connectors and use the tube cutter
to make sure that the pipes are cut cleanly and straight.
(c) The gutter line must be cut on the printhead side of the in-line A1 barb
connector, leaving the barb connector in the end of the gutter line to the DFC
module.
(d) Disconnect the DFC signal wire in-line connector from the DFC module
cableform (connector A in Figure 4).
NOTE: Figure 4 shows a 6900 printer, but the replacement procedure for the printhead
(printer with DFC) is the same on 7900 printers.
69626

Cut the pipe here

Printhead
conduit
In-line A1
barb connector

P/HD CONNECTOR

DFC Module
Cut the
pipe here GUTTER

Figure 1. Printhead removal

7 Fit the new printhead using the normal procedure for non-DFC printers. Connect
all electrical and fluid connections except the printhead connector PL6 on the IPM
PCB.
8 Remove the gutter restrictor from the gutter return line by cutting the pipe as
shown in Figure 2. Cut the pipe as close as possible to the 3-way fluid connector
barb and the gutter restrictor, and use the tube cutter to make sure that the pipes
are cut cleanly and straight. Discard the gutter restrictor.

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Printhead Replacement (Printer with DFC)

69629

Printhead
conduit Cut the pipe here

In-line A1
barb connector

P/HD CONNECTOR

DFC Module
GUTTER

Figure 2. Printhead fitting

9 Identify the pipe labelled “GUTTER” on the DFC module (this pipe has an in-line
barb connector inserted in the end). Connect the pipe to the gutter return line from
the printhead.
10 Identify the pipe labelled “P/HD CONNECTOR” on the DFC module. Connect the
pipe to the barb connector for the gutter return line on the 3-way fluid connector.
11 Insert the pin connector of the ‘DFC/Printhead Signal Wire Connector’ (blue wire)
into position 15 of the printhead connector PL6 (refer to Figure 3). (Position 15 is
above the orange wire.)

Connect blue DFC signal wire

to position 15 on PL6
(above orange wire)

69630

Figure 3. DFC module cableform—location of position 15 on PL6

12 Connect the printhead connector (PL6) to the IPM PCB.

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Printhead Replacement (Printer with DFC)

13 Connect the in-line connector that is on the other end of the ‘DFC/Printhead Signal
Wire Connector’ to the control signal connector of the DFC module (connector A in
Figure 4).

DFC module
cableform
69631

Figure 4. DFC module cableform—control signal connector ‘A’

14 Remove any absorbent material from the ink system enclosure and put the 3-way
fluid connector back in its original location.
15 Remove the ink and solvent filler caps.
16 Refit the top cover and secure the locking latch.
17 Refit the ink and solvent filler caps.
18 The ‘Printhead Replacement (Printer with DFC)’ maintenance instruction is now
completed.

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7900 Maintenance Instruction
Software Upgrade Using the 7900 Boot PROM

Parts required
FA75045 7900 Boot PROM (also called the ‘7900 Recovery EPROM’)

Equipment required
FA16005 Cover Removal Tool
Antistatic Wrist Strap and Lead

Introduction
One of the functions of the Linx Sync Service Tool is to upgrade or reinstall the printer
system software. The Linx Sync Service Tool software program uses the RS232 INTERFACE
connector on the rear panel of the printer and Microsoft® Windows® 2000 or XP
Professional. Other Windows® operating systems and PC outputs may not be compatible
with Linx Sync, or can cause problems.
The Linx Sync Service Tool is required to upgrade to 7900 Version 5.2 System Software (or
to reinstall Versions 5.1 and 5.2). If the Linx Sync Service Tool cannot connect to the printer
through the PC communications port, the following method can be used to upgrade the
printer software.
Linx provides a boot PROM for the 7900 printers that allows a software upgrade to
Version 5.2 to be done from a USB memory device through the printer USB port. The 7900
system software ‘.lsf’ file must be copied from a PC and saved into the folder:
\Linx\7900\FIRMWARE on the USB memory device. There must be only one software
upgrade file saved in the ‘FIRMWARE’ folder.
NOTE: Although the 7900 Boot PROM appears to be the same as earlier Boot PROMs used
to delete corrupt printer software, they do not perform the same function. The 7900
Boot PROM enables a USB update of the printer software without deleting the
system settings and the message store. However, Linx recommends that, as a
precaution, a backup copy is made of the printer settings and created messages
before the upgrade process is started.
Refer to the section ‘Possible problems’ at the end of this maintenance instruction for
information about errors that can occur during the upgrade procedure.

Procedure

WARNING: LETHAL VOLTAGE HAZARD. DANGEROUS VOLTAGES EXIST IN THIS

EQUIPMENT WHEN ELECTRICAL POWER IS APPLIED.
TURN OFF AND DISCONNECT THE PRINTER FROM THE MAINS ELECTRICAL SUPPLY
BEFORE THE COVER IS OPENED.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS SAFETY
WARNING IS IGNORED.

CAUTION: Static-Sensitive Devices. The PCBs contain static-sensitive devices. Take the
following antistatic precautions when PCBs are touched. Wear an antistatic wrist strap and
connect the lead to a good electrical earth. Always hold PCBs by their edges and do not touch
the components, printed circuit tracks or connector pins.

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Software Upgrade Using the 7900 Boot PROM

1 Make a note of the printer configuration code.

2 Use a USB memory device to back up the system settings and created messages.
3 Shut down and turn off the printer. Turn off the mains electrical supply and
disconnect the mains electrical supply cable from the printer.
4 Remove the ink and solvent filler caps.
5 Unlock the security latch on the front of the top cover and remove the cover.
Position the cover so that the display can be seen.
6 Temporarily refit the ink and solvent filler caps to reduce evaporation of the ink
and solvent.
7 Make sure that the 7900 Boot PROM is the latest version.
8 Fit the 7900 Boot PROM to the IC62 socket on the IPM PCB.
9 Fit link LK5 (Monitor) to the IPM PCB.
10 Turn on the printer. When the printer has started, the following message is displayed.
The USB firmware check takes approximately 20 seconds to complete.
79090

Figure 1. “Verifying USB Firmware” message

11 After the USB firmware check, the following instruction is displayed.
79091

Figure 2. “Insert USB” instruction

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12 Insert the USB memory device that contains the latest version of 7900 system
software (that is, Version 5.2). During the software download the following page is
displayed, which contains progress bars that give an indication of how much of
each process has been completed. The software download from the USB memory
device takes approximately 15 minutes.
79092

Figure 3. Download progress

13 When the software download process is completed, the following instruction is
displayed.
79093

Figure 4. “Reprogramming Complete ...” instruction

14 Remove the USB memory device from the printer.
15 Turn off the printer.Turn off the mains electrical supply and disconnect the mains
electrical supply cable from the printer.
16 Remove link LK5 (Monitor) from the IPM PCB.
17 Remove the 7900 Boot PROM from the IPM PCB.
18 Remove the ink and solvent filler caps.
19 Refit the top cover and secure the locking latch.
20 Refit the ink and solvent filler caps.

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21 Turn on the printer.

22 Make sure that the printer starts correctly and that the splash screen is displayed.
23 Restore the backup file from the USB memory device to the printer (if necessary).
NOTE: A USB memory device can now be used directly to upgrade the printer
with future versions of 7900 system software (The Linx Sync Service Tool
or the 7900 Boot PROM is not required).
24 The ‘Software Upgrade Using the 7900 Boot PROM’ maintenance instruction is now
completed.

Possible problems

No Firmware found
The printer cannot detect the software version on the USB memory device. This error can be
caused by one of the following:
 The software is not in the correct folder on the USB memory device
(Linx\7900\FIRMWARE).
 The name of the software file is incorrect (7900 v5.2.1.lsf).
 The USB memory device is not compatible (the maximum capacity must not be greater
than 4 GB).
 A fault on the printer USB port.

Verification Failed
The software file on the USB memory device has invalid or corrupt data. Download another
copy of the software file to the USB memory device and perform the upgrade procedure
again.

USB read failure

There is a problem with the software version file on the USB memory device. This error can
be caused by a corrupt software file. Download another copy of the software file to the USB
memory device and perform the upgrade procedure again.

Reprogramming Failed
Turn off and restart the printer. Perform the upgrade procedure again.

Unrecoverable USB fault

There is a possible IPM PCB fault. This fault can be caused by either of the following:
 The USB cable is not correctly connected to the IPM PCB. Disconnect and then
reconnect the USB cable on the IPM PCB. Perform the upgrade procedure again.
 A fault on the IPM PCB. Replace the IPM PCB and perform the upgrade procedure
again.

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7900 Maintenance Instruction
24 Volts Alarm Beacon Installation (Printer Mounted)

Parts required
FA61094 Alarm Beacon 6800

Procedure
1 Shut down and turn off the printer. Turn off the mains electrical supply and
disconnect the mains electrical supply cable from the printer.
2 Loosely fit the alarm beacon mounting bracket to the alarm beacon stalk assembly
in the correct orientation, as shown in Figure 1, using two of the four screws
provided in the kit.

48173

Clamp screw (x2)

Stalk assembly Mounting bracket

Figure 1. Alarm beacon mounting bracket fitted to the stalk assembly

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24 Volts Alarm Beacon Installation (Printer Mounted)

3 Fit the mounting bracket and stalk assembly to the two holes in the ink system vent
on the rear panel of the printer, using the two remaining screws provided in the kit
(Figure 2).

79067
Mounting bracket Alarm beacon
clamp screws (x2) stalk assembly

Ink system
vent

Fit mounting Alarm beacon

bracket securing cableform— connect to
screws here (x2) ALARM OUTPUT connector
Figure 2. Fitting the alarm beacon to the rear of the printer
4 Adjust the vertical position of the stalk assembly in the mounting bracket so that
the cableform exit from the stalk is clear of the printer mounting surface. Tighten
the mounting bracket clamp screws.

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24 Volts Alarm Beacon Installation (Printer Mounted)

CAUTION: Printer Electrical Damage. Do not connect the ALARM OUTPUT connector of the
printer to the mains electrical supply or any other power source. Damage to the printer can
occur if this caution is ignored.
5 Connect the stalk assembly cableform connector to the ALARM OUTPUT
connector on the rear of the printer.
6 Turn on the printer.
7 Access the Alarm Setup page (Print Monitor > Line Setup > Alarm).
8 Highlight the “3.12 Printhead Cover Off” warning message and press the Constant
key.
69362

Figure 3. Alarm Setup page — “3.12 Printhead Cover Off” set to Constant
9 Remove the printhead cover tube and make sure that the alarm beacon flashes on
and off continuously.
10 Refit the printhead cover tube and make sure that, after a few seconds, the alarm
beacon is not illuminated.
11 Turn off the printer.
12 The ‘24 Volts Alarm Beacon Installation (Printer Mounted)’ maintenance
instruction is now completed.

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24 Volts Alarm Beacon Installation (Printer Mounted)

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7900 Maintenance Instruction
Mains (VFC) External Alarm Conversion

Parts required
FA71080 VFC Alarm Conversion
comprising:
VFC Alarm Cableform
3-Way Buccaneer Plug Connector
Connector Pillar (x3)
3-Way Buccaneer Socket Connector
M3 Nyloc Nut (x3)
Alarm (VFC) Label

Equipment required
FA16005 Cover Removal Tool
DVM (Digital Voltmeter) or a mains-powered alarm beacon

Introduction
The Linx 7900 printer is fitted with a single 24 V alarm output as standard. The Mains (VFC)
External Alarm Conversion allows the alarm switching signal to operate a mains-powered
external alarm through a volt-free contact (VFC) relay instead.
The following procedure assumes that the printer is fitted with the standard 24 volts
external alarm.
NOTE: There are two yellow and black labels (‘PL10’ and ‘PL11’) supplied in the VFC
Alarm Conversion kit. These labels are not used on the 7900 printer.

Procedure

WARNING: LETHAL VOLTAGE HAZARD. DANGEROUS VOLTAGES EXIST IN THIS

EQUIPMENT WHEN ELECTRICAL POWER IS APPLIED.
TURN OFF AND DISCONNECT THE PRINTER FROM THE MAINS ELECTRICAL SUPPLY
BEFORE THE COVER IS OPENED.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS SAFETY
WARNING IS IGNORED.
1 Shut down and turn off the printer. Turn off the mains electrical supply and
disconnect the mains electrical supply cable from the printer.
2 Remove the ink and solvent filler caps.
3 Unlock the security latch on the front of the top cover and remove the cover.
Position the cover so that the keyboard can be accessed.
4 Temporarily refit the ink and solvent filler caps to reduce evaporation of the ink
and solvent.
5 Disconnect and remove the 24 V Alarm cableform from the Alarm PCB and the IPM
PCB (PL10). This cableform is not required for the Mains (VFC) External Alarm
Conversion, but it can be kept for future reinstallation of the standard 24 V Alarm
only option, if required.

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6 Disconnect the 14-way connector from PL20 (Auto Power On) on the IPM PCB to
allow better access to the Alarm PCB.
7 Remove the two Nyloc nuts that fasten the Alarm PCB to the back of the 24 V
Alarm connector. Retain the nuts for future reinstallation of the standard 24 V
Alarm only option, if required.
8 Remove and retain the Nyloc nut that fastens the Alarm PCB to the supporting
pillar.
9 Remove and retain the Alarm PCB.
10 Remove and retain the sealing cap/assembly tool and retaining strap from the 24 V
Alarm connector.
11 Remove the locking ring from the back of the 24 V Alarm connector, and remove
the connector from the standard rear panel plate. This alarm output connector is
not required for the Mains (VFC) External Alarm Conversion, but it can be retained
for future reinstallation of the standard 24 V Alarm only option, if required.
12 Remove the locking ring from the new 3-way plug connector that is supplied in the
kit.
13 Insert the connector and gasket into the standard rear panel plate. Make sure that
the locating lug on the connector engages in the cut-out in the gasket and the rear
panel plate, and then fit and tighten the connector locking ring.
14 Fit the Alarm PCB onto the three pillars on the connector and the PCB supporting
pillar.
15 Use the three new Nyloc nuts that are supplied in the kit to fasten the Alarm PCB to
the back of the connector.
16 Refit the Nyloc nut that fastens the Alarm PCB to the supporting pillar.
17 Refit the sealing cap/assembly tool and retaining strap to the new connector.
18 Connect the new VFC Alarm cableform to the Alarm PCB and the IPM PCB (PL11).
19 Reconnect the 14-way connector to PL20 (Auto Power On) on the IPM PCB.
20 Remove the warning label that is below the ALARM OUTPUT connector on the
standard rear panel plate (“Do Not Connect A Power Source To The Alarm Output”).
21 Attach the 'ALARM (VFC)' label that is supplied in the kit to the standard rear
panel plate below the ALARM OUTPUT connector.
22 If a mains-powered alarm beacon is available, proceed with the following
‘Mains-powered alarm test’. If a mains-powered alarm beacon is not available,
proceed with the ‘DVM test’ on page 5—202.

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Mains (VFC) External Alarm Conversion

Mains-powered alarm test

When the Mains (VFC) External Alarm conversion is fitted, the following warning is
applicable.

WARNING: LETHAL VOLTAGE HAZARD. DANGEROUS VOLTAGE EXISTS IN THE PRINTER

WHEN IT IS DISCONNECTED FROM THE MAINS ELECTRICAL SUPPLY, BUT A
MAINS-OPERATED EXTERNAL ALARM IS CONNECTED TO THE PRINTER. THERE CAN BE
MAINS VOLTAGE ON THE PCB ATTACHED TO THE ALARM CONNECTOR AND ON THE IPM
PCB IN THE AREA OF THE EXTERNAL ALARM RELAY.
WHEN THE PRINTER COVER IS REMOVED, DO NOT TOUCH THE ALARM CONNECTOR PCB,
OR THE IPM PCB IN THE AREA OF THE EXTERNAL ALARM RELAY.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS SAFETY
WARNING IS IGNORED.
23 Connect the mains-powered alarm beacon to the ALARM OUTPUT connector on
the rear panel of the printer.
24 Turn on the mains electrical supply to the alarm beacon.
25 Turn on the printer.
26 Access the Alarm Setup page (Print Monitor > Line Setup > Alarm).
27 Highlight the “3.12 Printhead Cover Off” warning message and press the Constant
key.
69362

Figure 1. Alarm Setup page — “3.12 Printhead Cover Off” set to Constant
28 Remove the printhead cover tube and make sure that the alarm beacon lights and
remains lit while the printhead cover tube is removed.
29 Refit the printhead cover tube and make sure that, after a few seconds, the alarm
beacon is not illuminated.
30 Turn off the printer.
31 Turn off the mains electrical supply to the alarm beacon.
32 Remove the ink and solvent filler caps.
33 Refit the top cover and secure the locking latch.

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Mains (VFC) External Alarm Conversion

34 Refit the ink and solvent filler caps.

35 The ‘Mains (VFC) External Alarm Conversion’ maintenance instruction is now
completed.

DVM test
23 Turn on the printer.
24 Access the Alarm Setup page (Print Monitor > Line Setup > Alarm).
25 Highlight the “3.12 Printhead Cover Off” warning message and press the Constant
key.
69362

Figure 2. Alarm Setup page — “3.12 Printhead Cover Off” set to Constant
26 Set the DVM to the resistance range and connect it between pins L and N
(‘normally closed’ contacts) on the ALARM OUTPUT connector (see Figure 4 on
page 5—206). The DVM should indicate a short circuit.
27 Remove the printhead cover tube and make sure that the DVM indicates an open
circuit.
28 Refit the printhead cover tube and make sure that, after a few seconds, the DVM
indicates a short circuit again.
NOTE: If it is required that the alarm output operates in the opposite sense (that is,
‘normally open’ contacts), the two wires on the external alarm device connector
must be connected to the pins corresponding to L and E on the ALARM OUTPUT
connector. Perform the following three steps to test the alarm output.
29 Connect the DVM between pins L and E (‘normally open’ contacts) on the ALARM
OUTPUT connector (see Figure 4 on page 5—206). The DVM should indicate an
open circuit.
30 Remove the printhead cover tube and make sure that the DVM indicates a short
circuit.
31 Refit the printhead cover tube and make sure that, after a few seconds, the DVM
indicates an open circuit again.
32 Turn off the printer.
33 Disconnect the DVM from the ALARM OUTPUT connector.
34 Remove the ink and solvent filler caps.

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Mains (VFC) External Alarm Conversion

35 Refit the top cover and secure the locking latch.

36 Refit the ink and solvent filler caps.
37 The ‘Mains (VFC) External Alarm Conversion’ maintenance instruction is now
completed.

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Mains (VFC) External Alarm Conversion

Electrical safety compliance information

Assembly and wiring of the external 3-way socket connector

IMPORTANT:
1. Assembly of the Mains (VFC) External Alarm external socket connector and any
maintenance work on the connector must be performed only by Linx
maintenance technicians, personnel trained by Linx, or a qualified and
authorized electrician.
2. The Mains (VFC) External Alarm connection is a double-insulated device; no
earth connection is required.
3. The upstream electrical supply for the external equipment must have a method
of isolation that is easily accessible for use during maintenance or in an
emergency. The external equipment must not be wired directly into the mains
electrical supply. The isolation device must have a clearance of  3 mm between
its contacts when open.
4. If the alarm fuse blows on the IPM PCB, the terminals in the Mains (VFC)
External Alarm external connector, the Alarm PCB, and the IPM PCB can remain
at a hazardous voltage.
The following table provides a ratings specification for the Mains (VFC) External Alarm
installation.

Item Specification
Maximum voltage 240 VAC
Internal fuse 1 A ceramic-bodied time delay
Recommended maximum load 1 A per relay connection
Upstream fuse The customer electrical feed must be limited by an upstream
fuse of 5 A (maximum) and approved to IEC 60127 with a
1500 A breaking capacity.

Table 1. Mains (VFC) External Alarm ratings specification

A cable specification for the external connector is provided in Table 2.

Item Specification
Cable type The cable used must have flexible (multi-strand) conductors
and have insulation of the correct type for the voltage and
application environment.
Overall cable diameter Minimum 6.0 mm
Maximum 8.0 mm
Conductors Maximum size 1.5 mm2 16 AWG)
Insulation stripping Strip the insulation back, so that no more than 2 mm max
2 mm of bare conductor is exposed when the
cable is clamped in the terminal.

Conductor clamping Clamp the conductor in the terminal so that a minimum of

0.5 x the conductor diameter is on the far side of the clamping
screw.

Table 2. External connector cable specification

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Mains (VFC) External Alarm Conversion

The following additional tools are required for this part of the procedure:
 Small flat-blade screwdriver
 11/16 inch spanner or a suitable adjustable spanner
 Connector sealing cap/assembly tool
Figure 3 identifies the parts of the external connector, shows the order of assembly, and
gives wire preparation information.
G
F
E 79078
D
C

H
B
A
m
m

m
m

20
6

A. Locking ring E. Gland

B. Socket insert F. Gland cage
C. Locking cap G. Gland nut
D. Main body H. Sealing cap/assembly tool

Figure 3. Assembly of the Mains (VFC) External Alarm external connector

IMPORTANT: Do not connect primary signals (> 42 VAC peak or 60 VDC) and low
voltage signals (< 42 VAC peak or 60 VDC) to the same external
connector.
1 Use the sealing cap/assembly tool (H) to remove the connector locking ring (A).
2 Remove the socket insert (B) from the connector.
3 Feed the cable through the connector components in the order shown in Figure 3.
4 Cut and remove 20 mm of outer insulation from the cable, as shown in Figure 3.
5 Cut and remove 6 mm of insulation from each of the conductors, as shown in
Figure 3.

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Mains (VFC) External Alarm Conversion

6 Insert the bare conductor ends into the terminals on the socket insert (B) according
to the pin-out information for the printer plug connector in the following
illustration. The conductors must be inserted into the terminals so that no more
than 2 mm of bare conductor is exposed when the cables are clamped in the
terminals (see Table 2). Completely tighten the terminal screws.
79079
MAINS (VFC) EXTERNAL ALARM CONNECTOR
Signal Pin

Common L
L
Normally closed (NC) N
E
N
Normally open (NO) E

3-way plug connector

on the printer

Figure 4. Mains (VFC) External Alarm connector details

7 Carefully pull the cable back until the socket insert (B) is correctly fitted in the
D-shaped location in the main body (D).
8 Insert the locking ring (A) into the main body (D), and use the sealing
cap/assembly tool (H) to tighten the locking ring (A).
9 Slide the gland cage (F) and the gland (E) down the cable and into the main body
(D), and then tighten the gland nut (G). The gland nut must be completely
tightened so that the cable is correctly sealed and tightly gripped.

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7900 Maintenance Instruction
Dual Alarm Installation

Parts required
FA72177 5900/7900 Dual Alarm Upgrade
comprising:
VFC Alarm PCB
VFC Alarm Cableform
3-Way Buccaneer Plug Connector
Connector Pillar (x3)
Buccaneer Connector Sealing Cap/Assembly Tool
3-Way Buccaneer Socket Connector
Dual Alarm Option Plate
Option Plate Gasket
M3 x 20 PCB Supporting Pillar
M3 Nyloc Nut (x6)
Alarm (VFC) Label

Equipment required
FA16005 Cover Removal Tool
DVM (Digital Voltmeter) or a mains-powered alarm beacon

Introduction
The Linx 7900 printer is fitted with a single 24 V alarm output as standard. The Dual Alarm
Upgrade allows an additional VFC alarm to be connected to the printer. Therefore, the
printer can control two alarm outputs (24 V and VFC).
NOTE: A configuration code is required to enable the second alarm in the software. When
enabled, Alarm 2 Setup is available on the Alarm page (Print Monitor > Line Setup
> Alarm).
The following procedure assumes that the printer is fitted with the standard 24 volts
external alarm.

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Dual Alarm Installation

Procedure

WARNING: LETHAL VOLTAGE HAZARD. DANGEROUS VOLTAGES EXIST IN THIS

EQUIPMENT WHEN ELECTRICAL POWER IS APPLIED.
TURN OFF AND DISCONNECT THE PRINTER FROM THE MAINS ELECTRICAL SUPPLY
BEFORE THE COVER IS OPENED.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS SAFETY
WARNING IS IGNORED.
1 Shut down and turn off the printer. Turn off the mains electrical supply and
disconnect the mains electrical supply cable from the printer.
2 Remove the ink and solvent filler caps.
3 Unlock the security latch on the front of the top cover and remove the cover.
Position the cover so that the keyboard can be accessed.
4 Temporarily refit the ink and solvent filler caps to reduce evaporation of the ink
and solvent.
5 Disconnect the 24 V Alarm cableform from the IPM PCB (PL10).
6 Disconnect the 14-way connector from PL20 (Auto Power On) on the IPM PCB to
allow better access to the Alarm PCB.
7 Disconnect the Ethernet cable from the Ethernet connector on the rear panel plate.
8 Remove and retain the six Nyloc nuts that fasten the standard rear panel plate to
the rear of the printer.
9 Remove the standard rear panel plate and gasket from the printer.
10 Remove and retain the two Nyloc nuts that fasten the Alarm PCB to the back of the
24 V Alarm connector.
11 Remove and retain the Nyloc nut that fastens the Alarm PCB to the supporting pillar.
12 Remove and retain the Alarm PCB.
13 Remove and retain the PCB supporting pillar from the standard rear panel plate.
14 Remove the locking ring from the back of the 2-way 24 V Alarm connector, and
remove the connector from the standard rear panel plate. Retain the connector and
locking ring.
15 Remove and retain the sealing cap and retaining strap from the Ethernet connector.
16 Remove and retain the four Nyloc nuts that fasten the Ethernet connector to the
standard rear panel plate.
17 Remove and retain the locking ring from the front of the Ethernet connector, and
remove the connector and gasket from the standard rear panel plate.
18 Retain the rear panel plate for future reinstallation of the standard 24 V Alarm only
option, if required.

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Dual Alarm Installation

Ethernet connector
19 Insert the Ethernet connector and gasket into the middle hole in the Dual Alarm
option plate (see Figure 1). Make sure that the flat side of the connector is aligned
with the 'D' shape of the option plate, and then fit and tighten the connector locking
ring.
VFC alarm 79083
connector location

Ethernet
connector location
PCB supporting
pillars
24 V alarm
connector location

Figure 1. Front view of the 7900 Dual Alarm option plate

20 Refit the four Nyloc nuts that fasten the Ethernet connector to the option plate.
21 Refit the sealing cap and retaining strap to the Ethernet connector.

24 Volt Alarm connector

22 Insert the original 24 V Alarm connector and gasket into the bottom hole in the
Dual Alarm option plate (see Figure 1). Make sure that the locating lug on the
connector engages in the cut-out in the gasket and the option plate, and then fit and
tighten the connector locking ring.
23 Refit the PCB supporting pillar to the post next to the 24 V Alarm connector on the
Dual Alarm option plate.
24 Fit the original Alarm PCB onto the two pillars on the connector and the PCB
supporting pillar.
25 Refit the two Nyloc nuts that fasten the Alarm PCB to the back of the connector.
26 Refit the Nyloc nut that fastens the Alarm PCB to the supporting pillar.

VFC Alarm connector

27 Remove the locking ring from the back of the 3-way plug connector that is supplied
in the kit.
28 Insert the connector and gasket into the top hole in the Dual Alarm option plate
(see Figure 1). Make sure that the locating lug on the connector engages in the
cut-out in the gasket and the option plate, and then fit and tighten the connector
locking ring.
29 Fit the PCB supporting pillar that is supplied in the kit to the post next to the VFC
Alarm connector on the Dual Alarm option plate.
30 Fit the Alarm PCB that is supplied in the kit onto the three pillars on the connector
and the PCB supporting pillar.

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Dual Alarm Installation

31 Use three of the retained Nyloc nuts to fasten the Alarm PCB to the back of the
connector.
32 Use one of the retained Nyloc nuts to fasten the Alarm PCB to the supporting pillar.
33 Fit the sealing cap/assembly tool and retaining strap that is supplied in the kit to
the new connector.

Dual Alarm option plate

34 Make sure that the gasket is fitted to the front face of the Dual Alarm option plate.
35 Orientate the option plate assembly in the printer, with the VFC Alarm connector
uppermost. Insert the option plate studs through the holes in the rear panel of the
printer.
36 Use the six Nyloc nuts that are supplied in the kit to fasten the option plate
assembly to the rear panel of the printer.
37 Reconnect the Ethernet cable to the Ethernet connector.
38 Reconnect the 24 V Alarm cableform to the IPM PCB (PL10).
39 Connect the new VFC Alarm cableform that is supplied in the kit to the VFC Alarm
PCB and the IPM PCB (PL11).
40 Reconnect the 14-way connector to PL20 (Auto Power On) on the IPM PCB.
41 Attach the ‘ALARM (VFC)’ label that is supplied in the kit to the rear of the printer
below the printhead conduit.
42 If a mains-powered alarm beacon is available, proceed with the following
‘Mains-powered alarm test’. If a mains-powered alarm beacon is not available,
proceed with the ‘DVM test’ on page 5—211.

Mains-powered alarm test

When the Dual Alarm option is fitted, the following warning is applicable.

WARNING: LETHAL VOLTAGE HAZARD. DANGEROUS VOLTAGE EXISTS IN THE PRINTER

WHEN IT IS DISCONNECTED FROM THE MAINS ELECTRICAL SUPPLY, BUT A
MAINS-OPERATED EXTERNAL ALARM IS CONNECTED TO THE PRINTER. THERE CAN BE
MAINS VOLTAGE ON THE PCB ATTACHED TO THE ALARM CONNECTOR AND ON THE IPM
PCB IN THE AREA OF THE EXTERNAL ALARM RELAY.
WHEN THE PRINTER COVER IS REMOVED, DO NOT TOUCH THE ALARM CONNECTOR PCB,
OR THE IPM PCB IN THE AREA OF THE EXTERNAL ALARM RELAY.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS SAFETY
WARNING IS IGNORED.
43 Connect the mains-powered alarm beacon to the ALARM OUTPUT connector on
the rear panel of the printer.
44 Turn on the mains electrical supply to the alarm beacon.
45 Turn on the printer.
46 Access the Alarm page (Print Monitor > Line Setup > Alarm).
47 Select the Alarm 2 Setup option.

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48 Highlight the “3.12 Printhead Cover Off” warning message and press the Constant
key.
69362

Figure 2. Alarm Setup page — “3.12 Printhead Cover Off” set to Constant
49 Remove the printhead cover tube and make sure that the alarm beacon lights and
remains lit while the printhead cover tube is removed.
50 Refit the printhead cover tube and make sure that, after a few seconds, the alarm
beacon is not illuminated.
51 Turn off the printer.
52 Turn off the mains electrical supply to the alarm beacon.
53 Remove the ink and solvent filler caps.
54 Refit the top cover and secure the locking latch.
55 Refit the ink and solvent filler caps.
56 The ‘Dual Alarm Installation’ maintenance instruction is now completed.

DVM test
43 Turn on the printer.
44 Access the Alarm page (Print Monitor > Line Setup > Alarm).
45 Select the Alarm 2 Setup option.

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Dual Alarm Installation

46 Highlight the “3.12 Printhead Cover Off” warning message and press the Constant
key.
69362

Figure 3. Alarm Setup page — “3.12 Printhead Cover Off” set to Constant
47 Set the DVM to the resistance range and connect it between pins L and N
(‘normally closed’ contacts) on the ALARM OUTPUT connector (see Figure 5 on
page 5—215). The DVM should indicate a short circuit.
48 Remove the printhead cover tube and make sure that the DVM indicates an open
circuit.
49 Refit the printhead cover tube and make sure that, after a few seconds, the DVM
indicates a short circuit again.
NOTE: If it is required that the alarm output operates in the opposite sense (that is,
‘normally open’ contacts), the two wires on the external alarm device connector
must be connected to the pins corresponding to L and E on the ALARM OUTPUT
connector. Perform the following three steps to test the alarm output.
50 Connect the DVM between pins L and E (‘normally open’ contacts) on the ALARM
OUTPUT connector (see Figure 5 on page 5—215). The DVM should indicate an
open circuit.
51 Remove the printhead cover tube and make sure that the DVM indicates a short
circuit.
52 Refit the printhead cover tube and make sure that, after a few seconds, the DVM
indicates an open circuit again.
53 Turn off the printer.
54 Disconnect the DVM from the ALARM OUTPUT connector.
55 Remove the ink and solvent filler caps.
56 Refit the top cover and secure the locking latch.
57 Refit the ink and solvent filler caps.
58 The ‘Dual Alarm Installation’ maintenance instruction is now completed.

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Dual Alarm Installation

Electrical safety compliance information

Assembly and wiring of the external 3-way socket connector

IMPORTANT:
1. Assembly of the Mains (VFC) External Alarm external socket connector and any
maintenance work on the connector must be performed only by Linx
maintenance technicians, personnel trained by Linx, or a qualified and
authorized electrician.
2. The Mains (VFC) External Alarm connection is a double-insulated device; no
earth connection is required.
3. The upstream electrical supply for the external equipment must have a method
of isolation that is easily accessible for use during maintenance or in an
emergency. The external equipment must not be wired directly into the mains
electrical supply. The isolation device must have a clearance of  3 mm between
its contacts when open.
4. If the alarm fuse blows on the IPM PCB, the terminals in the Mains (VFC)
External Alarm external connector, the Alarm PCB, and the IPM PCB can remain
at a hazardous voltage.
The following table provides a ratings specification for the Mains (VFC) External Alarm
installation.

Item Specification
Maximum voltage 240 VAC
Internal fuse 1 A ceramic-bodied time delay
Recommended maximum load 1 A per relay connection
Upstream fuse The customer electrical feed must be limited by an upstream
fuse of 5 A (maximum) and approved to IEC 60127 with a
1500 A breaking capacity.

Table 1. Mains (VFC) External Alarm ratings specification

A cable specification for the external connector is provided in Table 2.

Item Specification
Cable type The cable used must have flexible (multi-strand) conductors
and have insulation of the correct type for the voltage and
application environment.
Overall cable diameter Minimum 6.0 mm
Maximum 8.0 mm
Conductors Maximum size 1.5 mm2 16 AWG)
Insulation stripping Strip the insulation back, so that no more than 2 mm max
2 mm of bare conductor is exposed when the
cable is clamped in the terminal.

Conductor clamping Clamp the conductor in the terminal so that a minimum of

0.5 x the conductor diameter is on the far side of the clamping
screw.

Table 2. External connector cable specification

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Dual Alarm Installation

The following additional tools are required for this part of the procedure:
 Small flat-blade screwdriver
 11/16 inch spanner or a suitable adjustable spanner
 Connector sealing cap/assembly tool
Figure 4 identifies the parts of the external connector, shows the order of assembly, and
gives wire preparation information.
G
F
E 79078
D
C

H
B
A
m
m

m
m

20
6

A. Locking ring E. Gland

B. Socket insert F. Gland cage
C. Locking cap G. Gland nut
D. Main body H. Sealing cap/assembly tool

Figure 4. Assembly of the Mains (VFC) External Alarm external connector

IMPORTANT: Do not connect primary signals (> 42 VAC peak or 60 VDC) and low
voltage signals (< 42 VAC peak or 60 VDC) to the same external
connector.
1 Use the sealing cap/assembly tool (H) to remove the connector locking ring (A).
2 Remove the socket insert (B) from the connector.
3 Feed the cable through the connector components in the order shown in Figure 4.
4 Cut and remove 20 mm of outer insulation from the cable, as shown in Figure 4.
5 Cut and remove 6 mm of insulation from each of the conductors, as shown in
Figure 4.

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6 Insert the bare conductor ends into the terminals on the socket insert (B) according
to the pin-out information for the printer plug connector in the following
illustration. The conductors must be inserted into the terminals so that no more
than 2 mm of bare conductor is exposed when the cables are clamped in the
terminals (see Table 2). Completely tighten the terminal screws.
79079
MAINS (VFC) EXTERNAL ALARM CONNECTOR
Signal Pin

Common L
L
Normally closed (NC) N
E
N
Normally open (NO) E

3-way plug connector

on the printer

Figure 5. Mains (VFC) External Alarm connector details

7 Carefully pull the cable back until the socket insert (B) is correctly fitted in the
D-shaped location in the main body (D).
8 Insert the locking ring (A) into the main body (D), and use the sealing
cap/assembly tool (H) to tighten the locking ring (A).
9 Slide the gland cage (F) and the gland (E) down the cable and into the main body
(D), and then tighten the gland nut (G). The gland nut must be completely
tightened so that the cable is correctly sealed and tightly gripped.

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Multi-Stage Alarm (24 V) Conversion

Parts required
FA72180 5900/7900 Multi-Stage Alarm (24 V) and Parallel I/O Interface
comprising:
Multi-Stage Alarm PCB
Multi-Stage Alarm 24 V Cableform
7-Way Buccaneer Plug Connector
7-Way Buccaneer Socket Connector
7-Way Buccaneer Socket Connector Terminal Screw (x6)
Alarm, Ethernet and Parallel I/O Option Plate
Option Plate Gasket
M3 x 12 PCB Supporting Pillar
M3 Nyloc Nut (x12)
Parallel I/O PCB
Parallel I/O PCB Mounting Bracket
Snap Rivet (x2)
D-Type Connector Screwlock (x2)
Parallel I/O Interface Cable
25-Way D-Type Socket Dust Cover
M4 x 12 Screw Pan Head
Spacer

Equipment required
FA16005 Cover Removal Tool
Antistatic Wrist Strap and Lead

Introduction
The Multi-Stage Alarm (24 V) option provides a maximum of four outputs that can be used
to control a multi-stage alarm beacon.
This accessory can only be used if the Parallel I/O Interface Upgrade accessory (FA72178)
has also been installed.
The following procedure assumes that the printer is fitted with the standard 24 volts
external alarm.

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Multi-Stage Alarm (24 V) Conversion

Procedure

WARNING: LETHAL VOLTAGE HAZARD. DANGEROUS VOLTAGES EXIST IN THIS

EQUIPMENT WHEN ELECTRICAL POWER IS APPLIED.
TURN OFF AND DISCONNECT THE PRINTER FROM THE MAINS ELECTRICAL SUPPLY
BEFORE THE COVER IS OPENED.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS SAFETY
WARNING IS IGNORED.

CAUTION: Static-Sensitive Devices. The PCBs contain static-sensitive devices. Take the
following antistatic precautions when PCBs are touched. Wear an antistatic wrist strap and
connect the lead to a good electrical earth. Always hold PCBs by their edges and do not touch
the components, printed circuit tracks or connector pins.
1 Shut down and turn off the printer. Turn off the mains electrical supply and
disconnect the mains electrical supply cable from the printer.
2 Remove the ink and solvent filler caps.
3 Unlock the security latch on the front of the top cover and remove the cover.
4 Temporarily refit the ink and solvent filler caps to reduce evaporation of the ink
and solvent.
5 Disconnect the 24 V Alarm cableform from the IPM PCB (PL10).
6 Disconnect the 14-way connector from PL20 (Auto Power On) on the IPM PCB to
allow better access to the Alarm PCB.
7 Disconnect the Ethernet cable from the Ethernet connector on the rear panel plate.
8 Remove and retain the six Nyloc nuts that fasten the standard rear panel plate to
the rear of the printer.
9 Remove the standard rear panel plate and gasket from the printer.
10 Remove and retain the sealing cap/assembly tool and retaining strap from the 24 V
Alarm connector.
11 Remove and retain the sealing cap and retaining strap from the Ethernet connector.
12 Remove and retain the four Nyloc nuts that fasten the Ethernet connector to the
standard rear panel plate.
13 Remove and retain the locking ring from the front of the Ethernet connector, and
remove the connector and gasket from the standard rear panel plate.
14 Retain the rear panel plate, connector, PCB and cableform for future reinstallation
of the standard 24 V Alarm only option, if required.

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Multi-Stage Alarm connector

15 Remove the locking ring from the new 7-way socket connector that is supplied in
the kit.
16 Insert the connector and gasket into the top hole in the Alarm, Ethernet and Parallel
I/O option plate (see Figure 1). Make sure that the locating lug on the connector
engages in the cut-out in the gasket and the option plate, and then fit and tighten
the connector locking ring.
Multi-Stage alarm 79084
24 V connector location

PCB supporting pillar

Ethernet
connector location

Parallel I/O connector

location

Figure 1. Alarm (24 V), Ethernet and Parallel I/O option plate
17 Fit the PCB supporting pillar that is supplied in the kit to the post next to the
Multi-Stage Alarm connector on the new option plate.
18 Orientate the Multi-Stage Alarm PCB as shown in Figure 2, with the component
side of the PCB towards you.
69384
Location of the
six connector
terminal screws

PL1

Locating hole
for the PCB
supporting pillar

Figure 2. Multi-Stage Alarm PCB details

19 Align the threaded stud of the supporting pillar with the hole in the bottom left
corner of the PCB. Push the PCB onto the connector so that the connector socket
terminals are flush with the PCB spring terminals.
20 Use one of the Nyloc nuts that are supplied in the kit to fasten the Alarm PCB to the
supporting pillar.
21 Fit the six terminal screws that are supplied in the kit into the connector.
22 Refit the sealing cap/assembly tool and retaining strap to the new connector.

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Ethernet connector
23 Insert the Ethernet connector and gasket into the bottom hole in the Alarm,
Ethernet and Parallel I/O option plate (see Figure 1). Make sure that the flat side of
the connector is aligned with the ‘D’ shape of the option plate, and then fit and
tighten the connector locking ring.
24 Use four of the Nyloc nuts that are supplied in the kit to fasten the Ethernet
connector to the option plate.
25 Refit the sealing cap and retaining strap to the Ethernet connector.

Alarm, Ethernet and Parallel I/O option plate

26 Make sure that the gasket is fitted to the front face of the Alarm, Ethernet and
Parallel I/O option plate.
27 Orientate the option plate assembly in the printer, with the Multi-Stage Alarm
connector uppermost. Insert the option plate studs through the holes in the rear
panel of the printer.
28 Use the six Nyloc nuts that are supplied in the kit to fasten the option plate
assembly to the rear panel of the printer.
29 Reconnect the Ethernet cable to the Ethernet connector.

Parallel I/O PCB

30 Loosely fit the M4 screw and spacer that are supplied in the kit into the securing
hole for the Parallel I/O PCB in the bottom of the printer cabinet.
31 Remove the dust cap from the D-type connector on the Parallel I/O PCB (if fitted).
32 Put the Parallel I/O PCB into the printer in the correct orientation.
33 Align the slot in the PCB mounting bracket over the M4 screw in the bottom of the
printer cabinet. Slide the PCB towards the rear of the printer, so that the mounting
bracket slot fits under the head of the screw.
34 Use the two screwlocks that are supplied in the kit to fasten the D-type connector
on the Parallel I/O PCB to the Alarm, Ethernet and Parallel I/O option plate.
35 Fit the dust cap that is supplied in the kit to the D-type connector on the Parallel
I/O PCB.
36 Tighten the M4 screw in the bottom of the printer cabinet.
37 Connect the new Multi-Stage Alarm 24 V Cableform to PL1 on the Multi-Stage
Alarm PCB and PL29 on the top of the Parallel I/O PCB.
38 Connect one end of the Parallel I/O Interface Cable to PL14 on the IPM PCB.
39 Connect the other end of the Parallel I/O Interface Cable to PL30 (labelled ‘IPM
PCB’) on the Parallel I/O PCB.
40 Reconnect the 14-way connector to PL20 (Auto Power On) on the IPM PCB.
41 Remove the ink and solvent filler caps.
42 Refit the top cover and secure the locking latch.
43 Refit the ink and solvent filler caps.

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Multi-Stage Alarm (24 V) Conversion

44 Connect the wires for the multi-stage alarm input cable to the 7-way Buccaneer
plug connector according to the details in the following illustration.
73090
MULTI-STAGE ALARM (24 V) CONNECTOR
Signal Socket

Alarm 1 1
2
Alarm 2 2 3 1
7
Alarm 3 3
4 6

24 V 4 5

Not used 5

Alarm 4 6
7-way socket connector
on the printer
Not used 7

Figure 3. Multi-Stage Alarm (24 V) connector details

45 The ‘Multi-Stage Alarm (24 V) Conversion’ maintenance instruction is now
completed.

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Multi-Stage Alarm (24 V) Conversion

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7900 Maintenance Instruction
Multi-Stage Alarm (VFC) Conversion

Parts required
FA72181 5900/7900 Multi-Stage Alarm (VFC) and Parallel I/O Interface

comprising:
Multi-Stage Alarm PCB
Multi-Stage Alarm VFC Cableform
6-Way Buccaneer Plug Connector
6-Way Buccaneer Socket Connector
6-Way Buccaneer Plug Connector Terminal Screw (x6)
Alarm, Ethernet and Parallel I/O Option Plate
Option Plate Gasket
M3 x 10 PCB Supporting Pillar
M3 Nyloc Nut (x12)
Parallel I/O PCB
Parallel I/O PCB Mounting Bracket
Snap Rivet (x2)
D-Type Connector Screwlock (x2)
Parallel I/O Interface Cable
25-Way D-Type Socket Dust Cover
M4 x 12 Screw Pan Head
Spacer
Multi-Stage Alarm (VFC) Label

Equipment required
FA16005 Cover Removal Tool
Antistatic Wrist Strap and Lead

Introduction
The Multi-Stage Alarm (VFC) option provides a maximum of four outputs that can be used
to control a multi-stage alarm beacon.
This accessory can only be used if the Parallel I/O Interface Upgrade accessory (FA72178)
has also been installed.
The following procedure assumes that the printer is fitted with the standard 24 volts
external alarm.

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Multi-Stage Alarm (VFC) Conversion

Procedure

WARNING: LETHAL VOLTAGE HAZARD. DANGEROUS VOLTAGES EXIST IN THIS

EQUIPMENT WHEN ELECTRICAL POWER IS APPLIED.
TURN OFF AND DISCONNECT THE PRINTER FROM THE MAINS ELECTRICAL SUPPLY
BEFORE THE COVER IS OPENED.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS SAFETY
WARNING IS IGNORED.
When the Multi-Stage Alarm (VFC) option is fitted, the following warning is applicable.

WARNING: LETHAL VOLTAGE HAZARD. DANGEROUS VOLTAGE EXISTS IN THE PRINTER

WHEN IT IS DISCONNECTED FROM THE MAINS ELECTRICAL SUPPLY, BUT A
MAINS-OPERATED EXTERNAL ALARM IS CONNECTED TO THE PRINTER. THERE CAN BE
MAINS VOLTAGE ON THE PCB ATTACHED TO THE ALARM CONNECTOR AND ON THE
PARALLEL I/O PCB IN THE AREA OF THE EXTERNAL ALARM RELAY.
WHEN THE PRINTER COVER IS REMOVED, DO NOT TOUCH THE ALARM CONNECTOR PCB,
OR THE PARALLEL I/O PCB IN THE AREA OF THE EXTERNAL ALARM RELAY.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS SAFETY
WARNING IS IGNORED.

CAUTION: Static-Sensitive Devices. The PCBs contain static-sensitive devices. Take the
following antistatic precautions when PCBs are touched. Wear an antistatic wrist strap and
connect the lead to a good electrical earth. Always hold PCBs by their edges and do not touch
the components, printed circuit tracks or connector pins.
1 Shut down and turn off the printer. Turn off the mains electrical supply and
disconnect the mains electrical supply cable from the printer.
2 Remove the ink and solvent filler caps.
3 Unlock the security latch on the front of the top cover and remove the cover.
4 Temporarily refit the ink and solvent filler caps to reduce evaporation of the ink
and solvent.
5 Disconnect the 24 V Alarm cableform from the IPM PCB (PL10).
6 Disconnect the 14-way connector from PL20 (Auto Power On) on the IPM PCB to
allow better access to the Alarm PCB.
7 Disconnect the Ethernet cable from the Ethernet connector on the rear panel plate.
8 Remove and retain the six Nyloc nuts that fasten the standard rear panel plate to
the rear of the printer.
9 Remove the standard rear panel plate and gasket from the printer.
10 Remove and retain the sealing cap/assembly tool and retaining strap from the 24 V
Alarm connector.
11 Remove and retain the sealing cap and retaining strap from the Ethernet connector.

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Multi-Stage Alarm (VFC) Conversion

12 Remove and retain the four Nyloc nuts that fasten the Ethernet connector to the
standard rear panel plate.
13 Remove and retain the locking ring from the front of the Ethernet connector, and
remove the connector and gasket from the standard rear panel plate.
14 Retain the rear panel plate, connector, PCB and cableform for future reinstallation
of the standard 24 V Alarm only option, if required.

Multi-Stage Alarm connector

15 Remove the locking ring from the new 6-way plug connector that is supplied in the
kit.
16 Insert the connector and gasket into the top hole in the Alarm, Ethernet and Parallel
I/O option plate (see Figure 1). Make sure that the locating lug on the connector
engages in the cut-out in the gasket and the option plate, and then fit and tighten
the connector locking ring.
Multi-Stage alarm 79085
VFC connector location

PCB supporting pillar

Ethernet
connector location

Parallel I/O connector

location

Figure 1. Alarm (VFC), Ethernet and Parallel I/O option plate

17 Fit the PCB supporting pillar that is supplied in the kit to the post next to the
Multi-Stage Alarm connector on the new option plate.

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18 Orientate the Multi-Stage Alarm PCB as shown in Figure 2, with the component
side of the PCB towards you.
69384
Location of the
six connector
terminal screws

PL1

Locating hole
for the PCB
supporting pillar

Figure 2. Multi-Stage Alarm PCB details

NOTE: The pad numbers P1 to P6 printed on the Multi-Stage Alarm PCB are reversed
relative to the pin numbers on the internal 6-way chassis connector. That is, PCB
pad P1 connects to pin 6 on the chassis connector, PCB pad P2 connects to pin 5 on
the chassis connector, … , and PCB pad P6 connects to pin 1 on the chassis
connector.
19 Align the threaded stud of the supporting pillar with the hole in the bottom left
corner of the PCB. Push the PCB onto the connector so that the connector socket
terminals are flush with the PCB spring terminals.
20 Use one of the Nyloc nuts that are supplied in the kit to fasten the Alarm PCB to the
supporting pillar.
21 Fit the six terminal screws that are supplied in the kit into the connector.
22 Refit the sealing cap/assembly tool and retaining strap to the new connector.

Ethernet connector
23 Insert the Ethernet connector and gasket into the bottom hole in the Alarm,
Ethernet and Parallel I/O option plate (see Figure 1). Make sure that the flat side of
the connector is aligned with the ‘D’ shape of the option plate, and then fit and
tighten the connector locking ring.
24 Use four of the Nyloc nuts that are supplied in the kit to fasten the Ethernet
connector to the option plate.
25 Refit the sealing cap and retaining strap to the Ethernet connector.

Alarm, Ethernet and Parallel I/O option plate

26 Make sure that the gasket is fitted to the front face of the Alarm, Ethernet and
Parallel I/O option plate.
27 Orientate the option plate assembly in the printer, with the Multi-Stage Alarm
connector uppermost. Insert the option plate studs through the holes in the rear
panel of the printer.
28 Use the six Nyloc nuts that are supplied in the kit to fasten the option plate
assembly to the rear panel of the printer.
29 Reconnect the Ethernet cable to the Ethernet connector.

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Multi-Stage Alarm (VFC) Conversion

Parallel I/O PCB

30 Loosely fit the M4 screw and spacer that are supplied in the kit into the securing
hole for the Parallel I/O PCB in the bottom of the printer cabinet.
31 Remove the dust cap from the D-type connector on the Parallel I/O PCB (if fitted).
32 Put the Parallel I/O PCB into the printer in the correct orientation.
33 Align the slot in the PCB mounting bracket over the M4 screw in the bottom of the
printer cabinet. Slide the PCB towards the rear of the printer, so that the mounting
bracket slot fits under the head of the screw.
34 Use the two screwlocks that are supplied in the kit to fasten the D-type connector
on the Parallel I/O PCB to the Alarm, Ethernet and Parallel I/O option plate.
35 Fit the dust cap that is supplied in the kit to the D-type connector on the Parallel
I/O PCB.
36 Tighten the M4 screw in the bottom of the printer cabinet.
37 Connect the new Multi-Stage Alarm VFC Cableform to PL1 on the Multi-Stage
Alarm PCB and PL27 on the end of the Parallel I/O PCB.
38 Connect one end of the Parallel I/O Interface Cable to PL14 on the IPM PCB.
39 Connect the other end of the Parallel I/O Interface Cable to PL30 (labelled ‘IPM
PCB’) on the Parallel I/O PCB.
40 Reconnect the 14-way connector to PL20 (Auto Power On) on the IPM PCB.
41 Attach the 'MULTI-STAGE ALARM (VFC)' label that is supplied in the kit to the
option plate below the Multi-Stage Alarm connector.
42 Remove the ink and solvent filler caps.
43 Refit the top cover and secure the locking latch.
44 Refit the ink and solvent filler caps.
45 The ‘Multi-Stage Alarm (VFC) Conversion’ maintenance instruction is now
completed.

Electrical safety compliance information

Assembly and wiring of the external 6-way socket connector

IMPORTANT:
1. Assembly of the Multi-Stage Alarm (VFC) external socket connector and any
maintenance work on the connector must be performed only by Linx
maintenance technicians, personnel trained by Linx, or a qualified and
authorized electrician.
2. The Multi-Stage Alarm (VFC) connection is a double-insulated device; no earth
connection is required.
3. The upstream electrical supply for the external equipment must have a method
of isolation that is easily accessible for use during maintenance or in an
emergency. The external equipment must not be wired directly into the mains
electrical supply. The isolation device must have a clearance of  3 mm between
its contacts when open.
4. If the fuses blow on the Parallel I/O PCB, the terminals in the Multi-Stage Alarm
(VFC) external connector, the Alarm PCB, and the Parallel I/O PCB can remain at
a hazardous voltage.

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7900 Maintenance Instruction
Multi-Stage Alarm (VFC) Conversion

The following table provides a ratings specification for the Multi-Stage Alarm (VFC)
installation.

Item Specification
Maximum voltage 240 VAC
Internal fuses x 4 1 A ceramic-bodied time delay
Recommended maximum load 1 A per relay connection
Upstream fuse The customer electrical feed must be limited by an upstream
fuse of 5 A (maximum) and approved to IEC 60127 with a
1500 A breaking capacity.

Table 1. Multi-Stage Alarm (VFC) ratings specification

A cable specification for the external connector is provided in Table 2.

Item Specification
Cable type The cable used must have flexible (multi-strand) conductors
and have insulation of the correct type for the voltage and
application environment.
Overall cable diameter Minimum 6.0 mm
Maximum 8.0 mm
Conductors Maximum size 1.5 mm2 16 AWG)
Insulation stripping 2 mm max Strip the insulation back, so that no more than
2 mm of bare conductor is exposed when the
cable is clamped in the terminal.

Conductor clamping Clamp the conductor in the terminal so that a minimum of

0.5 x the conductor diameter is on the far side of the clamping
screw.

Table 2. External connector cable specification

The following additional tools are required for this part of the procedure:
 Small flat-blade screwdriver
 11/16 inch spanner or a suitable adjustable spanner
 Connector sealing cap/assembly tool

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Multi-Stage Alarm (VFC) Conversion

Figure 3 identifies the parts of the external connector, shows the order of assembly, and
gives wire preparation information. The illustration shows a 3-pin socket connector, but
assembly is the same for all connectors of this type.
G
F
E 79078
D
C

H
B
A

m
m

m
m

20
6

A. Locking ring E. Gland

B. Socket insert F. Gland cage
C. Locking cap G. Gland nut
D. Main body H. Sealing cap/assembly tool

Figure 3. Assembly of the Multi-Stage Alarm (VFC) external connector

IMPORTANT: Do not connect primary signals (> 42 VAC peak or 60 VDC) and low
voltage signals (< 42 VAC peak or 60 VDC) to the same external
connector.
1 Use the sealing cap/assembly tool (H) to remove the connector locking ring (A).
2 Remove the socket insert (B) from the connector.
3 Feed the cable through the connector components in the order shown in Figure 3.
4 Cut and remove 20 mm of outer insulation from the cable, as shown in Figure 3.
5 Cut and remove 6 mm of insulation from each of the conductors, as shown in
Figure 3.
6 Insert the bare conductor ends into the terminals on the socket insert (B) according
to the pin-out information for the printer plug connector in the following
illustration. The conductors must be inserted into the terminals so that no more
than 2 mm of bare conductor is exposed when the cables are clamped in the
terminals (see Table 2). Completely tighten the terminal screws.
73089
MULTI-STAGE ALARM (VFC) CONNECTOR
Signal Pin

Normally closed (NC) 4 1 5

4 6
Normally open (NO) 4 2

Common 3 3 1

2
Normally open (NO) 3 4

Normally open (NO) 2 5

6-way plug connector
Normally closed (NC) 1 6 on the printer

Figure 4. Multi-Stage Alarm (VFC) connector details

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7 Carefully pull the cable back until the socket insert (B) is correctly fitted in the
D-shaped location in the main body (D).
8 Insert the locking ring (A) into the main body (D), and use the sealing
cap/assembly tool (H) to tighten the locking ring (A).
9 Slide the gland cage (F) and the gland (E) down the cable and into the main body
(D), and then tighten the gland nut (G). The gland nut must be completely
tightened so that the cable is correctly sealed and tightly gripped.

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Parallel I/O Interface Installation

Parts required
FA72178 5900/7900 Parallel I/O Interface Upgrade
comprising:
Alarm, Ethernet and Parallel I/O Option Plate
Option Plate Gasket
M3 Nyloc Nut (x12)
Parallel I/O PCB
Parallel I/O PCB Mounting Bracket
Snap Rivet (x2)
D-Type Connector Screwlock (x2)
Parallel I/O Interface Cable
25-Way D-Type Socket Dust Cover
M4 x 12 Screw Pan Head
Spacer

Equipment required
FA16005 Cover Removal Tool
Antistatic Wrist Strap and Lead

Introduction
Linx 7900 printers can be fitted with a Parallel I/O interface, which is available as an
accessory. The accessory includes an additional Parallel I/O PCB with a D-type connector
that fits to an option plate on the rear panel of the printer. The interface provides 8-off 24 V
DC inputs and 8-off 24 V DC outputs that can be used by the printer software for different
applications, which include:
 Selecting a message for printing from a list.
 Remote start and stop, and production line interlocks.
 Separate indications for warnings and faults.
This accessory allows 7900 printers to interface easily with programmable logic controllers
(PLCs) and similar machine controls.
The following procedure assumes that the printer is fitted with the standard 24 volts
external alarm.
Procedure

WARNING: LETHAL VOLTAGE HAZARD. DANGEROUS VOLTAGES EXIST IN THIS

EQUIPMENT WHEN ELECTRICAL POWER IS APPLIED.
TURN OFF AND DISCONNECT THE PRINTER FROM THE MAINS ELECTRICAL SUPPLY
BEFORE THE COVER IS OPENED.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS SAFETY
WARNING IS IGNORED.

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CAUTION: Static-Sensitive Devices. The PCBs contain static-sensitive devices. Take the
following antistatic precautions when PCBs are touched. Wear an antistatic wrist strap and
connect the lead to a good electrical earth. Always hold PCBs by their edges and do not touch
the components, printed circuit tracks or connector pins.
1 Shut down and turn off the printer. Turn off the mains electrical supply and
disconnect the mains electrical supply cable from the printer.
2 Remove the ink and solvent filler caps.
3 Unlock the security latch on the front of the top cover and remove the cover.
Position the cover so that the keyboard can be accessed.
4 Temporarily refit the ink and solvent filler caps to reduce evaporation of the ink
and solvent.
5 Disconnect the 24 V Alarm cableform from the IPM PCB (PL10).
6 Disconnect the 14-way connector from PL20 (Auto Power On) on the IPM PCB to
allow better access to the Alarm PCB.
7 Disconnect the Ethernet cable from the Ethernet connector on the rear panel plate.
8 Remove and retain the six Nyloc nuts that fasten the standard rear panel plate to
the rear of the printer.
9 Remove the standard rear panel plate and gasket from the printer.
10 Remove and retain the two Nyloc nuts that fasten the Alarm PCB to the back of the
24 V Alarm connector.
11 Remove and retain the Nyloc nut that fastens the Alarm PCB to the supporting
pillar.
12 Remove and retain the Alarm PCB.
13 Remove and retain the PCB supporting pillar from the standard rear panel plate.
14 Remove the locking ring from the back of the 2-way 24 V Alarm connector, and
remove the connector from the standard rear panel plate. Retain the connector and
locking ring.
15 Remove and retain the sealing cap and retaining strap from the Ethernet connector.
16 Remove and retain the four Nyloc nuts that fasten the Ethernet connector to the
standard rear panel plate.
17 Remove and retain the locking ring from the front of the Ethernet connector, and
remove the connector and gasket from the standard rear panel plate.
18 Retain the rear panel plate for future reinstallation of the standard 24 V Alarm only
option, if required.

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Ethernet connector
19 Insert the Ethernet connector and gasket into the bottom hole in the Alarm,
Ethernet and Parallel I/O option plate (see Figure 1). Make sure that the flat side of
the connector is aligned with the ‘D’ shape of the option plate, and then fit and
tighten the connector locking ring.

24 V alarm 79086
connector location

PCB supporting pillar

Ethernet
connector location

Parallel I/O connector

location

Figure 1. Front view of the 7900 Alarm, Ethernet and Parallel I/O option plate
20 Use four of the Nyloc nuts that are supplied in the kit to fasten the Ethernet
connector to the option plate.
21 Refit the sealing cap and retaining strap to the Ethernet connector.

24 Volt Alarm connector

22 Insert the original 24 V Alarm connector and gasket into the top hole in the Alarm,
Ethernet and Parallel I/O option plate (see Figure 1). Make sure that the locating
lug on the connector engages in the cut-out in the gasket and the option plate, and
then fit and tighten the connector locking ring.
23 Refit the PCB supporting pillar to the post next to the 24 V Alarm connector on the
Alarm, Ethernet and Parallel I/O option plate.
24 Fit the original Alarm PCB onto the two pillars on the connector and the PCB
supporting pillar.
25 Refit the two Nyloc nuts that fasten the Alarm PCB to the back of the connector.
26 Refit the Nyloc nut that fastens the Alarm PCB to the supporting pillar.

Alarm, Ethernet and Parallel I/O option plate

27 Make sure that the gasket is fitted to the front face of the Alarm, Ethernet and
Parallel I/O option plate.
28 Orientate the option plate assembly in the printer, with the 24 V Alarm connector
uppermost. Insert the option plate studs through the holes in the rear panel of the
printer.
29 Use six of the Nyloc nuts that are supplied in the kit to fasten the option plate
assembly to the rear panel of the printer.
30 Reconnect the Ethernet cable to the Ethernet connector.

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Parallel I/O PCB

31 Loosely fit the M4 screw and spacer that are supplied in the kit into the securing
hole for the Parallel I/O PCB in the bottom of the printer cabinet.
32 Remove the dust cap from the D-type connector on the Parallel I/O PCB (if fitted).
33 Put the Parallel I/O PCB into the printer in the correct orientation.
34 Align the slot in the PCB mounting bracket over the M4 screw in the bottom of the
printer cabinet. Slide the PCB towards the rear of the printer, so that the mounting
bracket slot fits under the head of the screw.
35 Use the two screwlocks that are supplied in the kit to fasten the D-type connector
on the Parallel I/O PCB to the Alarm, Ethernet and Parallel I/O option plate.
36 Fit the dust cap that is supplied in the kit to the D-type connector on the Parallel
I/O PCB.
37 Tighten the M4 screw in the bottom of the printer cabinet.
38 Reconnect the 24 V Alarm cableform to the IPM PCB (PL10).
39 Connect one end of the Parallel I/O Interface Cable to PL14 on the IPM PCB.
40 Connect the other end of the Parallel I/O Interface Cable to PL30 (labelled ‘IPM
PCB’) on the Parallel I/O PCB.
41 Reconnect the 14-way connector to PL20 (Auto Power On) on the IPM PCB.
42 Remove the ink and solvent filler caps.
43 Refit the top cover and secure the locking latch.
44 Refit the ink and solvent filler caps.
45 The ‘Parallel I/O Interface Installation’ maintenance instruction is now completed.

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Parts required
Desktop or laptop PC running Microsoft® Windows® 2000 or XP
Professional.
System requirements: Pentium® II 450 MHz; 128 MB of RAM; CD-ROM
drive; an available COM port; 256 colour, 800 x 600-pixel display; 200 MB
of disk space; additional 25 MB of disk space for each Linx Sync system
software file (if downloaded from ExtraLinx), and a maximum of 2 MB for
each backup file.
FA16005 Cover Removal Tool
Antistatic Wrist Strap and Lead
FA67059 6800(SP) and 6900 Reboot Kit, comprising:
FA75038 6800(SP)/6900 Boot PROM Set, comprising:
6800(SP)/6900 Boot PROM (A-6-8-056 IPM IC62)
FA63033 RS-232 PC Cable IP67 2-metre Full Handshake

Introduction
Linx Sync v4.0 is compatible with 6900, 7300 and 7900 System Software and backward
compatible with all versions of 6800 System Software. In addition, 6800 data can be backed
up and upgraded from any version up to the latest version of system software.
Linx Sync v4.0 is compatible with the Boot PROMs issued with Linx Sync v2.0 and 6800 v1.6
System Software.
Linx Sync v4.0 is compatible with the Boot PROMs issued with Linx Sync v2.1 and 6800 v1.7
System Software.
Linx Sync v4.0 is compatible with the Boot PROMs issued with Linx Sync v3.0 and 6800 v2.0
System Software.
The table below shows the compatibility issues.

Linx Sync v1.2 Linx Sync v2.1 Linx Sync v3.0 Linx Sync v4.0
v1.2 Boot PROMs Compatible Compatible Compatible Compatible
v2.0 Boot PROMs Compatible Compatible Compatible Compatible
v3.0 Boot PROMs Not supported Not supported Compatible Compatible
.lsf file format Not supported Supported Supported Supported
.mot file format Supported Supported Supported Supported
Backup and Restore Not supported Supported Supported Supported

Table 1. Linx Sync compatibility issues

The Linx Sync Service Tool is intended for use only by maintenance technicians to perform
the following three tasks:
 Program (upgrade) a printer with a new version of system software.
2. Backup and restore a printer’s data.
3. Transfer data between a printer and a PC, or between printers via a PC using Linx Sync.

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IMPORTANT:
1. The printer must be in the ‘Idle’ state (that is, not printing) before any of the
following procedures can be carried out.
2. Some PC screen savers can severely impact the Linx Sync software by causing
programming problems if they are running at the same time. Linx strongly
recommends that any screen savers and power saving features are disabled before
the software programming, data backup or data transfer procedures are started.

Procedures
This maintenance instruction includes the following procedures:
 Software programming—normal.
 Software programming—corrupt/faulty software.
 Backing up and restoring data.
 Transferring data.
The first programming procedure (‘Software programming—normal’) describes the normal
procedure to program a printer with the system software from a PC in the following
circumstances:
 When upgrading the 7900 System Software (that is, installing a new version of system
software to replace a previous version).
 When the IPM PCB is replaced with a board that does not have 7900 System Software
installed.
The second programming procedure (‘Software programming—corrupt/faulty software’)
uses a PROM to copy software onto the printer, which is then used to program the printer.
This procedure is to be used in the following circumstances:
 When the system software installed on the printer is corrupt and Linx Sync cannot
identify the printer. More specifically, to correct corrupt software, or a total software
failure that cannot be cleared by turning the printer off and then on again (a reboot).
 When a printer is new and does not have software installed, or when an IPM PCB is
fitted that does not have software installed.
A ‘Failures while programming’ troubleshooting guide is also provided at the end of the
two programming procedures.

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Software programming—normal
NOTE: Only one printer can be programmed at a time.
1 Make sure that the printer is switched off at the mains electrical supply.
2 Connect the RS-232 interface cable between the PC and the RS232 INTERFACE
connector on the rear panel of the printer.
3 Turn on the printer and the PC. Wait until the printer has carried out the startup
checks and the Welcome screen is displayed.
4 Make sure that the communications protocol is set to RPC (Print Monitor > Menu >
Setup > Communications > Protocol > RS232 Protocol).
NOTE: If it is necessary to change the protocol to RPC, remember to reset it to its
original setting at the end of this procedure.
5 Download the Linx Sync v4.0 software and the latest version of Linx 7900 System
Software from ExtraLinx (Linx’s Extranet site) to the PC.
IMPORTANT: The Linx Sync Service Tool must never be copied to a customer’s PC. It
must only be used by Linx and Linx Distributor maintenance
technicians. Unauthorized use may result in loss of printer data.
6 Double click the ‘Linx Sync.exe’ file. (If required, a shortcut to the application can
be made now and placed on the desktop.)
7 All available COM ports are displayed in the left pane of the Linx Sync window,
with a ‘+’ symbol next to each one that has a printer connected to it. Click a COM
port’s ‘+’ symbol to reveal the connected printer, which is identified by its UNIC
code or “Printer Ready for Download”.
69512

Figure 1. Connected printers in the Linx Sync window

If “Printer Ready for Download” is displayed, this means that the printer is not
programmed with a version of system software. If nothing is displayed, check that
the interface cable is connected correctly and that the correct protocol is selected
(see step 4). If after doing this there is still nothing displayed, proceed with the
second part of this maintenance instruction, ‘Software
programming—corrupt/faulty software’.

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8 Use one of the following three methods to program a printer with system software
(the system software file has an ‘.lsf’ file extension, for example ‘6900v3.1.lsf’):
 Drag and drop the system software file onto the printer in the left pane.

69513

Figure 2. Dragging and dropping the system software file

 Select and copy the system software file (right-click to select the file, and then
click Copy), Select the printer in the left pane and paste the file to the printer
(Edit menu > Paste).

69514

Figure 3. Copying and pasting the system software file

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 Select the printer in the left pane. On the File menu, click Download, which
displays the Open dialog box:
(a) Browse for the system software file and select it.
(b) Click the Open button to start the programming process.
69515

Figure 4. Downloading the system software file using the Download menu command
When programming has started, if the printer already has software installed, the
option is given to maintain the store during the programming process.
Maintaining the store simply backs up stored items (that is, messages, logos and
all configuration data, including calibration values and configuration codes) to the
PC before software installation, and then restores the data after software
installation. The following message dialog box is displayed.
69516

Figure 5. “Maintain the store during download?” message dialog box

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9 Click the Yes button to restore the store when the software installation is complete,
or click the No button if you no longer wish to maintain the store.
A dialog box is displayed during the programming process, which shows the
progress of the software installation. It displays the total size of the file being
installed and how much has been installed so far. A progress bar also displays the
progress pictorially.
69517

Figure 6. Download progress dialog box

10 To abort the programming process, click the Cancel button. However, cancelling
programming may leave the printer in an unusable state. The 6800/6900 Boot
PROM Set is then needed to recover the printer to a useable state (refer to the
procedure, ‘Software programming—corrupt/faulty software’ in this maintenance
instruction). To help avoid this situation, a message dialog box is displayed that
warns of the consequences of cancelling and asks if you wish to continue.
11 Close Linx Sync when the software has been installed.
12 Turn Off the printer.
13 Disconnect the RS-232 interface cable from the printer.
14 Turn on the printer.
15 The ‘Software programming—normal’ procedure is now complete and the printer
is ready for use.

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Software programming—corrupt/faulty software

WARNING: LETHAL VOLTAGE HAZARD. DANGEROUS VOLTAGES EXIST IN THIS

EQUIPMENT WHEN ELECTRICAL POWER IS APPLIED.
TURN OFF AND DISCONNECT THE PRINTER FROM THE MAINS ELECTRICAL SUPPLY
BEFORE THE COVER IS OPENED.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS SAFETY
WARNING IS IGNORED.

CAUTION: Static-Sensitive Devices. The PCBs contain static-sensitive devices. Take the
following antistatic precautions when PCBs are touched. Wear an antistatic wrist strap and
connect the lead to a good electrical earth. Always hold PCBs by their edges and do not touch
the components, printed circuit tracks or connector pins.
1 Make sure that the printer is switched off at the mains electrical supply.
2 Remove the ink and solvent filler caps.
3 Unlock the security latch on the front of the top cover and remove the cover.
4 Temporarily refit the ink and solvent filler caps to reduce evaporation of the ink
and solvent.
NOTE: Make sure that you have the latest version of the 6800(SP)/6900 Boot PROM Set
(FA75038).
5 Fit the 6800(SP)/6900 Boot PROM (A-6-8-056) to the IPM PCB socket IC62.
6 Fit link LK5 to the IPM PCB.
7 Turn on the printer.
8 Wait approximately 25 seconds while the reboot software is copied to the PCB. On
completion of the reboot, the LED adjacent to LK5 on the IPM PCB flashes.
9 Turn off the printer.
10 Remove link LK5 from the IPM PCB.
11 Remove the Boot PROM from the IPM PCB.
12 Download the system software as described in steps 1 to 12 of the ‘Software
programming—normal’ procedure. Note that in this circumstance the Welcome
screen is not displayed as stated in step 3, but the indication to continue from step 4
is the LED adjacent to LK5 flashing.
13 Remove the ink and solvent filler caps.
14 Refit the top cover and secure the locking latch.
15 Refit the ink and solvent filler caps.
16 Turn on the printer.
17 The ‘Software programming—corrupt/faulty software’ procedure is now complete
and the printer is ready for use.

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Failures during programming

Failures can occur while programming a printer. The following are some possible problems
and solutions.

Printer is turned off while programming

If the power is turned off during the programming process, the programming fails and
must be restarted. Turn on the printer again and refer to 'Restarting programming' later in
this section.

Serial cable is disconnected while programming

If the serial cable is disconnected during the programming, Linx Sync will time out. An
advisory message dialog box is displayed to indicate the loss of the connection, and gives
the option to retry or cancel. Reconnect the cable and click the Retry button to allow the
programming to continue. After three attempts to continue, the only option that is made
available is to cancel. If the Cancel button is clicked at any time, the programming fails and
must be restarted. Refer to 'Restarting programming' later in this section.

Linx Sync is cancelled

If programming cancels or Linx Sync stops, the programming fails and must be restarted.
Refer to 'Restarting programming' later in this section.

Possible PC-related problems

If problems programming the printer or downloading software continue, do one or more of
the following:
 Disable any screen savers.
 Disable any power saving features, especially on laptops.
 Shut down other PC applications, especially any that use the serial ports.
 If necessary, restart the PC.

Restarting programming
If programming fails and cannot be restarted, begin the programming again.
If the LEDs on the IPM PCB are not flashing, the first step is to prepare the printer for
programming with the Boot PROMs, as described in the procedure 'Software
programming-corrupt/faulty software'.
If the store was maintained during the previous programming, a dialog box is displayed
that gives the option to maintain the store.
69518

Figure 7. “Maintain the store backed up last time?” message dialog box
Click the Yes button to restore the store when the programming is complete, or click the No
button if you no longer wish to maintain the store.

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Backing up and restoring data

A. Backing up
The backup files are stored in a default base directory (also known as a folder) called
‘C:\backup’, but this directory can be changed if required. If you wish to change the base
directory, carry out step 1 first; if not, proceed to step 2.
1 To change the base directory: on the Setup menu, click Backup Directory, which
displays the Backup Directory dialog box.

69519

Figure 8. Changing the base directory of the backup files

(a) Click the Modify button, which displays the Browse for Folder dialog box.
(b) Browse for the required new directory and select it.
(c) Click the OK button.
2 In the left pane of the Linx Sync window, select the printer to be backed up.

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3 On the File menu, click Backup.

69520

Figure 9. Selecting a printer to back up

The selected printer is backed up and the backup file is automatically named using
the time and date, and put in the printer’s backup directory on the PC.

69521

Figure 10. Named backup file in the printer’s backup directory

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B. Restoring
NOTES:
1. If a backup file was taken from a printer that has an earlier version of system
software than the printer it is being restored to, the data items (see NOTE 2 below)
being restored are upgraded, as necessary. For example, if a 6900 printer with v3.7
System Software was backed up, and then the backup file is restored to a 7900
printer with v5.1 System Software, data items in the backup file are upgraded to
work with v5.1.
2. When a backup file from a 6800 printer is restored to a 6900, 7300 or 7900 printer,
Linx Sync v4.0 only upgrades messages, logos and sequences data items. Setup
data is not maintained.
1 In the left pane of the Linx Sync window, select the printer to restore a backup to.
2 On the File menu, click Restore, which displays the Select Backup File dialog box
containing a list of backup files for the selected printer.
69522

Figure 11. Selecting a backup file to restore to a printer

3 If required, browse for the required backup file to restore, and then select it.
4 Click the OK button to restore the backup file to the selected printer.

Transferring data
Data can be transferred between one printer and another, between a printer and a backup
file, and between a printer and a PC.
Data transfer is done by either copy and paste, or drag and drop methods.
NOTE: As with backing up and restoring, a store item copied from one printer to another is
upgraded according to the versions of system software on the printers. See NOTE
at the start of the 'Restoring' procedure.

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A. Transferring from a printer

Data can be transferred from a printer to another printer, to a backup, or to an explorer
application.
NOTE: Data types cannot be transferred from a printer to an explorer application.
1 To transfer one or more data items from a printer, copy them from the printer and
paste them to the destination, or drag them from the printer onto the destination
(see the following NOTE), as shown in the following screen.

69523

Figure 12. Transferring data items from a printer

NOTE: It is not possible to drag and drop data items from a printer to an explorer
application.
2 To transfer one or more data types from a printer to a backup, copy them from the
printer and paste them to the backup, or drag them from the printer onto the
backup, as shown in the following screen.
69524

Figure 13. Transferring data types from a printer to a backup

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B. Transferring from a backup

Data can be transferred from a backup to a printer, to another backup, or to an explorer
application.
1 To transfer one or more data items from a backup, copy them from the backup and
paste them to the destination, or drag them from the backup onto the destination,
as shown in the following screen.
69525

Figure 14. Transferring data items from a backup

2 To transfer one or more data types from a backup, copy them from the backup and
paste them to the destination, or drag them from the backup onto the destination,
as shown in the following screen.
69526

Figure 15. Transferring data types from a backup

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C. Transferring from a PC
Data can be transferred from a PC to a printer or a backup.
1 To transfer one or more data items from a PC, copy them from the explorer
application and paste them to the destination, or drag them from the explorer
application onto the destination, as shown in the following screen.

69527

Figure 16. Transferring data items from a PC

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 CHAPTER 6: SYSTEM EVENTS
6.1 Introduction
This chapter describes the system events that can occur on 7900 printers. System events are
divided into four categories:
 System Failures
2. Print Failures
3. System Warnings
4. Information Events
System Failures, Print Failures, and System Warnings are defined as those that can occur at
any time and are not a direct response to operator commands.
Information events are not failures or warnings, but are events that are reported when
specific jet functions have occurred.
Each event message is given a unique code number, which identifies the type and source of
the event, and is followed by a short description, for example:
“3.18 Low Pressure”
When an event occurs, the System Event page is displayed, which provides information
about the event that includes the time and date that it occurred (the Timestamp). The page
shows a list of the last six reported events.
NOTE: The Event Log and System Event pages are mutually exclusive, which means that
if one page is displayed, the other page cannot be displayed. Therefore, if the Event
Log is being used when an event occurs, the System Event page is not displayed.
Refer to Chapter 4: ‘System Options’ for information about the Event Log.
73065

3.18 Low Pressure.

13-12-31 23:59:59

3.18 Low Pressure 13-12-31 23:59:59

Figure 6-1. System Event page

The internal alarm tone is activated when a system event occurs. If the OK key on the
System Event page is pressed, the event message is acknowledged and the page is closed. If
the same event occurs again after its time interval (refer to ‘Log At Intervals’ on page 4—14,
in the ‘Event Log’ description), the event is reported again.
When the System Event page is closed, the message “Print Failures Exist” or “System
Warnings Exist” is displayed in the bottom line of the Printer Status area of the Print
Monitor. This message is a continuous prompt that there is a problem with the printer.

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6.2 System event identifications
6.2.1 System Failures
These failures prevent normal printer operation. The messages are prefixed with ‘1’, that is,
1.XX.

6.2.2 Print Failures

These failures occur when the software detects a problem that affects printing. The
messages are prefixed with ‘2’, that is, 2.XX.

6.2.3 System Warnings

These are events that are not serious enough to shut down the printer, but give advanced
warning of potential problems. The messages are prefixed with ‘3’, that is, 3.XX.

6.2.4 Information events

These are events that inform the operator that specific jet functions have occurred. The
messages are prefixed with ‘4’, that is, 4.XX, and the limited number of designated ones are
listed in the ‘Event Filtering’ description in Chapter 4: System Options > Menu Page >
Event Log.

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6.3 Summary of system events
1. System Failures 2. Print Failures
1.00 Internal Failure 2.00 Printhead Over Temperature
1.01 Stack Overflow 2.01 EHT Trip
1.02 Corrupt Program Data 2.02 Phase Failure
1.03 Internal Software 2.03 Time Of Flight Failure
Failure (ASSERT)
2.04 300V Power Supply
2.05 Ink Tank Empty
2.06 Solvent Tank Empty
2.07 Internal Spillage
2.08 Printer Over Temperature
2.09 Misaligned Ink Jet
2.10 Not used
2.11 Pressure Limit Reached
2.12 Viscosity
2.13 Hardware Safety Trip
2.14 Pressure O/ride Circuit Tripped
2.15 Scheduled Maintenance is
overdue by 3 months–Please
contact your local Linx Service
Centre immediately
2.16 System Configuration Not
Recognised
Table 6-1. System events summary table
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3. System Warnings
3.00 Shutdown Incomplete
3.01 Shutdown Incomplete (Failure)
3.02 Memory Corrupt
3.03 Ink Low
3.04 Solvent Low
3.05 Over Speed (Print Trigger)
3.06 Over Speed (Synchronous Data)
3.07 Over Speed (Asynchronous Data)
3.08 Over Speed (Line Speed)
3.09 Over Speed (Compensation)
3.10 Under Speed (Line Speed)
3.11 Printer Requires Scheduled
Maintenance
3.12 Printhead Cover Off
3.13 Cover Override Link Fitted
3.14 Power Off Override Active
3.15 Safety Override Active
3.16 Gutter Override Active
3.17 Gate Array Test Mode Active
3.18 Low Pressure
3.19 Valid UNIC Chip Not Found
3.20 No Time Of Flight
3.21 Ink Low Prevented Mix
3.22 Fault Prevented Mix
3.23 Power Off Occurred During Mixing
3.24 Restart In Progress
3.25 Ink Unmixed For 4 Weeks
3.26 User Data Corrupt–Please contact
your local Linx Service Centre
3.27 Mix Disabled
3.28 Printhead requires cleaning at
shutdown
3.29 Over Speed (No Remote Data)
3.30 Remote Error
3.31 Restarted Print Delay
3.35 Printer Requires Scheduled
Maintenance Within One Month
Oct 2013
6.4 System Failures
System Failures occur when the software detects a condition that prevents the printer from
operating. System Failures are fatal; it is not possible to continue to operate the printer after
a System Failure has occurred. The only way to clear the failure is to switch the printer off
and then on again.
Most System Failures are reported while the software is performing the self test and
initialization routines, which are carried out after the printer is switched on, that is, while
the splash screen is displayed. When the Print Monitor is displayed, all the initialization
and self tests have been completed.

WARNING: LETHAL VOLTAGE. BECAUSE SYSTEM FAILURES 1.00 AND 1.01 INDICATE A
FAILURE IN THE MICROPROCESSOR, THE SOFTWARE CANNOT BE DEPENDED ON TO SET
THE PRINTER TO A SAFE STATE. THE EHT AND THE 300 VOLTS DC CAN CONTINUE TO BE
GENERATED IN THE PRINTER.
EXTREME CARE MUST BE TAKEN WHEN WORK IS DONE ON THE PRINTER WHILE SYSTEM
FAILURES 1.00 AND 1.01 EXIST AND THE TOP COVER IS REMOVED. THE CORRECT,
STANDARD ELECTRICAL SAFETY PRECAUTIONS MUST BE TAKEN.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THE CORRECT
ELECTRICAL SAFETY PRECAUTIONS ARE NOT TAKEN.
System Failures that occur during normal operation indicate a serious problem that
prevents further printer operation. The software attempts to set the printer to a safe state
when the failure occurs, as follows:
 Set the pressure to zero.
 Turn off the EHT.
 Close all valves.
 Turn off the 300 V DC.
System Failures cause the printer to stop printing by simply closing the ink system and
printhead Feed valves; a normal jet shutdown is NOT performed. This leads to a
subsequent messy startup and can cause permanent damage to the printhead if it is left in
this condition.
When a System Failure occurs, the ‘print ready’ line is set low and a System Failure message
is displayed. The internal alarm tone is activated twice, but the external alarm is not
activated because the software cannot be certain of the ‘alarm enable’ state following some
System Failures.

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 6.4.1 “1.00 Internal Failure”
Undefined software failure. This failure 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:
 Printer top cover not correctly secured or printhead cover tube screw not in place.
 Dirty IPM PCB caused by a damaged or missing air inlet filter.
 Faulty IPM PCB.
 EMC interference or spike on the mains electrical supply.
 Static discharge to the printhead from the operating environment.
 Poor electrical connections.

6.4.2 “1.01 Stack Overflow”

Software failure. The software stack has exceeded the maximum expected size. The stack is
an area of memory used by the microprocessor in which information is temporarily stored.

Possible causes:
 Faulty or corrupt microprocessor.
 Faulty IPM peripheral that is issuing too many interrupts.

6.4.3 “1.02 Corrupt Program Data”

Program and/or Data stored in Flash memory is corrupt.

Possible causes:
 Faulty or corrupt Flash memory—reload the software.
 Faulty IPM PCB.

6.4.4 “1.03 Internal Software Failure”

This software failure is not defined. The failure message indicates that the software received
a signal that has errors, and the software was reset to a state that is not defined. If this
failure occurs, the fault is normally detected when the printer is in operation, after
successful completion of the startup system checks.

Possible causes:
 Software errors.
 A fault on the IPM PCB.
 The printer top cover is not correctly fitted, or the printhead cover tube screw is not
fitted.
 Dirty IPM PCB caused by a damaged or missing air inlet filter.
 A large amount of EMC interference or spikes on the mains electrical supply.
 Static discharge to the printhead from the operating environment.
 A fault in the electrical connections.

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6.5 Print Failures
Print Failures occur when the software detects an electrical or mechanical failure that
prevents printing. When a Print Failure occurs, the ‘print ready’ line is set low, the System
Event page is displayed, and a jet shutdown sequence is started. The internal alarm tone is
activated twice and, depending on the settings of the Alarm Setup options (Print Monitor >
Line Setup > Alarm), the external alarm may be activated continuously.
In some cases, although some message editing facilities may still be available, the printer
must be switched off at the mains electrical supply switch and then back on before printing
can be continued. This is to reset the hardware. With these Print Failures the conditions
cannot be altered until the cause of the failure has been rectified, that is, the jet cannot be
restarted. However, most Print Failures start a normal shutdown sequence and the jet can
be restarted in the normal manner afterwards without the need to switch the mains
electrical supply off and then on.
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 DC.

6.5.1 Restart sequence

Before the jet starts, all the normal static checks are made, such as pressure/filter check, ink
and solvent levels, and time to the next Service. As the jet starts, the dynamic functional
checks and adjustments are carried out: ink in gutter check, pressure check, phasing and
TOF adjustments. The printer enters the Jet Running state only after all these functions have
been successfully completed. However, if any of the checks or adjustments are invalid, the
printer attempts a further three starts (four in total) using the Restart sequence. If an invalid
condition still exists, the printer provides an audible and on-screen warning, or fails with a
Print Failure message.

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 6.5.2 “2.00 Printhead Over Temperature”

WARNING: HIGH TEMPERATURE. WHEN THIS FAULT IS REPORTED, THE PRINTHEAD AND
COVER TUBE CAN BE VERY HOT.
EXTREME CARE MUST BE TAKEN TO PREVENT SKIN BURNS AND TO DECREASE THE RISK
OF A FIRE. DO NOT TOUCH THE PRINTHEAD, OR TRY TO REMOVE THE PRINTHEAD COVER
TUBE UNTIL THE PARTS BECOME SAFELY COOL NATURALLY.
THERE IS A DANGER OF SEVERE BURNS TO THE HANDS IF THE PRINTHEAD COVER TUBE
IS REMOVED BEFORE IT HAS BECOME SAFELY COOL. THERE IS ALSO AN INCREASED RISK
OF FIRE CAUSED BY THE SUDDEN INCREASE OF AIR AROUND THE OPEN PRINTHEAD.
An excessive high temperature has been detected at the printhead indicating a high
ambient temperature or a possible fire condition. The trip temperature is approximately
60 C.

Possible causes:
 Printhead too close to source of high temperature.
 Short circuit printhead thermistor.
 Short circuit connection on printhead connector.
 Faulty IPM PCB.
NOTE: Hot substrates should be printed on from the side to avoid heat convection to the
printhead.

6.5.3 “2.01 EHT Trip”

The EHT trip sense software has detected that an EHT trip has occurred, that is, the EHT
output has been switched off.

Possible causes:
 Excessive build-up of ink on the EHT deflector plate, or the ink is shorting the plate to
another item in the printhead, for example, the gutter.
 Static discharge.
 High humidity.
 Vibration.
 Jet instability caused by contaminated ink or debris in the nozzle.
 Printhead too close to the substrate.
 High or low ink viscosity causing satellite drops, which have built up on the deflector
plates.
 No modulation.

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 6.5.4 “2.02 Phase Failure”
The printer failed to obtain a valid phase position. This failure is normally associated with
invalid data from the hardware and can be caused if the printhead becomes very dirty with
ink, particularly around the DPP.
When the jet is running, the phase position must be adjusted to ensure the correct charge is
applied to the drops to give a good print.
A phase failure occurs if the microprocessor has not received a phase feedback signal to
indicate the true phase position. A maximum number of attempts are made to find the
phase position, after which the printer fails and performs the jet shutdown sequence.

Possible causes:
 No jet:
 Nozzle blocked.
 No ink feed to the printhead.
 Poor jet break-up:
 Ink viscosity too high or too low.
 Reference modulation set very low.
 Modulation too high or too low.
 No modulation signal.
 Jet misalignment:
 Partly blocked nozzle.
 Debris in the nozzle.
 Contaminated ink.
 Mechanical misalignment.
 An obstruction such as a fine hair impeding the jet, for example, through the charge
electrode.
 No charge to the charge electrode caused by bad connections, faulty charge amplifier or
incorrect charge DAC calibration.
 No signal from the phase/TOF connections.
 Faulty phase amplifier on IPM PCB.
 Faulty gate array circuitry on the IPM PCB.
 Conductivity problems due to contaminated ink.
 Very heavy ink build-up in the printhead.
 EHT tracking on the printhead due to very damp/humid environments.
NOTE: This failure detection is disabled whenever the Jet Test – Start option is used.

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 6.5.5 “2.03 Time Of Flight Failure”
This failure occurs if, after the jet has been started, there are no valid TOF readings for a
period of 40 minutes.

Possible causes:
 The shaft encoder or production line stops mid-print (only applicable to IPM PCBs that
have an earlier than Issue 4 Gate Array).
 Incorrect or no signal from the TOF sensor caused by a partially blocked nozzle or jet
misalignment.
 Poor drop break-up caused by incorrect modulation/ink viscosity.
 The ink viscosity is so far out of range that correctly measured TOF values are rejected
as being spurious readings.
 Heavy build-up of dry ink on the deflector plates.
 Noise (EMC) interference.
 The inter-print distance is too small to allow TOF measurement.
NOTE: This failure detection is disabled whenever the Jet Test – Start option is used.

6.5.6 “2.04 300V Power Supply”

The 300 volts sense signal has detected that the 300 V output from the EHTPSU is not
present.

Possible causes:
 The EHTPSU 300 V output has failed.
 Faulty 5 volts reference, which is compared with a proportion of the 300 volts line to
determine the presence of the 300 volts.
 Printhead modulation/charge short circuit.
 Faulty 300 volts control circuit on IPM PCB.
 Faulty 300 volts sense comparator (IC35A).

6.5.7 “2.05 Ink Tank Empty”

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

6.5.8 “2.06 Solvent Tank Empty”

This failure occurs when the solvent level sensor has been indicating low (“3.04 Solvent
Low” warning) for a predetermined time of 12 hours for all printheads.
The time limit prevents the solvent from running out completely if the operator fails to refill
the solvent reservoir following a System Warning “3.04 Solvent Low” message. This failure
only occurs when the jet is running, as the jet cannot normally be started when the solvent
is low.

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 6.5.9 “2.07 Internal Spillage”
The base of the ink system enclosure is sealed in order to contain any ink or solvent spillage,
preventing external leakage. In the event of a pressurized ink leak from an ink system pipe,
manifold assembly or pump head, a spillage sensor stops the pump within 5 seconds of
detection (that is, there is no jet shutdown). The sensor is fitted through (but insulated from)
the lower front wall of the ink system enclosure. When a spillage reaches a minimum of 50
ml, a short circuit occurs between the sensor and the ink system enclosure through the
conductive ink. This short circuit is detected by the microprocessor on the IPM PCB and the
System Failure “2.07 Internal Spillage” is reported.

Possible causes:
 Ink or solvent reservoir overflow.
 Incorrect ink replenishment procedure.
 Leak within the ink system.
 Faulty spillage detection circuit.

6.5.10 “2.08 Printer Over Temperature”

The printer cabinet maximum internal temperature has been reached. The threshold of the
cooling failure detection circuit is 58 °C.

Possible causes:
 Blocked air filter.
 Fan failure, caused by:
 Bad electrical connections to the fan.
 Fan blade obstruction.
 Fan control circuit failure.
 Fire within the printer cabinet.

6.5.11 “2.09 Misaligned Ink Jet”

Under normal operating conditions, the gutter sense circuit detects the presence of ink flow
in the gutter. If ink flow is not detected in the gutter for any reason (for example, a
misaligned jet), the software shuts down the jet. Absence of ink in the gutter is detected
within approximately 2 seconds.

Possible causes:
 Partly blocked nozzle.
 Debris in the nozzle.
 Blocked gutter.
 Contaminated ink.
 Mechanical misalignment.
 An obstruction, such as a fine hair, impeding the jet through the charge electrode.

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 6.5.12 “2.11 Pressure Limit Reached”
The software is unable to increase the pressure sufficiently to achieve a TOF measurement
equal to the Reference TOF. This can occur during the jet start process.

Possible causes:
 Blocked ink pick-up tube in-line filter or main ink filter.
 Leaking purge or gutter valve.
 Very high ink viscosity.
 No modulation.
 No charge.
 Worn pump.
 Faulty pressure transducer.
 Incorrect calibration code entered.
 Incorrect printhead type selected.
 Excessive noise on the phase/TOF signal.

6.5.13 “2.12 Viscosity”

The software is unable to establish Reference TOF at or below the Solvent Add Pressure.
The printer has added solvent eight times (for MEK inks, 12 times for Mixed Base inks)
without being able to bring the pressure below the Solvent Add Pressure.
When the jet is running, the normal TOF adjustment routine may add solvent if the Solvent
Add conditions are met (refer to Chapter 3: ‘Technical Description’ > Ink system > Ink and
solvent flows > Solvent addition). A Solvent Add allows a fixed amount of solvent to be
added to the ink reservoir. Typically, it takes approximately 20 minutes for the full effect of
the solvent addition to be seen at the nozzle.
After a solvent addition, the pressure is adjusted to control the TOF. However, if after 20
minutes the pressure is still greater than the Solvent Add Pressure, a further solvent
addition is allowed. This is repeated until the pressure is below the Solvent Add Pressure.
A maximum limit of eight successive solvent additions (for MEK inks, 12 for Mixed Base
inks) is allowed in any one TOF correction loop. If this limit is exceeded, this failure is
reported and the jet is shut down.

Possible causes:
 Blocked ink pick-up tube in-line filter or main ink filter.
 Leaking purge or gutter valve.
 Incorrect calibration code entered.
 Solvent pick-up tube in-line filter blocked.
 There is a loss of pressure in the ink system and the pressure has been set artificially
high in order to reach the TOF reference. Consequently, the maximum number of
solvent additions may have been exceeded, which results in this failure being reported.
 Ink has been added to the solvent tank by mistake.
NOTE: This failure detection is disabled whenever the Jet Test – Start option is used.

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 6.5.14 “2.13 Hardware Safety Trip”
The hardware safety trip has activated locking out certain hardware functions. This may be
initially reported as Print Failures “2.00 Printhead Over Temperature” or “2.01 EHT Trip”.

Possible causes:
 See Print Failures “2.00 Printhead Over Temperature” or “2.01 EHT Trip”.

6.5.15 “2.14 Pressure O/ride Circuit Tripped”

Currently not used.

6.5.16 “2.15 Scheduled Maintenance is overdue by 3

months–Please contact your local Linx Service Centre
immediately”
The remaining time to the next scheduled maintenance is monitored. This failure occurs
under one of the following conditions, whichever occurs first:
 When the current date is more than 90 days after the ’Maintenance Due By’ date.
 When the ‘Maintenance Due Within’ time is more than 2160 hours (90 days) past zero.
The failure puts the jet control system into the fault state, which prevents the jet from being
started.
The failure is reported on the System Event page each time the printer is turned on. An
information message is also displayed every 24 hours after the printer is turned on. Both of
these messages continue to be displayed until the scheduled maintenance has been done,
and the intervals to the next scheduled maintenance have been reset by the maintenance
technician.

6.5.17 “2.16 System Configuration Not Recognised”

The 7900 System Software is not compatible with 7300 printer hardware. If 7900 System
Software is downloaded to a 7300 printer, this failure is reported on the 7300 printer when
an attempt is made to put the printer into the ‘Printing’ state. The failure puts the jet control
system into the fault state, which prevents the jet from being started. However, the user
interface can still be used (for example, to create messages).

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6.6 System Warnings
System Warnings inform the operator of problems that may affect the operation of the
printer, but are not serious enough to require a shutdown. When a System Warning event
occurs, the System Event page containing the warning message is displayed. The internal
alarm tone is activated twice and, depending on the settings of the Alarm options (Print
Monitor > Line Setup > Alarm > Alarm Setup), the external alarm may be activated twice.

6.6.1 “3.00 Shutdown Incomplete”

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

6.6.2 “3.01 Shutdown Incomplete (Failure)”

The printer did not perform a complete shutdown following a System Failure or Print
Failure.
If a System Failure or Print Failure occurs while the jet is running, the jet is simply stopped.
Printer start problems may be experienced if the shutdown sequence was incomplete; these
could be a blocked nozzle, a dirty start or a misaligned jet.
The warning is reported on every subsequent printer power-up until a jet shutdown
sequence is fully completed.

6.6.3 “3.02 Memory Corrupt”

When the printer is switched on, each individual item stored in the back-up NVR is checked.
If one or more items are corrupt, the default values for those items are loaded and this event
is reported. The system still functions, but some values may have been reset to the defaults.

Possible causes:
 The battery back-up has partially failed (flat battery).
 Link LK4 is not fitted on the IPM PCB.
 Electrical spikes.
 Faulty memory ICs.

6.6.4 “3.03 Ink Low”

If the ink level sensor indicates that the volume of ink in the tank is low, this warning is
reported. Unlike other event messages that are displayed on the System Event page, the Ink
Low warning is displayed on the SureFill page. This page includes a request to enter the
SureFill code, which is on the ink bottle label, before the new ink is added.
The warning is cleared automatically when a sufficient quantity of ink is added to the tank.
If this event is detected before the jet is started, the jet cannot be started until the event has
been cleared (that is, the ink tank is refilled). If the event is detected while the jet is running,
the jet continues to run for 6 hours (Ultima plus and Midi plus printheads) or 8 hours
(Ultima, Midi, Mini, and Micro printheads) until the ink level is critically low, at which
point the printer fails (see Print Failure “2.05 Ink Tank Empty”).
IMPORTANT: The ink tank should be refilled only when this warning is reported (one
bottle of ink only).

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 6.6.5 “3.04 Solvent Low”
If the solvent level sensor indicates that the volume of solvent in the tank is low, this
warning is reported. Unlike other event messages that are displayed on the System Event
page, the Solvent Low warning is displayed on the SureFill page. This page includes a
request to enter the SureFill code, which is on the solvent bottle label, before the new
solvent is added.
The warning is cleared automatically when a sufficient quantity of solvent is added to the
tank.
If this event is detected before the jet is started, the jet cannot be started until the event has
been cleared (that is, the solvent tank is refilled). If the event is detected while the jet is
running, the jet continues to run for 12 hours (all printheads) until the solvent level is
critically low, at which point the printer fails (see Print Failure “2.06 Solvent Tank Empty”).
IMPORTANT: The solvent tank should be refilled only when this warning is reported (one
bottle of solvent only).

6.6.6 “3.05 Over Speed (Print Trigger)”

Print triggers are occurring more quickly than the printer can print. This indicates that the
printer has received a second or false print trigger, and the delay has expired, when it is
currently printing a message.
When the Print Trigger option (Print Monitor > Line Setup > Trigger > Print Trigger) is set
to Edge Triggers or Level Triggers, each print delay is started following the trigger signal.
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, the warning is reported and the new message is not
printed. In effect, this means that alternate objects may not be printed upon.

Possible causes:
 The trigger device is providing false triggers due to electrical noise, or an inadequate
trigger device is being used for the application.
 There is electrical ‘bounce’ on the trigger device input. Try moving the debounce link
LK36 to the SLOW position.
 The distance from the trigger device to the printhead is greater than the distance from
one product to the next.

6.6.7 “3.06 Over Speed (Synchronous Data)”

A ‘print go’ occurred before the message data could be generated and printing may or may
not take place. When this warning is reported, one message may be missed but the printer
continues to print.
This warning indicates that the printer may have missed printing at least one message
because it was unable to generate the message’s variable data (for example, sequential
numbers) before the next ‘print go’. That is, the printer was still generating the pixel data
for the next message.
NOTE: This warning indicates that the printer cannot generate pixels fast enough,
whereas System Warning “3.05 Over Speed (Print Trigger)” indicates that the
printer cannot print the rasters fast enough. This event is only likely to occur with
fast rasters, where pixel generation by the software is slower than the rate at which
the hardware can print rasters.

Possible causes:
 The amount of variable data in the message is too high for the current rate of print
triggers.
 False trigger device triggers.

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 6.6.8 “3.07 Over Speed (Asynchronous Data)”
A ‘print go’ occurred before the message data could be generated in response to an
asynchronous event. The unmodified message may be printed without the asynchronous
data.
While printing is taking place an asynchronous command may be received, which attempts
to change the printed message, for example, invert or reverse the message. The software
may assume that the data has not arrived and ignore the command, depending on the
software setting, in which case the printer continues to print the unchanged previous
message.

Possible causes:
 The printer has received a command to change the message during the delay time.
 ‘Time change’ related data (a sequential message with a time trigger) has changed after
the delay time has started.

6.6.9 “3.08 Over Speed (Line Speed)”

The production line is travelling too fast for the printer to generate the raster, typically
because the shaft encoder is giving more pulses than the gear ratio has been calculated for.

Possible causes:
 The shaft encoder gear ratio is too big.
 The shaft encoder gear wheel is too small.
 The production line speed is greater than the maximum speed for the message type
(raster).

6.6.10 “3.09 Over Speed (Compensation)”

This warning message is similar to “3.08 Over Speed (Line Speed)”. The production line is
travelling too fast, or the print delay is too short to perform line speed compensation.

Possible causes:
 The shaft encoder gear ratio is too big.
 The shaft encoder gear wheel is too small.
 The production line speed is greater than the maximum speed for the message type
(raster).

6.6.11 “3.10 Under Speed (Line Speed)”

The pitch value is too big, which results in the shaft encoder counter exceeding its
maximum value.

Possible causes:
 The shaft encoder gear ratio is too small.
 The shaft encoder gear wheel is too big.
 The production line is travelling too slowly or has stopped.

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 6.6.12 “3.11 Printer Requires Scheduled Maintenance”
The remaining time to the next scheduled maintenance is monitored. If the time has expired
or is a negative value, this warning is reported and the jet can be started as normal. The
remaining time decrements only when the jet is running.
When the Maintenance Due Within time or the Maintenance Due By date (Print Monitor
> Menu > Maintenance > Maintenance Times > Maintenance Due Within/Maintenance
Due By) reaches zero time or the current date, this warning message is displayed each time
the printer is turned on. The warning message continues to be displayed until the
scheduled maintenance has been done, and the intervals to the next scheduled maintenance
have been reset by the maintenance technician. The Maintenance Finished key on the
Maintenance Times page automatically resets the maintenance intervals according to the
ink type that is used in the printer. See Chapter 5: ‘Maintenance’ > Maintenance page >
Maintenance Times for more information.

6.6.13 “3.12 Printhead Cover Off”

WARNING: LETHAL VOLTAGE HAZARD. WHEN THE ‘COVER OFF OVERRIDE’ LINK LK21 IS
FITTED AND THE PRINTHEAD COVER TUBE IS REMOVED, 300 VOLTS DC CONTINUES TO BE
SUPPLIED TO THE CHARGE ELECTRODE. THE EHT ALSO CONTINUES TO BE SUPPLIED TO
THE DEFLECTOR PLATES.
THE CORRECT, STANDARD ELECTRICAL SAFETY PRECAUTIONS MUST BE TAKEN WHEN
WORK IS DONE ON THE PRINTHEAD WITH LINK LK21 FITTED AND WITH THE COVER TUBE
REMOVED. DO NOT FIT LINK LK21 PERMANENTLY AND DO NOT LEAVE THE PRINTER
UNATTENDED WHILE THE LINK IS FITTED.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS SAFETY
WARNING IS IGNORED.
This warning is reported if the printhead cover tube is removed. The +8 kV EHT supply to
the positive deflector plate is automatically switched off and printing is suspended when
the cover tube is removed. Printing is resumed a few seconds after the cover tube is refitted.
The red strobe LED is also switched on when the cover tube is removed.
See also: System Warning “3.13 Cover Override Link Fitted” below.
Chapter 3: ‘Technical Description’ > Printhead components > Printhead cover
sensor.

6.6.14 “3.13 Cover Override Link Fitted”

WARNING: LETHAL VOLTAGE HAZARD. WHEN THE ‘COVER OFF OVERRIDE’ LINK LK21 IS
FITTED AND THE PRINTHEAD COVER TUBE IS REMOVED, 300 VOLTS DC CONTINUES TO BE
SUPPLIED TO THE CHARGE ELECTRODE. THE EHT ALSO CONTINUES TO BE SUPPLIED TO
THE DEFLECTOR PLATES.
THE CORRECT, STANDARD ELECTRICAL SAFETY PRECAUTIONS MUST BE TAKEN WHEN
WORK IS DONE ON THE PRINTHEAD WITH LINK LK21 FITTED AND WITH THE COVER TUBE
REMOVED. DO NOT FIT LINK LK21 PERMANENTLY AND DO NOT LEAVE THE PRINTER
UNATTENDED WHILE THE LINK IS FITTED.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS SAFETY
WARNING IS IGNORED.
This warning is reported if link LK21 (Cover Off Override) is fitted on the IPM PCB.

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 When this software-readable link is fitted, the EHT and charge voltages remain on while the
printhead cover tube is removed (that is, they are not automatically disabled). This allows
printing to continue for fault diagnosis purposes. The red strobe LED also remains lit. After
removing the printhead cover tube and then fitting the link (or refitting the printhead cover
tube), a few seconds elapse before printing recommences.
See also: System Warning “3.12 Printhead Cover Off” above.
Chapter 3: ‘Technical Description’ > Electronics and software > IPM PCB > Test
points and links > LK21 (Cover Off Override).
Chapter 4: ‘System Options’ > Setup > Installation > Printhead > Cover
Override.

6.6.15 “3.14 Power Off Override Active”

This warning is reported if link LK20 (Power Off Override) is fitted on the IPM PCB.
When this link is fitted, the auto power down mains on/off switch cannot be switched off
by the software.

6.6.16“3.15 Safety Override Active”

WARNING: LETHAL VOLTAGE HAZARD. IF LINK LK19 IS FITTED WHILE THE ‘PRINTHEAD
OVER TEMPERATURE’ OR ‘EHT TRIP’ FAULT CONDITIONS OCCUR, 300 VOLTS DC
CONTINUES TO BE SUPPLIED TO THE PRINTHEAD.
THE CORRECT, STANDARD ELECTRICAL SAFETY PRECAUTIONS MUST BE TAKEN WHEN
WORK IS DONE ON THE PRINTHEAD WITH LINK LK19 FITTED. DO NOT FIT LINK LK19
PERMANENTLY AND DO NOT LEAVE THE PRINTER UNATTENDED WHILE THE LINK IS
FITTED.
THERE IS A DANGER OF INJURY OR DEATH FROM ELECTRIC SHOCK IF THIS SAFETY
WARNING IS IGNORED.
This warning is reported if link LK19 (Safety Override) is fitted on the IPM PCB.
When this link is fitted, the printhead Over Temperature sense and the EHT Trip sense
signals do not disable the 300 V, ink system pump, feed valves, and EHT. However, the
EHT Trip sense will disable the EHT internally on the EHTPSU regardless of LK19 being
fitted. The link may be fitted with caution to aid fault diagnosis.

6.6.17 “3.16 Gutter Override Active”

This warning is reported if link LK27 (Gutter Sense Override) is fitted on the IPM PCB.
The purpose of the gutter sense function is to detect the presence of ink flow in the gutter
during a normal jet start sequence and under normal jet running conditions.
During a normal jet start sequence, the gutter detection is regularly switched on and off
while the printer is attempting to establish a jet. When the jet is established, the gutter
detection remains on throughout the jet running state.
If ink flow is not detected in the gutter for any reason (for example, a misaligned jet), the
software shuts down the jet. Absence of ink from the gutter is detected within
approximately 2 seconds. With link LK27 fitted, the software starts and maintains the jet
regardless of the gutter detection status.
When the Jet Test – Start function is used, the gutter detection remains off while the jet start
sequence is in progress. Because there is no attempt to establish the jet properly during a
Jet Test – Start sequence, there is no need to switch the gutter detection on and off regularly.
When the jet start sequence is completed, the jet parameters are set to their defaults and the
gutter detection is switched on, and remains on throughout the jet running state.

FA69398–1
Linx 7900 Maintenance Manual 6—17 Oct 2013
 6.6.18 “3.17 Gate Array Test Mode Active”
This warning is reported if link LK26 (Built In Self-Test) is fitted on the IPM PCB.
When this link is fitted, it places the gate array (IC58) in test mode, which generates a
staircase waveform with historic correction.

6.6.19 “3.18 Low Pressure”

Each time the jet is started a pressure and filter check is carried out—the pressure is set to
4.14 bar (59.90 p.s.i.) and the pressure ADC is used to check that this pressure is actually
reached. If the difference between the pressure DAC setting (Set Pressure) and the pressure
ADC reading (Actual Pressure) is greater than a predetermined value—currently 0.09 bar
(1.27 p.s.i.)—this warning is reported. The jet continues to run.
The primary function of this test is to detect ink system faults or pressure loss. The test
pressure is well above normal running pressures, so it is possible that printing may still
take place with a partially blocked filter, hence the jet is not shut down.
When this warning is reported no solvent addition is permitted; pressure only is used to
control the TOF. This may result in the ink viscosity increasing and the pressure being
increased to the maximum running pressure. The effect would be poor print quality.

Possible causes:
 The main ink filter or the ink pick-up tube in-line filter are blocked (most probable).
 Some other loss of pressure in the ink system.
 Faulty pump.
 Faulty pump drive circuit.

6.6.20 “3.19 Valid UNIC Chip Not Found”

The UNIC on the IPM PCB is missing, of an unrecognizable type, or is not functioning
correctly.

6.6.21 “3.20 No Time Of Flight”

This event message indicates that the printer has been unable to obtain a valid TOF over a
predetermined period of time.
It is only likely to be reported after the jet has been started using the Jet Test – Start function.
It is most likely to occur when a shaft encoder is used, and the encoder or production line
stops in mid-print. It occurs 5 minutes after jet start, during which time there has been no
TOF readings recorded. If this condition continues for a further 35 minutes a “2.03 Time Of
Flight Failure” occurs and the printer shuts down. This occurs regardless of which jet state
the printer is in, that is, ‘Jet Running’ or ‘Printing’.

Possible causes:
 The software is not receiving TOF signals.
 Incorrect or no signal from the TOF sensor caused by a partially blocked nozzle or jet
misalignment.
 Poor jet break-up caused by incorrect modulation/ink viscosity.
 The ink viscosity is so far out of range that correctly measured TOF values are rejected
as being spurious readings.
 Heavy build-up of dry ink on the deflector plates.
 Noise (EMC) interference.

FA69398–1
Oct 2013 6—18 Linx 7900 Maintenance Manual
 6.6.22 “3.21 Ink Low Prevented Mix”
7900 Spectrum only. A mix will not take place while the ink is low.

6.6.23 “3.22 Fault Prevented Mix”

7900 Spectrum only. A mix will not take place while there is an active fault.

6.6.24 “3.23 Power Off Occurred During Mixing”

7900 Spectrum only. The printer was powered down before the mix sequence was
completed.
This warning is reported at power-up. It indicates that the printer was previously switched
off while the mix sequence was still running.

6.6.25 “3.24 Restart In Progress”

During a normal startup only, the printer is attempting to restart the jet after failing to start
it the first time. A further two restarts are attempted after which, if unsuccessful, the printer
fails.

Possible cause:
 The jet was misaligned during startup and the restart sequence is attempting to clear a
suspected blockage.

6.6.26 “3.25 Ink Unmixed For 4 Weeks”

7900 Spectrum only. The ink has remained unmixed for at least 4 weeks.

6.6.27 “3.26 User Data Corrupt–Please contact your local Linx

Service Centre”
Internal software error. On startup, checks are made for invalid data, and if found this
event is reported.

6.6.28 “3.27 Mix Disabled”

7900 Spectrum only. The mix sequence has been disabled by selecting the Disable Mix
function on the Ink/Solvent page (Print Monitor > Menu > Setup > Installation > Ink/
Solvent).

6.6.29 “3.28 Printhead requires cleaning at shutdown”

The wording of this warning message used to be “3.28 Phase Amplifier Saturated” but was
changed to “3.28 Printhead requires cleaning at shutdown”. A phase fault is normally
generated when the printhead components are contaminated by ink build-up, therefore,
this new wording is more relevant and understandable to the user.
If this warning is displayed, the printhead must be cleaned after the next shutdown as
described in the Linx 5900 & 7900 Quick Start Guide.
The technical description of what actually causes this warning to be reported remains the
same as the former “3.28 Phase Amplifier Saturated” and has been retained as follows.
The software is unable to reduce the phase packet size sufficiently to prevent phase
amplifier saturation.
During the phasing process, a series of 8 drops (default number) are charged and form a
phase packet, which is then detected by the phase sensor. The software selects the ideal phase
position where the detected signal is maximum. If the signal is greater than a
predetermined software level, and therefore unreadable, the next phase packet is reduced
by 1 drop, to 7 drops, and the detection process is repeated.

FA69398–1
Linx 7900 Maintenance Manual 6—19 Oct 2013
 The phase packets are reduced by 1 drop each time the signal is too large, down to a
minimum of 2 drops. If the signal is still too large when the phase packet contains only 2
drops, this System Warning is reported.

Possible causes:
 Poor drop break-up caused by incorrect modulation/ink viscosity.
 Misaligned jet.
 Build-up of wet ink between the EHT deflector plate and earth.
 Conductivity problems due to contaminated ink.
 Faulty phase amplifier on the IPM PCB.
 Noise (EMC) interference.
 Bad earthing.
 Incorrect printhead type entered on the Printhead Type page (Print Monitor > Menu >
Setup > Installation > Printhead > Printhead Type).
 EHT leakage due to contamination of the printhead.
 EHT leakage due to moisture on and around the EHT deflector plate caused by
condensation or a high humidity environment.

6.6.30 “3.29 Over Speed (No Remote Data)”

This warning occurs in Single print mode. The printer has tried to print a message that
contains one or more remote fields, and no data has been received over the
Communications interface to fill these remote fields.

Possible causes:
 Print rate is too fast.
 Data was sent too late.
 The baud rate is too low.

6.6.31 “3.30 Remote Error”

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

6.6.32 “3.31 Restarted Print Delay”

This warning can occur when production schedules are used, which can be standard,
remote interface fast message selection, or PIO production schedules.
A new message in the schedule has been selected after the next product was detected and
the delay has been started. The only action the printer can take is to restart the delay, but it
is probable that the print will be too late to hit the product. This warning is an indication
that this condition has occurred.

FA69398–1
Oct 2013 6—20 Linx 7900 Maintenance Manual
 6.6.33 “3.35 Printer Requires Scheduled Maintenance Within
One Month”
The remaining time to the next scheduled maintenance is monitored. This warning occurs
under one of the following conditions, whichever occurs first:
 When the current date is within 30 days of the ’Maintenance Due By’ date.
 When the ‘Maintenance Due Within’ time is less than 240 hours.
The ‘Maintenance Due By’ date check is a definite 1 month that remains, and the
‘Maintenance Due Within’ hours check is an estimated 1 month that remains. The 240 hours
value is 10 days of a 24 hours a day, 7 days a week operation, and 30 working days of an 8
hours a day, 5 days a week operation.
The warning is reported on the System Event page each time the printer is turned on. An
information message is also displayed each time the jet is started and every 24 hours after
the printer is turned on. Both of these messages continue to be displayed until the
scheduled maintenance has been done, and the intervals to the next scheduled maintenance
have been reset by the maintenance technician.

FA69398–1
Linx 7900 Maintenance Manual 6—21 Oct 2013
 This page left blank intentionally

FA69398–1
Oct 2013 6—22 Linx 7900 Maintenance Manual
 CHAPTER 7: TROUBLESHOOTING
7.1 Introduction
The troubleshooting flow charts in this chapter have been created to include the large
amount of knowledge that Linx has about printer problems, and to present this knowledge
in clear and easy to follow procedures. Flow charts do not replace the requirement for a
maintenance technician trained by Linx, as there is always a time when there is no flow
chart for a particular problem. The flow charts must be used only by maintenance
technicians who have used them for fault diagnosis during a Linx training course.

7.2 How to use the flow charts

To use a flow chart, read the instructions in the first box and complete the action as required
before moving to the next applicable box. Decisions must be made at different stages in a
flow chart, and the next path to follow depends on the answer to the question in a decision
box. An example of a simple flow chart is shown in Figure 7-1.
Table lamp does
not illuminate

Is the lamp Connect the lamp to the

connected to the NO mains electrical supply and
mains electrical turn on the supply.
supply?

YES

Is the mains electrical Turn on the mains

YES NO electrical supply.
supply turned on?

YES Is the lamp NO Replace the bulb.

illuminated?

Is the lamp Replace the fuse in the

YES NO mains electrical connector.
illuminated?

End

Figure 7-1. Simple flow chart example

If the steps are not followed correctly, it is not possible to find and repair the fault.
Therefore, the instructions in each box must be read and followed very carefully.
A description of how a flow chart is created, what the different box shapes indicate, and
how to use a flow chart are shown in Figure 7-2.

FA69398–1
Linx 7900 Maintenance Manual 7—1 Oct 2013
 FCXXX Each flow chart is identified
with a code number, which
can be referenced in the
Start Index.

A terminator box is the start

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

Always note and follow the

direction of the arrows.

A decision box requires you to

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

Procedure location
Decision YES and title

This symbol instructs you to

NO perform an action a number
of times. When this has been
completed, continue with the
flow chart as directed.
… until
Sometimes a number
of instructions are
to be repeated.
Test ...

This termination box directs you

to the final flow chart FC999. This termination box
It assumes that the fault has indicates that you must
been found and rectified. If other return to the last flow chart
faults exist, you must restart you were working through
from flow chart FC001. before this one.
This repeats until all faults have
been rectified.

Final Test Return

Figure 7-2. How to use a flow chart

FA69398–1
Oct 2013 7—2 Linx 7900 Maintenance Manual
7.3 First steps
The first flow chart in the series is ‘Troubleshooting Start’, for which the reference is FC001.
This flow chart must always be followed first no matter what the fault is. It ensures that
all the parameters are set for the troubleshooting session.

7.4 Fault recording

All details of the printer and the fault should be recorded on a Flow Chart Record Sheet, an
example of which is given in Table 7-2 on page 7—4. This sheet provides the ability to
understand the troubleshooting process, so that when the fault has been identified and
rectified it is possible to evaluate how to avoid the fault reoccurring.

7.5 When flow charts seem inappropriate

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

7.6 Miscellaneous faults

There are occasions when the flow charts are not appropriate for the particular fault. If this
is the case, it is necessary to resort to the standard fault diagnosis techniques, which are
taught during the Linx training course. In addition, the following miscellaneous fault
symptoms are provided, with recommended remedies.

Symptom Fault Remedy

Spectrum printer—no print Pump seized Replace the pump
Spectrum printer—printing, but low Ink tank ‘plugged’ 1. Run the ink mixing sequence. If symptom is
ink opacity still apparent, try:
2. Empty the ink tank and flush the system.

Table 7-1. Miscellaneous faults

FA69398–1
Linx 7900 Maintenance Manual 7—3 Oct 2013
 7900 Troubleshooting Flow Chart Record Sheet
Printer 7900 Printhead
Serial Number Serial Number
Line Setup >Trigger: Line Setup > Speed:
Print Trigger Speed Selection
Trigger/Printhead Distance Line speed
Inter-Print Distance Pulses per mm
Dual Trigger details
Installation > Ink/Solvent: Installation > Ink/Solvent:
Ink Type Solvent Type
Installation > P/Head: Installation > ID:
Printhead Type UNIC Code
Conduit Length Printer Config Code
Printhead Height Printer Name
Printhead Code
Fault observations:

Flow Chart FC001 Result

Flow Chart Result

Flow Chart Result

Flow Chart Result

Flow Chart Result

Flow Chart Result

Flow Chart Result

Flow Chart Result

Flow Chart Result

Flow Chart Result

Flow Chart Result

Conclusion Components replaced

Final test of system Precautionary measures

Table 7-2. Flow chart record sheet

FA69398–1
Oct 2013 7—4 Linx 7900 Maintenance Manual
7.7 List of flow charts
LIST OF TROUBLESHOOTING FLOW CHARTS
Flow chart Title Purpose
FC001 Troubleshooting Start Always start here
FC002 Jet To examine the jet
FC003 Modulation To examine modulation
FC004 Charge To examine drop charging
FC005 Phase To examine phase synchronization
FC006 Low Pressure To test primary ink circuit. Can be used when
event "3.18 Low Pressure" occurs
FC007 Ink Quality To test ink quality
FC008 Low Viscosity Ink To find the cause of the ink viscosity being too low
for the printer to operate
FC009 High Viscosity Ink To find the cause of the ink viscosity being too
high for the printer to operate
FC010 EHT Deflection To test the EHT system
FC011 Print To find the cause of print problems
FC012 Print Quality To find the cause of print quality problems
FC200 2.00 Printhead Over Temperature For when the displayed event occurs
FC201 2.01 EHT Trip For when the displayed event occurs
FC202 2.02 Phase Failure For when the displayed event occurs
FC203 2.03 Time of Flight Failure For when the displayed event occurs
FC204 2.04 300V Power Supply For when the displayed event occurs
FC205 2.05 Ink Tank Empty For when the displayed event occurs
FC206 2.06 Solvent Tank Empty For when the displayed event occurs
FC207 2.07 Internal Spillage For when the displayed event occurs
FC208 2.08 Printer Over Temperature For when the displayed event occurs
FC209 2.09 Misaligned Ink Jet For when the displayed event occurs
FC211 2.11 Pressure Limit Reached For when the displayed event occurs
FC212 2.12 Viscosity For when the displayed event occurs
FC213 2.13 Hardware Safety Trip For when the displayed event occurs
FC999 Final Test When the problem has been solved

Table 7-3. List of troubleshooting flow charts

FA69398–1
Linx 7900 Maintenance Manual 7—5 Oct 2013
 FC001 Troubleshooting Start

FC001
Troubleshooting
Start

Shut down and turn off the

Has the printer failed? YES printer, and then turn it on
again.

NO

Note any printer failure or

warning messages from
the Event Log and enter
these on the Flow Chart
Record Sheet.

Check all the installation

data on the Installation
menu and enter the
required data on the Flow Read the explanation of
Chart Record Sheet. the event message in the
Maintenance Manual.

Create a test message

using the maximum size
message type.

Clean the printhead and

cover tube, if necessary.

Set: Line Setup menu >

Trigger menu > Leading
Edge Primary.
Speed menu > Speed
Selection > Fixed Speed.

Select: Maintenance menu

> Jet Functions menu > Jet
Test – Start.

Go to the appropriate
Troubleshooting Flow Chart
Figure 7-3. FC001 Troubleshooting Start

FA69398–1
Oct 2013 7—6 Linx 7900 Maintenance Manual
FC002 Jet

FC002

Jet

Does
Set Pressure = Flow Chart
Actual Pressure NO FC006
(±0.25 bar / 3.57 p.s.i. ‘Low Pressure’
/ 14 bits)?

YES

Maintenance Manual
Is the jet going Chapter 5
straight into NO
the gutter? ‘Jet Alignment and
Nozzle Cleaning’

YES

Return Final Test

Figure 7-4. FC002 Jet

FA69398–1
Linx 7900 Maintenance Manual 7—7 Oct 2013
 FC003 Modulation

FC003

Modulation

Examine the jet break-up in

the charge electrode and
assess which image the jet
break-up most looks like.

YES Return

NO

NO NO

Note the presence

of satellites
YES YES YES

Test the modulation signal

Increase the modulation Decrease the pressure and output from the IPM PCB
and observe jet break-up. observe jet break-up. (TP32) with a DVM set to
the AC volts range.

Is an Is an
improvement improvement Is the signal present?
observed? observed?

YES NO
NO YES NO

NO
Maintenance Manual
Replace the printhead. Chapter 5 Replace the IPM PCB.
‘Modulation Range’

YES

Final Test

Figure 7-5. FC003 Modulation

FA69398–1
Oct 2013 7—8 Linx 7900 Maintenance Manual
FC004 Charge

FC004

Charge

From the Maintenance

menu > Jet Functions
menu, put the printer into
the "Ready to Print" state
by selecting the Start Print
option.
Place a piece of paper at
the printhead outlet and
select the Test Print option.

Check the continuity of

Is a message printed? NO the charge coaxial cable.

Is the charge cable

continuity
NO
YES
good?

YES

Maintenance Manual Maintenance Manual

Chapter 5 Chapter 5
Replace the printhead.
‘Charge Amplifier ‘Charge Amplifier
Calibration’ Calibration’

Can you perform

the Charge Amplifier
Calibration?
YES

NO

Replace the IPM PCB.

Return Final Test

Figure 7-6. FC004 Charge

FA69398–1
Linx 7900 Maintenance Manual 7—9 Oct 2013
 FC005 Phase

FC005

Phase

Flow Chart
FC007
‘Ink Quality’

Test the continuity of

Is the phase
the phase coaxial cable, NO value good?
YES Return
including the outer screen.

Is the phase
cable continuity NO Replace the printhead.
good?

YES Replace the IPM PCB.

Final Test

Figure 7-7. FC005 Phase

FA69398–1
Oct 2013 7—10 Linx 7900 Maintenance Manual
FC006 Low Pressure

FC006

Low Pressure

Maintenance Manual
Test the pressure
Chapter 5
transducer and NO YES
associated electronics. Is the printer ‘Scheduled
due for scheduled Maintenance’
maintenance?

Final Test

Is the pressure Replace the pressure

Check for ink flow from the
pump outlet.
YES transducer operating NO transducer or associated
correctly? components as necessary.

Is there good
Check for ink flow from the Check for vacuum at the
main filter outlet.
YES ink flow from NO pump inlet.
the pump?

Is there good ink Is there good

YES flow from the main ink vacuum at the NO
filter? pump inlet?

Examine the manifold Test the pump and

and associated piping. associated electronics.
Replace components NO YES Replace components
as necessary. as necessary.

Examine the ink

pick-up tube and
Replace the associated piping.
main ink filter.
Replace components
as necessary.

Check the maintenance manual amendments to make

sure that scheduled maintenance is being completed
to the latest specification.
Confirm that the maintenance interval is appropriate
for the installation.

Final Test

Figure 7-8. FC006 Low Pressure

FA69398–1
Linx 7900 Maintenance Manual 7—11 Oct 2013
 FC007 Ink Quality

FC007

Ink Quality

Make sure that the printer

is in the
‘Jet Running’ state.

Set TOF to Off (Monitor Jet

page).

From the Maintenance

menu > Jet Functions
menu, put the printer into
the ‘Ready to Print’ state by
selecting the Start Print
option.
YES

… phase number
=
0, 4, 8 and 12.
Take a print sample.

Repeat four times

at ...

Maintenance Manual
Chapter 5 Is one of the print
NO samples good?
‘Charge Amplifier
Calibration’

YES

Was charge
calibration required? Reset TOF to TOF/Phase
(Monitor Jet page)

NO

Replace the ink. Return

Final Test

Figure 7-9. FC007 Ink Quality

FA69398–1
Oct 2013 7—12 Linx 7900 Maintenance Manual
FC008 Low Viscosity Ink

FC008
Low Viscosity Ink

Make sure that the

pressure transducer is
correctly calibrated.

Maintenance Manual
Chapter 5
‘Solvent Add
Valve Tests’

Replace the ink.

Maintenance Manual
Chapter 5
‘Solvent Flush
Valve Tests’

Maintenance Manual
Chapter 5
‘Purge and Gutter
Valves Tests’

Make sure that there is

no blockage in
the feed line.

If all systems are considered to be

functioning correctly, monitor
the printer for a further 2 hours.
If the printer correctly adds solvent, assume
that the initial problem was caused by the
operator adding solvent to the ink tank.

Final Test

Figure 7-10. FC008 Low Viscosity Ink

FA69398–1
Linx 7900 Maintenance Manual 7—13 Oct 2013
 FC009 High Viscosity Ink

FC009

High Viscosity Ink

Check for correct TOF.

Flow Chart
FC203
Is TOF OK? NO
‘Time Of Flight
Failure’

YES

Is there
Refill the solvent tank. NO solvent in the solvent
tank?

YES

Maintenance Manual
Test the solvent level Chapter 5
sensor. ‘Solvent Add
Valve Tests’

If all systems are considered to be

functioning correctly, monitor the printer for a
further 2 hours.
If the printer correctly adds solvent, assume
that the initial problem was caused by the
operator adding ink to the solvent tank.
Therefore, the condition of the solvent must be
checked.

Final Test

Figure 7-11. FC009 High Viscosity Ink

FA69398–1
Oct 2013 7—14 Linx 7900 Maintenance Manual
FC010 EHT Deflection

FC010

EHT Deflection

Make sure that the

printhead and cover tube
are clean.
Make sure that the
printhead cover tube is
fitted correctly.
Initiate message printing
using the Test Print option.

Examine the printhead

output, the printhead
components, and the
printhead cover tube for
indications that ink drops
have been diverted from
the ink jet.

Have ink drops

NO been diverted?
YES

Test the EHT control signal Make sure that the

into the EHTPSU (TP3). calibration code
is entered correctly.
Test the continuity of the
EHT cable (approximately Check that the printhead
cover tube detection is
20 M ). functioning correctly.

Did the Test for the correct voltage

tests reveal a NO on the EHT plate.
problem?

Was the voltage

YES NO as expected?

Replace faulty component

as necessary.
YES

Final Test Return

Figure 7-12. FC010 EHT Deflection

FA69398–1
Linx 7900 Maintenance Manual 7—15 Oct 2013
 FC011 Print

FC011

From the Maintenance Print

menu > Jet Functions
menu, put the printer into
the ‘Ready to Print’ state by
selecting the Start Print
option.
YES Flow Chart
Place a piece of paper at
the printhead outlet and FC203
Is TOF OK? NO
select the Test Print option. ‘Time Of Flight
Failure’

Is ink Test the trigger, trigger

Does the printer
ejected from the YES print when
NO setup and associated
printhead? electronics.
triggered?

NO YES

Clean the printhead.

Examine the printhead for Test the line speed sensor,
Does the printer
obstructions.
print at the correct
NO line speed setup and
Repeat the Test Print associated electronics.
rate?
procedure twice more.

YES

Flow Chart
Is the fault still
apparent?
NO Is the print sample NO FC012
good? ‘Print Quality’

YES YES

Maintenance Manual
Does Chapter 5
the Print Count NO ‘Software
increment? Programming’
procedure

YES

Flow Chart Is the fault still

FC010 apparent?
NO
‘EHT Deflection’

YES

Is the fault still

apparent?
YES Replace the IPM PCB.

Final Test
NO
Figure 7-13. FC011 Print

FA69398–1
Oct 2013 7—16 Linx 7900 Maintenance Manual
FC012 Print Quality

FC012

Print Quality

Maintenance Manual
Chapter 5 Is the problem
‘Charge Amplifier solved?
Calibration’

NO

Flow Chart
Is the problem
FC010
solved?
‘EHT Deflection’

NO

Flow Chart
Is the problem
FC007
solved?
‘Ink Quality’

NO

YES
Maintenance Manual
Chapter 5 Is the problem
‘Modulation Range solved?
Checks’
YES

NO

Maintenance Manual
YES
Chapter 5
‘Software
Programming’
procedure YES

Final Test

Figure 7-14. FC012 Print Quality

FA69398–1
Linx 7900 Maintenance Manual 7—17 Oct 2013
 FC200 2.00 Printhead Over Temperature

FC200

2.00 Printhead Over Temperature

Is the
printhead ambient
NO temperature less than
YES
60 °C ?

Place the printer and

printhead in an
Disconnect printhead
environment where
connector PL6 from the
the temperature is
IPM PCB.
within operational
range for 1 hour.

Does the fault

YES still exist?
NO

The printer must be located

in an environmental
temperature of less than
60 °C.

Examine connector PL6

for obvious damage,
Replace the IPM PCB.
and repair if necessary and
possible.

Does the fault

still exist?
YES

Replace the printhead.

NO

Final Test

Figure 7-15. FC200 2.00 Printhead Over Temperature

FA69398–1
Oct 2013 7—18 Linx 7900 Maintenance Manual
FC201 2.01 EHT Trip

FC201

2.01 EHT Trip

Flow Chart
FC002
‘Jet’

Flow Chart
FC003
Make sure that the event ‘Modulation’
settings are correct.
Make sure that the Cover
Examine the printhead Off Override link LK21
cover tube detection is removed.
system, and replace faulty
components as necessary.
Remove the printhead
from the printhead cover
tube, and then refit it.

NO YES

Was Was
warning 3.12 warning 3.13 "Cover
"Printhead Cover Off"
YES Override Link Fitted"
displayed? displayed?

Disconnect the EHTPSU NO

Take a print sample.
output cable.

Make sure that the

NO environment is within
YES operating parameters.
Make sure that cleaning
procedures are being
Does the adhered to.
Replace the IPM PCB.
printer fail?
Make sure that there is no
vibration being transmitted
to the printhead.
If everything else is OK,
replace the EHTPSU.

Final Test

Figure 7-16. FC201 2.01 EHT Trip

FA69398–1
Linx 7900 Maintenance Manual 7—19 Oct 2013
 FC202 2.02 Phase Failure

FC202

2.02 Phase Failure

Flow Chart
FC002
‘Jet’

NO Is the problem solved?

Flow Chart
FC003
‘Modulation’

NO Is the problem solved?

Flow Chart
FC004
‘Charge’

NO Is the problem solved?

YES

Flow Chart
FC005
‘Phase’

YES

NO Is the problem solved?

YES

Flow Chart
FC001 YES
‘Troubleshooting Start’

Final Test

Figure 7-17. FC202 2.02 Phase Failure

FA69398–1
Oct 2013 7—20 Linx 7900 Maintenance Manual
FC203 2.03 Time Of Flight Failure

FC203

2.03 Time Of Flight Failure

Flow Chart
FC002
‘Jet’

Flow Chart
FC003
‘Modulation’

Electrical noise is being Flow Chart Electrical noise

generated on the FC004 is being generated
production line. ‘Charge’ within the printer.

Make sure that the NO YES

Examine all printer earth
electrical supply is free connections.
from noise, earthing to the Flow Chart
printer FC005 Make sure that the
is in place, and the printhead cover tube screw
‘Phase’ has good earth continuity
printhead is isolated from
other earthing sources. to the printer.

Replace in turn:
1. LVPSU
Move the printer to an area 2. IPM PCB
Make sure that auxiliary
where there is no electrical 3. Pump
components are screened.
noise and a good earth. 4. Printhead

Retest the system after

each replacement.
Refit the original
component if the fault is
still apparent.
Make sure that there is no
Does the fault
static on the production
still exist?
line.

Final Test

Figure 7-18. FC203 2.03 Time Of Flight Failure

FA69398–1
Linx 7900 Maintenance Manual 7—21 Oct 2013
 FC204 2.04 300V Power Supply

FC204

2.04 300V Power Supply

Make sure that the printer is

turned off.
Remove IPM PCB link LK8.
Remove IPM PCB link LK25.
Turn on the printer.

Does the
fault still exist?
YES

NO

Turn off the printer.

Refit link LK8 and link LK25.
Disconnect the charge cable.
Replace the EHTPSU.
Disconnect the modulation
cable.
Turn on the printer.

Does the
fault still exist?
YES NO

Replace the IPM PCB. Replace the printhead.

Final Test

Figure 7-19. FC204 2.04 300V Power Supply

FA69398–1
Oct 2013 7—22 Linx 7900 Maintenance Manual
FC205 2.05 Ink Tank Empty

FC205

2.05 Ink Tank Empty

YES
Is the ink tank
nearly empty?

NO
YES

Turn off the printer. Add one bottle of ink.

Examine the ink level
sensor and wiring, and (Only add a maximum of
replace as necessary. two bottles.)

Is the warning
Has the fault cleared? "3.03 Ink Low" still
present?

NO YES

Test the ink level sensor

electronics, and replace the
IPM PCB, if necessary.

NO

Final Test

Figure 7-20. FC205 2.05 Ink Tank Empty

FA69398–1
Linx 7900 Maintenance Manual 7—23 Oct 2013
 FC206 2.06 Solvent Tank Empty

FC206

2.06 Solvent Tank Empty

YES
Is the solvent tank
nearly empty?

NO
YES

Turn off the printer. Add one bottle of solvent.

Examine the solvent level
sensor and wiring, and (Only add a maximum of
replace as necessary. two bottles.)

Is the warning
Has the fault cleared? "3.04 Solvent Low" still
present?

NO YES

Test the solvent level

sensor electronics, and
replace the IPM PCB, if
necessary.
NO

Final Test

Figure 7-21. FC206 2.06 Solvent Tank Empty

FA69398–1
Oct 2013 7—24 Linx 7900 Maintenance Manual
FC207 2.07 Internal Spillage

FC207

2.07 Internal Spillage

Is there ink
YES or solvent in the NO
ink tray?

Clean the ink tray.

Remove and clean
the ink spillage sensor. Disconnect the ink system
Examine the ink system connector PL1.
to determine the cause
of the leak, and repair as
necessary. YES

Does the Does the

fault still exist? YES fault still exist?

NO NO

Test the leak detection

wiring for short circuit to
Replace the IPM PCB.
earth, and repair as
necessary.

Final Test

Figure 7-22. FC207 2.07 Internal Spillage

FA69398–1
Linx 7900 Maintenance Manual 7—25 Oct 2013
 FC208 2.08 Printer Over Temperature

FC208

2.08 Printer Over Temperature

Is the external
temperature greater
NO than +58 °C?

Is the fan rotating YES

after the printer is YES
NO turned on?

Examine the air filter, and

Examine the fan and fan replace as necessary.
wiring, and repair or Examine the air inlet and
replace as necessary. outlet vents for
obstructions. Clean as
necessary.
Make sure that routine
maintenance programmes
are being followed.

Test the fan output voltage

at connector PL2.
Make sure that the
NO Has the fault cleared? operating environment is
within the limits stated in
the maintenance manual.
Reload the system
software.
Maintenance Manual
Chapter 5
‘Software
Programming’
procedure

Has the fault cleared?

NO
YES

YES
Replace the IPM PCB.

Final Test

Figure 7-23. FC208 2.08 Printer Over Temperature

FA69398–1
Oct 2013 7—26 Linx 7900 Maintenance Manual
FC209 2.09 Misaligned Ink Jet

FC209

2.09 Misaligned Ink Jet

Make sure that the jet is

running.

Is the jet
entering the centre of
the gutter?
YES

NO

Connect pin 12 to pin 13 on

the printhead connector
PL6.
Monitor TP6.

Flow Chart
Is the voltage on
FC002 TP6 greater than
‘Jet’ 4 volts DC?
NO YES

Replace the printhead. Replace the IPM PCB.

Final Test

Figure 7-24. FC209 2.09 Misaligned Ink Jet

FA69398–1
Linx 7900 Maintenance Manual 7—27 Oct 2013
 FC211 2.11 Pressure Limit Reached

FC211

2.11 Pressure Limit Reached

Is the warning "3.18

NO Low Pressure"
YES
present?

Flow Chart Flow Chart

FC003 FC006
‘Modulation’ ‘Low Pressure’

NO Is the problem solved?

Flow Chart
FC004
‘Charge’

YES

NO Is the problem solved?

YES
Flow Chart
FC001
‘Troubleshooting Start’

Final Test

Figure 7-25. FC211 2.11 Pressure Limit Reached

FA69398–1
Oct 2013 7—28 Linx 7900 Maintenance Manual
FC212 2.12 Viscosity

FC212

2.12 Viscosity

Increase or decrease the

pressure to bring the jet
break-up into the charge
electrode and achieve
good TOF.

Is it
possible to achieve
good TOF?
YES
NO

Maintenance Manual
Chapter 5
‘Modulation Range
Checks’

Flow Chart
What is the FC203
viscosity of the ink? ‘Time Of Flight
Failure’
Low or High or
lower higher
than than
expected expected

Flow Chart Flow Chart

FC008 FC009
‘Low Viscosity Ink’ ‘High Viscosity Ink’

Final Test

Figure 7-26. FC212 2.12 Viscosity

FA69398–1
Linx 7900 Maintenance Manual 7—29 Oct 2013
 FC213 2.13 Hardware Safety Trip

FC213

2.13 Hardware Safety Trip

Flow Chart
FC201
‘EHT Trip’

NO Is the problem solved?

Flow Chart
FC200
‘Printhead Over
Temperature’ YES

NO Is the problem solved?

Flow Chart
FC001
‘Troubleshooting Start’

YES

Final Test

Figure 7-27. FC213 2.13 Hardware Safety Trip

FA69398–1
Oct 2013 7—30 Linx 7900 Maintenance Manual
FC999 Final Test

FC999

Final Test

Clean the printhead and

make sure that the cover
tube is clear of any
obstruction.

Start the jet using

the green [start] key.

Does the printer

start and print OK?
NO

YES
Flow Chart
FC001
‘Troubleshooting Start’

Note any conclusions on

the Flow Chart Record
Sheet.

Evaluate any
precautionary measures
to be taken to avoid
a reoccurrence
of the problem.
Put the printer back on
the production line and run
it, observing
its operation, for
at least ½ hour.
Clean the working area.
Dispose of all liquid
and solid waste in
accordance with local
regulations.

Clean the printer.

Complete all relevant

paperwork.

Report any conclusions

and preventative actions to
be taken to whoever is
responsible
for the printer.

Finish

Figure 7-28. FC999 Final Test

FA69398–1
Linx 7900 Maintenance Manual 7—31 Oct 2013
 This page left blank intentionally

FA69398–1
Oct 2013 7—32 Linx 7900 Maintenance Manual
 CHAPTER 8: TRAINING COURSE
GUIDES
Course One: Printer Operation (Level C & Level A)
Course summary
Purpose
These training courses are intended for anyone who is required to operate a Linx 7900
printer on a production line.
The courses are designed to enable a maintenance technician to train personnel, in the
necessary skills needed, to maintain normal line operation of the printer on a day-to-day
basis. To achieve this, the courses make use of the Linx 5900 & 7900 Quick Start Guide.
The training provided here is for a printer that has been previously commissioned and has a
number of suitable messages already stored in it. The maintenance technician should also
make sure that he is fully aware of the customer’s printing requirements, and that the
default options are correctly set for the application.
It is essential that the printer is set to the correct/appropriate security access level prior to
commencing these courses.

Level C course objectives

This training course guide is to be used following the installation of a Linx 7900 Continuous
Ink Jet Printer, to train operators to Level C.
The Level C course is designed to enable the trainee to safely set up the printer on a variety
of production lines, together with any associated ancillary components. In addition, the
trainee will be able to start and stop the printer, select and print messages, create and edit
messages, and carry out the more advanced routine maintenance tasks and simple
troubleshooting. The trainee will also be conversant with the safety implications and be
aware of the location in the manuals of basic First Aid instructions.
This course is therefore suitable for the Line Supervisor or more advanced Line Operator.

Level A course objectives

This training course guide is to be used following the installation of a Linx 7900 Continuous
Ink Jet Printer, to train operators to Level A.
The Level A course is designed to enable the trainee to safely set up the printer on a variety
of production lines, together with any associated ancillary components. In addition, the
trainee will be able to start and stop the printer, select and print messages, and carry out
basic maintenance tasks. The trainee will also be conversant with the safety implications
and be aware of the location in the manuals of basic First Aid instructions.
This course is therefore suitable for a Base Level user or Line Attendant.

FA69398–1
Linx 7900 Maintenance Manual 8—1 Oct 2013
 Level C modules
01. Introduction
02. Continuous ink jet printing
03. Getting started and printing messages
04. Navigating the 7900
05. Creating and editing messages
06. Stopping print and shutting down
07. Looking after your printer
08. Routine maintenance
09. Line installation
10. Review

Level A modules
01. Introduction
02. Continuous ink jet printing
03. Getting started and printing messages
06. Stopping print and shutting down
07. Looking after your printer
09. Line installation
10. Review

Equipment list
Equipment Quantity
Linx 7900 printer 1
Linx 5900 & 7900 Quick Start Guide
1 per printer
Magnifier or eyeglass 1
Safety eye glasses 1 pair per trainee
Protective gloves sufficient for the course
Paper towels sufficient for the course
Hand cleanser sufficient for the course
Eyewash 1 bottle
Paper for printing onto As required (optional)
Make sure that all local Health and Safety regulations are complied with.

FA69398–1
Oct 2013 8—2 Linx 7900 Maintenance Manual
Level C: Module 01 – Introduction
Aims
 To establish the credibility of the course, the trainer and the course materials.
 To establish a relaxed atmosphere in which to learn.
 To make the trainees aware of the relevant health and safety aspects.

Key points
 Outline the course objectives.
 Cover the health and safety aspects of working with a CIJ printer, inks and solvents.

Activities
Introduce yourself and the training course to the trainees.
Explain domestic arrangements (timings, breaks, lunch, facilities).
Explain the use of the Linx 5900 & 7900 Quick Start Guide.
Outline the course objectives.
Explain the warnings and cautions. Use the Linx 5900 & 7900 Quick Start Guide to illustrate
the relevant points.
Explain the safety implications (hazards and their prevention, and accident management)
for the following:
 Ink/solvent flammability
 Eye and skin contact
 Inhalation
 Ingestion
Stress the importance of keeping the printer cover fitted.

Equipment
Ink and solvent bottles
Personal safety equipment
Fire extinguisher

FA69398–1
Linx 7900 Maintenance Manual 8—3 Oct 2013
Level C: Module 02 – Continuous ink jet printing
Aims
 To give some awareness of what continuous ink jet printing is and, in particular, how
the Linx printer achieves its purpose.

Key points
 Continuous ink jet printing is a non-contact printing method for printing small variable
characters and images.
 The Linx printer achieves this by creating a stream of ink drops, from which individual
drops are electrically charged and deflected out of the printhead onto the product in a
predetermined manner.

Activities
Ask the trainees if they can give examples of where continuous ink jet printers might be
used. Examples could be food products for legislation reasons, pills, motor parts for
product traceability, and cable for marking the product length. In fact, there are very few
products manufactured today that do not require a mark for one reason or another, and
many of these applications are satisfied by marking the product using continuous ink jet
technology.
State that ink jet is usually selected for its capacity to print a large number of characters
every second, at production line speeds of more than 7 m/s.
Explain that when the printhead cover tube is removed, all dangerous voltages are
removed and the printhead can be handled and viewed safely.
Show the passage of the ink from the nozzle to the gutter.
Explain that, as the drops are formed they can be given an electric charge that causes them
to be deflected by the deflector plate onto the passing product.
Explain that, as the uncharged drops receive no charge they are not deflected and pass
directly into the gutter at the end of the printhead.
Point out the sensors on the DPP and explain that they are used to control the charge and
speed of the drops.

Equipment
Magnifier or eyeglass
Safety eye glasses

FA69398–1
Oct 2013 8—4 Linx 7900 Maintenance Manual
Level C: Module 03 – Getting started and printing
messages
Aims
 To make sure that there is understanding as to what is required for the printer to be
used successfully on the production line.
 To make sure that the trainees are able to bring the printer to a state where it can be run
on line.

Key points
 Powering up the printer.
 The keyboard and display.
 Printing a message.
 Using the Linx 5900 & 7900 Quick Start Guide.
 Selecting a message.

Activities
Refer the trainees to the section in the Linx 5900 & 7900 Quick Start Guide about how to turn
on the printer. Invite the trainees to turn on the printer and observe the startup page.
Refer the trainees to the section in the Linx 5900 & 7900 Quick Start Guide about the printer
display and explain the use of each of the items on the display.
Refer the trainees to the section in the Linx 5900 & 7900 Quick Start Guide about how to start
printing.
Briefly explain what is happening during start up.
Show when the printer status changes to ‘Printing’ and demonstrate printing onto a
product. (You may have to improvise and explain the installation at this point.)
Show that Print Count increments each time the message is printed.
Explain that the message displayed on the Current Message page when the printer was
switched off, will be available for immediate printing the next time the printer is switched
on.
Refer the trainees to the section in the Linx 5900 & 7900 Quick Start Guide about how to select
a message. Indicate the Message Store option on the Print Monitor page.
Invite each of the trainees to select a message from the list of stored messages.
Make sure that all the trainees can select and print messages.

FA69398–1
Linx 7900 Maintenance Manual 8—5 Oct 2013
Level C: Module 04 – Navigating the 7900
Aims
 To make sure that the trainees become familiar with, and can confidently use, the
cursor control keys.
 To make sure that the trainees become familiar with the menu structure.

Key points
 Using the Up, Down, Left, and Right cursor control keys.
 Understanding the menu structure.

Activities
Introduce the cursor control keys.
Explain the principle menu options.

FA69398–1
Oct 2013 8—6 Linx 7900 Maintenance Manual
Level C: Module 05 – Creating and editing
messages
Aims
 To make sure that the trainees can access and use the functions of the Message Editor to
create their messages.

Key points
 Using the Message Editor.
 Placing fields using the cursor keys.
 Saving and printing newly created messages.
 Adjusting the position and appearance of the message.
 Editing messages.

Activities
Before starting this module, the printer must be set up with the default message type for the
particular line the printer is to be running on.
Invite the trainees to access the Message Store menu and select the New option.
Demonstrate entering text into the message by using the insert text options.
After entering text, demonstrate how the message can be saved and printed.
Invite each of the trainees to create a new message and input their name, and then save and
print each message.
Invite the trainees to adjust the appearance of their message using distance, height, and
pitch.
Explain how other fields, such as the time and date, can be added to a message and moved
into position using the cursor control keys.
Discuss with the operators what message they will be printing on the production line. Ask
the trainees to enter the message into the printer and to print it.
Explain how to edit the message and change the data within it.
Remember to save the message before attempting to print it.
Demonstrate how to change the setting of the message type if more than one message type
is to be used on site (optional).

FA69398–1
Linx 7900 Maintenance Manual 8—7 Oct 2013
Level C: Module 06 – Stopping print and shutting
down
Aims
 To show the difference between a paused print and a stopped jet.
 To emphasize that the 7900 is a completely automatic printer requiring minimum
intervention.

Key points
 Pausing stops the printing but the jet continues to run.
 The [stop] key initiates a full shutdown sequence.
 The full shutdown sequence stops the jet, flushes the nozzle with solvent, and leaves
the printer in a condition ready for a clean and reliable startup next time.
 The [stop] key is the preferred method for switching off the printer.
 The power switch should only be used if the printer has failed (as displayed in the
Printer Status area of the Print Monitor page), or in the event of a hazardous situation
(for example, fire).

Activities
Refer the trainees to the section in the Linx 5900 & 7900 Quick Start Guide about how to
pause printing.
Invite a trainee to demonstrate the correct key to stop and restart the print.
Show how the status message changes.
Demonstrate to the trainees that when printing is paused, the jet is still running (emphasize
the importance of wearing safety eye glasses during this operation).
At this point, it may be an opportunity to demonstrate the ink jet and drop formation
(optional).
Refer the trainees to the section in the Linx 5900 & 7900 Quick Start Guide about how to stop
printing and shut down the printer.
Invite one of the trainees to shut down the printer, noting that the status message changes
in the Printer Status area of the Print Monitor page.
Explain what is happening as the printer shuts down. Observe the printer switching itself
off and explain that the whole operation is automatic with no user intervention required.

Equipment
Safety eye glasses
Magnifier or eyeglass

FA69398–1
Oct 2013 8—8 Linx 7900 Maintenance Manual
Level C: Module 07 – Looking after your printer
Aims
 To demonstrate to the trainees that minimum intervention is required for basic printer
operation, and if a few simple rules are followed the printer will give trouble-free
operation.
 To demonstrate the correct method of filling the printer with ink and solvent, as
required.

Key points
 System Event (warning) messages and appropriate actions.
 ‘Ink low’ and ‘solvent low’ warnings.
 Ink and solvent dos and don’ts.
 Ink and solvent addition.
 Event message log.

Activities
Demonstrate a warning on the printer (a simple one is to remove the printhead from its
cover tube) and show the warning message on the System Event page.
Explain that all printer ‘events’ are logged and demonstrate how to access the Event Log.
Explain that the Printer Status area of the Print Monitor page should be examined
whenever they are close to the printer to make sure that no attention is needed.
Explain that if the printer is reporting an ‘ink low’ or ‘solvent low’ warning, this is a
continuous reminder that a tank needs refilling.
Refer the trainees to the section in the Linx 5900 & 7900 Quick Start Guide about ink and
solvent safety precautions.
A ‘Quick Quiz’ can be given to cover all the relevant safety aspects about working with the
printer.
Make sure that there is complete understanding of all the points. In particular, show the
protective gloves and eye glasses symbols, which remind operators that protective
equipment is to be worn when handling ink and solvents.
Show the trainees the section in the Linx 5900 & 7900 Quick Start Guide about First Aid
instructions.
Refer the trainees to the section in the Linx 5900 & 7900 Quick Start Guide about adding ink
and solvent.
Show the adhesive label on the solvent filler cap, which indicates the solvent type to be
used. Emphasize that this must be compared to the markings on the solvent bottle itself and
be the same. Also show the ‘Use-by’ date on the bottle.
Repeat the above activity for the ink filler cap and ink bottle.
Demonstrate, using an empty bottle, how the bottle should be placed into the filler tube.
Show the serrated teeth, which are designed to pierce the foil on the bottle neck.
Advise caution that the bottle must not be removed too early.
Emphasize that only one bottle of ink or solvent is to be added at any one time.

FA69398–1
Linx 7900 Maintenance Manual 8—9 Oct 2013
Level C: Module 08 – Routine maintenance
Aims
 To make the trainees aware of the regular maintenance activities necessary to ensure
trouble-free operation of a Linx 7900 Continuous Ink Jet Printer.

Key points
 How and when to clean the printhead.
 How and when to clean or replace the air filter.
 Accessing the Monitor Jet page and the Event Log page.
 Use of the Nozzle Flush and Nozzle Clear functions.

Activities
Refer the trainees to the section in the Linx 5900 & 7900 Quick Start Guide about how to look
after the printer. Demonstrate how to clean the printhead and printhead cover tube.
Emphasize that in a clean operating environment the printhead requires cleaning only once
every week.
Indicate the location of the air filter and demonstrate how to remove it. For the 7900 (IP55
version) model, demonstrate the cleaning procedure. State the cleaning interval.
Explain that the filter on the 7900 (IP65 version) model cannot be cleaned, but must be
replaced when it becomes excessively dirty.
Demonstrate and explain the Monitor Jet page (optional).
Emphasize that correct nozzle alignment is very important and must not be mechanically
adjusted.
Explain the causes of a blocked nozzle and demonstrate the use of the Nozzle Flush
function. Show the jet of solvent coming from the nozzle.
Demonstrate the Nozzle Clear procedure and encourage each trainee to try it himself or
herself.
Emphasize that, in the case of an incorrectly aligned nozzle, only the Nozzle Flush and
Nozzle Clear functions must be used to rectify the fault. No one should try to physically
move the nozzle without first seeking advice from a person trained to do so, or a Linx or
Linx Distributor maintenance technician.
Emphasize that moving the nozzle with non-approved tools cancels any current warranty
or service contract.

Equipment
Safety eye glasses
Protective gloves

FA69398–1
Oct 2013 8—10 Linx 7900 Maintenance Manual
Level C: Module 09 – Line installation
Aims
 To ensure that the trainees are able to install and change the setup parameters for
typical product sensors and line speed detectors.

Key points
 A product sensor sends a signal to the printer to start a message printing onto the
product after a delay.
 A line speed detector sends a number of pulses to the printer, which interprets them as
a line speed.
 Correct setup is essential to ensure correct printing.
 Product sensors and line speed detectors are optional components.
 All line setup functions are accessed from the Line Setup page.
 Security.

Activities (all activities are optional based upon installation

setup)
Trigger the product sensor and explain how the signal is transmitted to the printer.
Explain the correct positioning of the printhead.
View the Trigger page on the Line Setup menu. Explain the options and settings,
particularly those that are used on the production line.
Explain line speed detection, if fitted.
Look at the Speed page on the Line Setup menu. Explain the options and settings,
particularly those that are used on the production line.
If a shaft encoder is fitted, emphasize the need to correctly calculate the number of pulses
per mm, as this can seriously influence the further positioning of the message (optional).
If a double trigger is used for line speed detection, emphasize that product size and pitch
must be accurately measured. If this is not done, adverse effects may be seen when selecting
a message type or printing a given message (optional).
If the production lines also uses other ancillary equipment, such as secondary triggers or
alarms, these also require explanation. Show their locations on the Line Setup menu.
Explain their uses and functions as necessary (optional).
Describe password entry and refer the trainees to the section in the Linx 5900 & 7900 Quick
Start Guide about user levels and passwords.
Explain the importance of using the correct level of password for the requirements of the
user.

FA69398–1
Linx 7900 Maintenance Manual 8—11 Oct 2013
Level C: Module 10 – Review
Aims
 To answer any questions that arise.
 To ensure all Aims have been adequately met.

Key points
 Agreement of Aims.
 Decide upon any future training requirements.

Activities
Ask if there are any questions.
Review the Objectives from Module 01 and get agreement from the trainees that they are
happy that these have been met.
If there is any confusion, run through the particular points again.
If necessary, arrange a convenient time to cover again any areas where there is still
confusion. These needs may only be relevant to individual trainees.

FA69398–1
Oct 2013 8—12 Linx 7900 Maintenance Manual
Level A: Module 01 – Introduction
Aims
 To establish the credibility of the course, the trainer and the course materials.
 To establish a relaxed atmosphere in which to learn.
 To make the trainees aware of the relevant health and safety aspects.

Key points
 Outline the course objectives.
 Cover the health and safety aspects of working with a CIJ printer, inks and solvents.

Activities
Introduce yourself and the training course to the trainees.
Explain domestic arrangements (timings, breaks, lunch, facilities).
Explain the use of the Linx 5900 & 7900 Quick Start Guide.
Outline the course objectives.
Explain the warnings and cautions. Use the Linx 5900 & 7900 Quick Start Guide to illustrate
the relevant points.
Explain the safety implications (hazards and their prevention, and accident management)
for the following:
 Ink/solvent flammability
 Eye and skin contact
 Inhalation
 Ingestion
Stress the importance of keeping the printer cover fitted.

Equipment
Ink and solvent bottles
Personal safety equipment
Fire extinguisher

FA69398–1
Linx 7900 Maintenance Manual 8—13 Oct 2013
Level A: Module 02 – Continuous ink jet printing
Aims
 To give some awareness of what continuous ink jet printing is and, in particular, how
the Linx printer achieves its purpose.

Key points
 Continuous ink jet printing is a non-contact printing method for printing small variable
characters and images.
 The Linx printer achieves this by creating a stream of ink drops, from which individual
drops are electrically charged and deflected out of the printhead onto the product in a
predetermined manner.

Activities
Ask the trainees if they can give examples of where continuous ink jet printers might be
used. Examples could be food products for legislation reasons, pills, motor parts for
product traceability, and cable for marking the product length. In fact, there are very few
products manufactured today that do not require a mark for one reason or another, and
many of these applications are satisfied by marking the product using continuous ink jet
technology.
State that ink jet is usually selected for its capacity to print a large number of characters
every second, at production line speeds of more than 7 m/s.
Explain that when the printhead cover tube is removed, all dangerous voltages are
removed and the printhead can be handled and viewed safely.
Show the passage of the ink from the nozzle to the gutter.
Explain that, as the drops are formed they can be given an electric charge that causes them
to be deflected by the deflector plate onto the passing product.
Explain that, as the uncharged drops receive no charge they are not deflected and pass
directly into the gutter at the end of the printhead.
Point out the sensors on the DPP and explain that they are used to control the charge and
speed of the drops.

Equipment
Magnifier or eyeglass
Safety eye glasses

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Oct 2013 8—14 Linx 7900 Maintenance Manual
Level A: Module 03 – Getting started and printing
messages
Aims
 To make sure that there is understanding as to what is required for the printer to be
used successfully on the production line.
 To make sure that the trainees are able to bring the printer to a state where it can be run
on line.

Key points
 Powering up the printer.
 The keyboard and display.
 Printing a message.
 Using the Linx 5900 & 7900 Quick Start Guide.
 Selecting a message.

Activities
Refer the trainees to the section in the Linx 5900 & 7900 Quick Start Guide about how to turn
on the printer. Invite the trainees to turn on the printer and observe the startup page.
Refer the trainees to the section in the Linx 5900 & 7900 Quick Start Guide about the printer
display and explain the use of each of the items on the display.
Refer the trainees to the section in the Linx 5900 & 7900 Quick Start Guide about how to start
printing.
Briefly explain what is happening during start up.
Show when the printer status changes to ‘Printing’ and demonstrate printing onto a
product. (You may have to improvise and explain the installation at this point.)
Show that Print Count increments each time the message is printed.
Explain that the message displayed on the Current Message page when the printer was
switched off, will be available for immediate printing the next time the printer is switched
on.
Refer the trainees to the section in the Linx 5900 & 7900 Quick Start Guide about how to select
a message. Indicate the Message Store option on the Print Monitor page.
Invite each of the trainees to select a message from the list of stored messages.
Make sure that all the trainees can select and print messages.

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Linx 7900 Maintenance Manual 8—15 Oct 2013
Level A: Module 06 – Stopping print and shutting
down
Aims
 To show the difference between a paused print and a stopped jet.
 To emphasize that the 7900 is a completely automatic printer requiring minimum
intervention.

Key points
 Pausing stops the printing but the jet continues to run.
 The [stop] key initiates a full shutdown sequence.
 The full shutdown sequence stops the jet, flushes the nozzle with solvent, and leaves
the printer in a condition ready for a clean and reliable startup next time.
 The [stop] key is the preferred method for switching off the printer.
 The power switch should only be used if the printer has failed (as displayed in the
Printer Status area of the Print Monitor page), or in the event of a hazardous situation
(for example, fire).

Activities
Refer the trainees to the section in the Linx 5900 & 7900 Quick Start Guide about how to
pause printing.
Invite a trainee to demonstrate the correct key to stop and restart the print.
Show how the status message changes.
Demonstrate to the trainees that when printing is paused, the jet is still running (emphasize
the importance of wearing safety eye glasses during this operation).
At this point, it may be an opportunity to demonstrate the ink jet and drop formation
(optional).
Refer the trainees to the section in the Linx 5900 & 7900 Quick Start Guide about how to stop
printing and shut down the printer.
Invite one of the trainees to shut down the printer, noting that the status message changes
in the Printer Status area of the Print Monitor page.
Explain what is happening as the printer shuts down. Observe the printer switching itself
off and explain that the whole operation is automatic with no user intervention required.

Equipment
Safety eye glasses
Magnifier or eyeglass

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Oct 2013 8—16 Linx 7900 Maintenance Manual
Level A: Module 07 – Looking after your printer
Aims
 To demonstrate to the trainees that minimum intervention is required for basic printer
operation, and if a few simple rules are followed the printer will give trouble-free
operation.
 To demonstrate the correct method of filling the printer with ink and solvent, as
required.

Key points
 System Event (warning) messages and appropriate actions.
 ‘Ink low’ and ‘solvent low’ warnings.
 Ink and solvent dos and don’ts.
 Ink and solvent addition.
 Event message log.

Activities
Demonstrate a warning on the printer (a simple one is to remove the printhead from its
cover tube) and show the warning message on the System Event page.
Explain that all printer ‘events’ are logged.
Explain that the Printer Status area of the Print Monitor page should be examined
whenever they are close to the printer to make sure that no attention is needed.
Explain that if the printer is reporting an ‘ink low’ or ‘solvent low’ warning, this is a
continuous reminder that a tank needs refilling.
Refer the trainees to the section in the Linx 5900 & 7900 Quick Start Guide about ink and
solvent safety precautions.
A ‘Quick Quiz’ can be given to cover all the relevant safety aspects about working with the
printer.
Make sure that there is complete understanding of all the points. In particular, show the
protective gloves and eye glasses symbols, which remind operators that protective
equipment is to be worn when handling ink and solvents.
Show the trainees the section in the Linx 5900 & 7900 Quick Start Guide about First Aid
instructions.
Refer the trainees to the section in the Linx 5900 & 7900 Quick Start Guide about adding ink
and solvent.
Show the adhesive label on the solvent filler cap, which indicates the solvent type to be
used. Emphasize that this must be compared to the markings on the solvent bottle itself and
be the same. Also show the ‘Use-by’ date on the bottle.
Repeat the above activity for the ink filler cap and ink bottle.
Demonstrate, using an empty bottle, how the bottle should be placed into the filler tube.
Show the serrated teeth, which are designed to pierce the foil on the bottle neck.
Advise caution that the bottle must not be removed too early.
Emphasize that only one bottle of ink or solvent is to be added at any one time.

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Linx 7900 Maintenance Manual 8—17 Oct 2013
Level A: Module 09 – Line installation
Aims
 To make sure that the trainees are familiar with their installations.

Key points
 A product sensor sends a signal to the printer to start a message printing onto the
product after a delay.
 A line speed detector sends a number of pulses to the printer, which interprets them as
a line speed.
 Correct setup is essential to ensure correct printing.
 Product sensors and line speed detectors are optional components.
 Security.

Activities (all activities are optional based upon installation

setup)
Trigger the product sensor and explain how the signal is transmitted to the printer.
Explain the correct positioning of the printhead.
Explain line speed detection, if fitted.
If the production lines also uses other ancillary equipment, such as secondary triggers or
alarms, these also require explanation.
Define the functions that the trainees have access to, and explain that to access other
functions they need further training.

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Oct 2013 8—18 Linx 7900 Maintenance Manual
Level A: Module 10 – Review
Aims
 To answer any questions that arise.
 To make sure that all Aims have been adequately met.

Key points
 Agreement of Aims.
 Decide upon any future training requirements.

Activities
Ask if there are any questions.
Review the Objectives from Module 01 and get agreement from the trainees that they are
happy that these have been met.
If there is any confusion, run through the particular points again.
If necessary, arrange a convenient time to cover again any areas where there is still
confusion. These needs may only be relevant to individual trainees.

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 This page left blank intentionally

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Oct 2013 8—20 Linx 7900 Maintenance Manual
 APPENDIX A: 7900 FOOD GRADE
PRINTER
A.1 Introduction
The Linx 7900 Food Grade printer is a special version of the standard 7900 printer that uses
only food grade inks. The two products are very similar, with some differences in operation
and design. Where the 7900 Food Grade printer is different from the standard 7900 printer
described in this manual, the alternative information is provided in this appendix.
Cross-references are shown in bold typeface to sections in other chapters of the manual and
have one of the following statements:
 Read this section in conjunction with …
 Read this section instead of …

A.2 Summary of differences

The following is a summary of the 7900 Food Grade printer differences from the standard
7900 printer.

A.2.1 Hardware
 The 7900 Food Grade printer has a MidiEC printhead, optimized for up to 3 lines of text
or graphics and is specifically for use with Linx food grade inks.
 The nozzle assembly is not interchangeable with other types.
 The MidiEC printhead is only available as a straight printhead with a 2-metre conduit.
 The ink system uses a dual-circuit pump, which provides continuous gutter suction in
the primary circuit of the ink system.
 Unlike the pump in the standard 7900 printer, the pump fitted in the 7900 Food Grade
printer ink system does not have an internal pressure relief valve (PRV). Instead, an
external PRV is fitted across the inlet and outlet ports of the primary ink circuit pump.
 A different type of damper is used in the ink system.

A.2.2 Configuration
 The operating temperature range for the 7900 Food Grade printer is 0 °C to +40 °C,
compared to the recommended temperature range of +5 °C to +45 °C for a standard
7900 printer. See page 2—2 for decreased ink temperature range information.
 Only Linx Red Food Grade ink 6100, Linx Blue Food Grade ink 6120, and Linx Blue
Food Grade ink 6220 can be used.
 A software link must be fitted to configure a standard 7900 printer to a 7900 Food Grade
printer. When the software link is fitted, the printhead type and the ink types that are
available are limited to those used by the 7900 Food Grade printer.

A.2.2.1 Ink type dependent parameters

The ‘Ink type dependent parameters’ table for the MidiEC printhead is included in the
section ‘Ink system’ in Chapter 3: ‘Technical Description’.

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 A.2.3 Software
 To minimize the risk of printer failure due to a dirty printhead, an EHT flash test is
performed before each jet startup to check that the printhead is clean and dry.
 When the 7900 Food Grade printer is turned on, the jet start is delayed for a 5-minute
warm-up period. This delay helps to minimize the risk of EHT failure at jet startup due
to condensation within the printhead, which can occur in food marking environments.
 To prevent potential problems related to short print runs, if the [stop] key is pressed the
shutdown is delayed (if necessary) until a calculated, temperature-dependent,
minimum run time has elapsed. This delay helps to minimize over-dilution of the ink.
 The Set Pressure is normally approximately 0.07 bar (1.02 p.s.i.) below the Solvent Add
Pressure. At low temperatures, this pressure can be much higher than the Reference
Pressure. This pressure difference helps to minimize over-dilution of the ink.
 Modulation Tracking is not used on the 7900 Food Grade printer.
 The damper Easi-Change® process does not apply to the 7900 Food Grade printer.

A.2.4 User interface

 The Ink/Solvent page provides a facility for automatically calibrating the Reference
Pressure for food grade inks.

A.3 Technical Description

A.3.1 Printhead components
A.3.1.1 Printhead temperature sensor
Read this section in conjunction with the section ‘Printhead temperature sensor’ in
Chapter 3: ‘Technical Description’.
The MidiEC printhead temperature sensor is also used to provide temperature
measurement for the following:
 Calculation of the minimum run time when the jet is started.
 Calculation of the Reference Pressure for food grade inks using the Calibrate 6xxx Ink
option on the Ink/Solvent page (see ‘Ink/Solvent’ on page A—20 for more information).

A.3.1.2 Standard gutter restrictor

Read this section instead of the section ‘Standard gutter restrictor’ in
Chapter 3: ‘Technical Description’.
The gutter restrictor is not fitted to MidiEC printheads.

A.3.2 Printhead theory of operation

A.3.2.1 Printhead types
Read this section instead of the section ‘Printhead types’ in Chapter 3: ‘Technical
Description’.
The 7900 Food Grade printer uses a Mk7 MidiEC printhead. The nozzle orifice size (jewel
size—measured in micrometres) is 62 µm.
The MidiEC printhead is suitable for printing up to 3 lines of 7 High characters.
NOTE: The MidiEC nozzle is not interchangeable with nozzles from any other type of
printhead. The nozzle is stamped with the letters “EC” to distinguish it from other
types.

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Oct 2013 A—2 Linx 7900 Maintenance Manual
 Refer to the Linx 5900 & 7900 Quick Start Guide for more information about the different
message types (rasters) that are available for the MidiEC printhead and printer
configuration combination, and for related speed and quality data.

A.3.2.2 Modulation
Read this section in conjunction with the section ‘Modulation’ in Chapter 3: ‘Technical
Description’.
The modulation frequency for the MidiEC printhead is 80 kHz.

A.3.2.3 Viscosity control

Read this section in conjunction with the section ‘Viscosity control’ in
Chapter 3: ‘Technical Description’.
The warm-up time described in the section ‘Viscosity control’ in Chapter 3: ‘Technical
Description’ refers to the time allowed for the system to stabilize after jet startup. This must
not be confused with the 5-minute printhead warm-up time for the MidiEC printhead,
which occurs after power-up and before jet startup. This delay allows the heater in the
printhead to clear condensation from the printhead.
For the 7900 Food Grade printer, the initial stabilization period before the first solvent
addition after jet startup is 45 minutes. Thereafter, the minimum period between solvent
additions is 20 minutes.
The 7900 Food Grade printer uses a different algorithm to adjust the system pressure as the
ambient temperature changes. The Set Pressure is normally about 0.07 bar (1.02 p.s.i.) below
the Solvent Add Pressure. At low temperatures, the Set Pressure can be considerably higher
than the Reference Pressure.
The maximum number of consecutive solvent additions allowed is 25.

A.3.2.4 Starting up and shutting down

Read this section in conjunction with the section ‘Starting up and shutting down’ in
Chapter 3: ‘Technical Description’.
There are two additional items in the list of actions performed during startup: an ‘EHT flash
test’ and a warm-up delay. A function called ‘minimum run time’ is also used to determine
when the jet shuts down.

EHT flash test

The water content of the ink used in the 7900 Food Grade printer can create a humid
environment around the components inside the printhead cover. This condition can cause
condensation if the temperature falls (condensation is caused by a combination of humidity
and falling temperature). It is important to note that condensation can occur even in warm
environments and with small temperature changes. Any ink residue or condensation in the
area of the EHT deflector plate, charge electrode or DPP can cause electrical leakage
between the printhead components. This can cause Print Failure “2.01 EHT Trip” during
printing, followed by immediate jet shutdown.
To minimize the risk of printer failure during printing, the 7900 Food Grade printer performs
a 10-second EHT flash test before each jet startup to check that the printhead is clean and
dry. If this test fails, Print Failure “2.01 EHT Trip” is reported, the EHT output is turned off,
and the jet is not started.
If this failure occurs, turn off the printer and clean the printhead, using the cleaning
procedure in the ‘MidiEC Printhead Cleaning’ maintenance instruction in
Chapter 5: ‘Maintenance’.
Refer to ‘System Options’ on page A—18 of this appendix for more information.

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 Warm-up delay
In conditions of high humidity, condensation can cause any dried ink deposits on the
printhead components to become conductive, which can cause EHT trip failures. To avoid
this, there is a 5-minute warm-up time after the 7900 Food Grade printer is switched on, which
allows the printhead heater time to disperse any condensation before the software allows the
jet to start.
During the warm-up time, the jet cannot be started with the [start] key. The jet starts
automatically at the end of the warm-up time, unless the [stop] key is pressed first to cancel
the automatic startup.

Minimum run time

Short jet running times must be avoided because the solvent used at startup and shutdown
may not have time to evaporate during printing. This can cause poor viscosity control and
overflow of the ink tank.
At each startup of a 7900 Food Grade printer, the software calculates and sets the minimum
run time required, which is dependent on ambient temperature. (The run time is longer at
lower temperatures.) This ensures that the run time is sufficient to allow solvent used at
startup and shutdown to evaporate during operation, and therefore avoids overdilution of
the ink and overflow of the ink tank.
If the [stop] key is pressed before the minimum run time has elapsed, an advisory message
is displayed that shows the remaining time until jet shutdown.
At the end of the minimum run delay time, the printer shuts down automatically. Two
methods can be used by maintenance technicians to override the delay, if necessary. Refer
to ‘Overriding the minimum run time delay’ on page A—21 of this appendix for more
information.

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 A.3.3 Ink system
A.3.3.1 General description
Read this section instead of the section ‘General description’ in ‘Ink system’ in
Chapter 3: ‘Technical Description’.
NOTE: All specified filter sizes are nominal ratings.
The ink system is contained in a stainless steel enclosure, which is part of the base unit of
the cabinet. The cabinet top cover has two openings through which the ink and solvent
tanks are filled, by internal filler tubes. The filler tubes are sealed by removable protective
caps. Both the filler tubes and protective caps are colour coded—black for ink and white for
solvent. Adhesive identification labels for the ink and solvent types are supplied with the
printer, which can be attached to the protective caps.
The ink system contains the following main components (refer to Figure A-1 on page A—7,
‘Static ink system—7900 Food Grade printer’):
 Ink tank
 Ink pick-up tube that includes a 40 µm stainless steel in-line filter
 Dual-circuit pump and motor assembly
 Pressure relief valve (PRV)
 10 µm (nominal) main ink filter
 Small ink manifold assembly, which includes the pressure transducer and venturi
 Damper
 Solvent tank
 Solvent pick-up tube that includes a 20 µm stainless steel in-line filter
 Five solenoid-operated valves
 Interconnecting pipes
NOTE: The symbol ‘µm’ stands for micrometre, which is the SI unit of length and formerly
called the micron.
The 7900 Food Grade printer has polyethylene ink and solvent tanks with nominal capacities
of 1440 ml. Both tanks are fitted with fluid level sensors (float switches) to detect when the
level of ink or solvent is below a set point. If either sensor detects a low fluid level, a System
Warning message is displayed (“3.03 Ink Low” or “3.04 Solvent Low”).
If, during a print run, the low ink condition is allowed to continue, the system reports the
Print Failure “2.05 Ink Tank Empty” after 8 hours. If, during a print run, the low solvent
condition is allowed to continue, the system reports the Print Failure “2.06 Solvent Tank
Empty” after 12 hours. This response prevents the ink or solvent from running out
completely.
The ink system pump used in the 7900 Food Grade printer is a dual-circuit pump, which has
an external pressure relief valve (PRV) connected across the pump inlet and outlet ports.
The pump and motor assembly is controlled by a 0 volts to +5 volts drive signal (which
depends on the requested pressure) supplied by the IPM PCB.
The pump draws ink from the tank through the ink pick-up tube, which includes a 40 µm
in-line filter. The ink then flows through the primary circuit of the dual-circuit pump to the
10 µm main ink filter, which provides the primary filtration within the ink system. The filter
removes any remaining particles before the ink reaches the venturi manifold and the
printhead. From the main ink filter, the ink is fed through the venturi manifold, damper,
and open Feed valve, and then through a Y-piece connector out to the printhead. The
damper minimizes any ink pressure fluctuations within the primary circuit, and isolates the
printhead from pressure fluctuations.

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Linx 7900 Maintenance Manual A—5 Oct 2013
 Ink is fed to and from the printhead through the feed, purge and gutter lines, and a 3-way
fluid connector, which connects the printhead to the ink system. This connector is within
the ink system enclosure and contains a 15 µm filter in the feed line. The ink system and
printhead interconnecting pipes are colour-coded: red stripe for the feed line, blue stripe for
the purge line, and no stripe for the gutter line.
The ink pick-up tube and filter, and main ink filter are replaced at every scheduled
maintenance. The damper is replaced annually. All of these items must be replaced
according to the ‘Scheduled Maintenance’ procedure provided in Chapter 5: ‘Maintenance’.
The venturi in the manifold provides suction to return surplus ink from the printhead
gutter to the ink tank through the Gutter valve. This suction also draws solvent from the
solvent tank as required. The secondary circuit of the dual-circuit pump provides
additional gutter suction to return surplus ink to the ink tank.
During solvent addition, solvent is drawn from the tank through the solvent pick-up tube,
which includes a 20 µm in-line filter. The solvent is then drawn through the de-energized
Solvent Flush valve, energized Solvent Add (Solvent Top-up) valve and the venturi to the
ink tank.
During a solvent flush, solvent is drawn from the tank through the solvent pick-up tube.
The solvent is then drawn through the de-energized Solvent Add (Solvent Top-up) valve,
energized Solvent Flush valve, Y-piece connector, and out to the printhead along the feed
line.

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Oct 2013 A—6 Linx 7900 Maintenance Manual
 Gun Printhead Printhead Feed valve and PIPE FLUID KEY
chamber Purge valve 15 µm filter assembly
Ink
Purge line
Ink with air bubbles
Printhead OFF Feed line Solvent

FA69398–1
Gutter line

3-way fluid connector and 15 µm

in-line feed filter assembly
10 µm main ink Damper H
filter J

7 25 1 K 21 73082_01_Stat

19 20

Linx 7900 Maintenance Manual

Venturi
24

14 OFF 15 OFF 16 OFF 17 OFF 18 OFF

8
Pressure
transducer

A—7
9 3 10 4 11 5 12 6 13
Feed Purge Gutter Solvent Solvent
valve valve valve Add Flush
A valve valve
C

E Vent
F

Dual-circuit 22
G Vent
pump
40 µm in-line
filter fitted in
ink pick-up tube Pipe bend 20 µm in-line
radius filter fitted in
Pressure relief template solvent
INK SOLVENT
valve pick-up tube

Figure A-1. Static ink system—7900 Food Grade printer

Oct 2013
 A.3.3.2 Damper
Read this section instead of the section ‘Damper’ in Chapter 3: ‘Technical Description’.
The 7900 Food Grade printer is fitted with the type of damper shown in Figure A-2. The
damper minimizes any ink pressure fluctuations within the primary circuit, and isolates the
printhead from pressure fluctuations.
A drain fitted to the bottom of the damper allows the ink system to be easily emptied.
NOTE: The damper Easi-Change® process described in the section ‘Damper’ on
page 3—29 of Chapter 3: ‘Technical Description’ does not apply to the 7900 Food
Grade printer.

79089

Figure A-2. Damper

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Oct 2013 A—8 Linx 7900 Maintenance Manual
 A.3.3.3 Ink system connections
Read this section instead of the section ‘Ink system connections’ in Chapter 3: ‘Technical
Description’.
The pipe connections to the venturi manifold are made with barb or Festo fittings. The
barbs are sealed by interference-fit to the manifold and cannot be removed, and so cannot
be replaced.
The following illustration shows the Mk4 venturi manifold assembly and ink system valves
used in the 7900 Food Grade printer, and provides information about the ink system pipe
connections. Refer to the static ink system diagram (Figure A-1 on page A—7) with the
following illustration.
22

21

20 19
Venturi manifold Mk4

1
18 17 16 15 14
25

8 7

6 5 4 3 2
B
13 12 11 10 9
C
A Solvent Flush Solvent Add Gutter Purge Feed
24 (5) (4) (3) (2) (1)
73031
7300 AND 7900 FOOD GRADE PRINTER—INK SYSTEM PIPE CONNECTIONS
From To Pipe lengths
Port 1 (venturi) Damper inlet (bleed cap end) 400 mm natural pipe (1/8 in. o.d.)
Port 2 not used — —
Port 3 (Purge valve) 3-way fluid connector (purge) 360 mm blue stripe pipe (1/8 in. o.d.)
Port 4 (Gutter valve) Port 8 (venturi) 160 mm natural pipe (1/8 in. o.d.)
Port 5 (Solvent Add valve) Port 6 (Solvent Flush valve) 160 mm natural pipe (1/8 in. o.d.)
Port 9 (Feed valve) Port A (new Y-piece connector) 120 mm red stripe pipe (1/8 in. o.d.)
Port 10 (Purge valve) E (Purge valve T-piece connector) 250 mm natural pipe (1/8 in. o.d.)
Port 12 (Solvent Add valve) Port 7 (venturi) 160 mm yellow stripe pipe (1/8 in. o.d.)
Port 13 (Solvent Flush valve) Port B (new Y-piece connector) 120 mm red stripe pipe (1/8 in. o.d.)
Port 15 (Purge valve) Port 11 (Gutter valve) 160 mm natural pipe (1/8 in. o.d.)
Port 16 (Gutter valve) J (Gutter valve T-piece connector) 220 mm natural pipe (1/8 in. o.d.)
Port 17 (Solvent Add valve) 19 (Y-piece connector) 90 mm natural pipe (1/8 in. o.d.)
Port 18 (Solvent Flush valve) 20 (Y-piece connector) 90 mm natural pipe (1/8 in. o.d.)
Port 21 (Y-piece connector) 22 (solvent tank pick-up tube) 260 mm natural pipe (1/8 in. o.d.)
Port 24 (venturi) Ink tank (ink return line) 500 mm natural pipe (6 mm o.d.)
Port C (new Y-piece connector) 3-way fluid connector (feed) 300 mm red stripe pipe (1/8 in. o.d.)
Damper outlet Port 14 (Feed valve) 360 mm red stripe pipe (1/8 in. o.d.)
Main ink filter outlet Port 25 (venturi & pressure transducer) 185 mm natural pipe (6 mm o.d.)
Ink pick-up tube Primary pump inlet T-piece connector 100 mm natural pipe (6 mm o.d.)
Primary pump inlet T-piece connector Primary pump inlet 100 mm natural pipe (6 mm o.d.)
Primary pump outlet Primary pump outlet T-piece connector 80 mm natural pipe (6 mm o.d.)
Primary pump outlet T-piece connector Main ink filter inlet 80 mm natural pipe (6 mm o.d.)
Ink tank (vent) Solvent tank (vent) 300 mm natural pipe (3/16 in. o.d.)
Solvent tank (vent) Ink tray (vent) 480 mm natural pipe (3/16 in. o.d.)
G (Purge valve T-piece connector) Ink tank 60 mm natural pipe (1/8 in. o.d.)
3-way fluid connector (gutter) K (Gutter valve T-piece connector) 220 mm natural pipe (1/8 in. o.d.)
H (Gutter valve T-piece connector) Secondary pump inlet 220 mm natural pipe (1/8 in. o.d.)
Secondary pump outlet F (Purge valve T-piece connector) 170 mm natural pipe (1/8 in. o.d.)
Primary pump outlet T-piece connector PRV inlet 45 mm natural pipe (6 mm o.d.)
PRV outlet Primary pump inlet T-piece connector 45 mm natural pipe (6 mm o.d.)

Figure A-3. Ink system pipe connections—7900 Food Grade printer

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 A.3.3.4 Ink and solvent flows
Read this section instead of the section ‘‘Ink and solvent flows’ in Chapter 3: ‘Technical
Description’.
Read the following ink and solvent flow descriptions with the ink and solvent flow
diagrams on the following pages.
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 A-4 on page A—11)

The ink flow in the primary circuit is from the ink tank through the ink pick-up tube and
in-line filter to the dual-circuit pump. The ink is then fed under pressure from the pump
through the main ink filter to the venturi manifold. The pressurized ink within the manifold
passes the pressure transducer, which sends an electrical feedback signal to the electronics
system. This signal is an indication of the Actual Pressure at which the pump is operating,
and is used to control the pump speed to set the required pressure. After the pressure
transducer, the ink flows through the venturi, where the vacuum is generated, and then
returns to the ink tank.

Secondary circuit (Figure A-5 on page A—12)

The secondary ink flow circuit operates when the Ink System Feed valve and the Printhead
Feed valve are opened. A fluid connection within the manifold feeds the ink from the
primary circuit at the venturi out to the damper and the open Feed valve. This valve allows
the pressurized ink to be fed along the feed line, through a Y-piece connector and the in-line
feed filter in the 3-way fluid connector. The ink continues along the feed line to the
printhead, and then passes through the open Printhead Feed valve to the printhead nozzle,
which creates the jet.
Drops of ink that are not used for printing enter the gutter. The venturi vacuum action on
the gutter draws the surplus ink back into the system through the 3-way fluid connector,
Gutter valve T-piece connector, and de-energized Gutter valve. The ink is then returned to
the ink tank through the venturi. The secondary circuit of the dual-circuit pump provides
additional gutter suction. This suction draws surplus ink from the gutter through the 3-way
fluid connector and the other port of the Gutter valve T-piece connector. The ink is then
returned to the ink tank through the pump and the Purge valve T-piece connector.

FA69398–1
Oct 2013 A—10 Linx 7900 Maintenance Manual
 Gun Printhead Printhead Feed valve and PIPE FLUID KEY
chamber Purge valve 15 µm filter assembly
Ink
Purge line
Ink with air bubbles
Printhead OFF Feed line Solvent

FA69398–1
Gutter line

3-way fluid connector and 15 µm

in-line feed filter assembly
10 µm main ink Damper H
filter J

7 25 1 K 21 73082_02_Pri

19 20

Linx 7900 Maintenance Manual

Venturi
24

14 OFF 15 OFF 16 OFF 17 OFF 18 OFF

8
Pressure
transducer
9 3 10 4 11 5 12 6 13

A—11
Feed Purge Gutter Solvent Solvent
valve valve valve Add Flush
A valve valve
C

E Vent
F

Dual-circuit 22
G Vent
pump
40 µm in-line
filter fitted in
ink pick-up tube Pipe bend 20 µm in-line
radius filter fitted in
Pressure relief template solvent
INK SOLVENT
valve pick-up tube

Figure A-4. Primary circuit—7900 Food Grade printer

Oct 2013
 Gun Printhead Printhead Feed valve and PIPE FLUID KEY
chamber Purge valve 15 µm filter assembly
Ink
Purge line
Ink with air bubbles

Oct 2013
Printhead ON Feed line Solvent
Gutter line

3-way fluid connector and 15 µm

in-line feed filter assembly
10 µm main ink Damper H
filter J

7 25 1 K 21 73082_03_Sec

19 20
Venturi
24

14 ON 15 OFF 16 OFF 17 OFF 18 OFF

8
Pressure
transducer
9 3 10 4 11 5 12 6 13

A—12
Feed Purge Gutter Solvent Solvent
valve valve valve Add Flush
A valve valve
C

E Vent
F

Dual-circuit 22
G Vent
pump
40 µm in-line
filter fitted in
ink pick-up tube Pipe bend 20 µm in-line
radius filter fitted in
Pressure relief template solvent
INK SOLVENT
valve pick-up tube

Figure A-5. Secondary circuit (normal running after a start purge)—7900 Food Grade printer

FA69398–1
Linx 7900 Maintenance Manual
 Solvent addition (Figure A-6 on page A—14)
Under normal operating conditions, the Set Pressure is adjusted as the ink viscosity changes
to maintain a regular TOF. For example, as the ink viscosity increases caused by solvent
evaporation, the Set Pressure is increased to maintain a fixed TOF (at the Reference TOF)
with the thicker ink. If the Set Pressure reaches the known Solvent Add Pressure, solvent is
added to the ink to decrease the viscosity and so maintain the Actual TOF at Reference TOF.
A solvent addition occurs only if all of the following conditions apply:
 The pressure check is good (that is, the pressure generation circuits operated correctly
at jet startup and the System Warning “3.18 Low Pressure” has not occurred).
 The Set Pressure is greater than the Solvent Add Pressure.
 The Actual TOF is within ±0.3% of the Reference TOF.
 The warm-up time has expired (that is, the jet has been in operation for 45 minutes).
 The solvent level is acceptable (that is, the printer solvent level is above the minimum
required and the System Warning “3.04 Solvent Low” has not occurred).
NOTE: Solvent is not added if the System Warning “3.18 Low Pressure” occurs, because
this warning indicates that there is a loss of pressure in the system. In this condition
a higher pressure is then required to get the correct TOF, although the ink viscosity
is probably acceptable.
During a solvent addition sequence, the Solvent Add (Solvent Top-up) valve is energized.
The venturi vacuum is now applied through the energized Solvent Add (Solvent Top-up)
valve, as well as the Gutter valve. The venturi vacuum draws solvent from the solvent tank,
through the Solvent Flush valve and the energized Solvent Add (Solvent Top-up) valve to
the venturi. At the venturi, the solvent mixes with the ink that is returning to the ink tank.
The lower viscosity ink that is now in the ink tank is then fed to the printhead.
The Solvent Add (Solvent Top-up) valve is energized for a set time, which is calculated to
allow an exact quantity of solvent to be added in a single ‘solvent add’ sequence. This
Solvent Add Time depends on the ink type and printhead type. Refer to the ‘Ink type
dependent parameters’ table for the MidiEC printhead in the section ‘Ink system’ in
Chapter 3: ‘Technical Description’ for more information.
When solvent is added to the ink in the ink tank, the viscosity of the ink is lowered. This
thinner ink reaches the printhead within 3 minutes, and the jet speed increases. The Set
Pressure is then decreased to maintain the jet speed at the Reference TOF. If after
20 minutes (the Viscosity Settle Time), the Set Pressure value remains above the Solvent Add
Pressure value, more solvent is added to the ink tank.
After solvent is added, further solvent additions are prevented for the Viscosity Settle Time.
This time allows the solvent to mix in the ink tank, and for the effects of the solvent addition
to begin to be seen at the printhead.

Normal shutdown (Figure A-7 on page A—15)

During a Normal Shutdown, the ink is removed from the printhead nozzle and the gun by
suction through the feed and purge lines. Before final shutdown, solvent is flushed through
the printhead to clean the gun, and the feed and purge lines. Then, a solvent jet cleans the
nozzle and gutter, which prepares the printer for the next jet startup.
Figure A-7 shows the state of the ink system after successful completion of the Normal
Shutdown sequence.

FA69398–1
Linx 7900 Maintenance Manual A—13 Oct 2013
 Gun Printhead Printhead Feed valve and PIPE FLUID KEY
chamber Purge valve 15 µm filter assembly
Ink
Purge line
Ink with air bubbles

Oct 2013
Printhead ON Feed line Solvent
Gutter line

3-way fluid connector and 15 µm

in-line feed filter assembly
10 µm main ink Damper H
filter J

7 25 1 K 21 73082_04_SolvAdd

19 20
Venturi
24

14 ON 15 OFF 16 OFF 17 ON 18 OFF

8
Pressure
transducer
9 3 10 4 11 5 12 6 13

A—14
Feed Purge Gutter Solvent Solvent
valve valve valve Add Flush
A valve valve
C

E Vent
F

Dual-circuit 22
G Vent
pump
40 µm in-line
filter fitted in
ink pick-up tube Pipe bend 20 µm in-line
radius filter fitted in
Pressure relief template solvent
INK SOLVENT
valve pick-up tube

Figure A-6. Solvent addition—7900 Food Grade printer

FA69398–1
Linx 7900 Maintenance Manual
 Gun Printhead Printhead Feed valve and PIPE FLUID KEY
chamber Purge valve 15 µm filter assembly
Ink
Purge line
Ink with air bubbles
Printhead OFF Feed line Solvent

FA69398–1
Gutter line

3-way fluid connector and 15 µm

in-line feed filter assembly
10 µm main ink Damper H
filter J
73082_05_
7 25 1 K 21 AfterSdown

19 20

Linx 7900 Maintenance Manual

Venturi
24

14 OFF 15 OFF 16 OFF 17 OFF 18 OFF

8
Pressure
transducer
9 3 10 4 11 5 12 6 13

A—15
Feed Purge Gutter Solvent Solvent
valve valve valve Add Flush
A valve valve
C

E Vent
F

Dual-circuit 22
G Vent
pump
40 µm in-line
filter fitted in
ink pick-up tube Pipe bend 20 µm in-line
radius filter fitted in
Pressure relief template solvent
INK SOLVENT
valve pick-up tube

Figure A-7. Ink system after a successful normal shutdown—7900 Food Grade printer

Oct 2013
 A.3.4 Electrical components
A.3.4.1 Ink system pump
Read this section instead of the section ‘Ink system pump’ in Chapter 3: ‘Technical
Description’.
This unit is a dual-circuit pump and DC motor assembly, which is fitted through the front
wall of the ink system enclosure. The pump body contains two pump units fitted on a
common driveshaft, that provide two separate pump circuits.
The larger, primary circuit circulates ink around the ink system at different pressures, as
required by the ink system control electronics. These pressure values depend on the
different functions performed by the printer during startup, normal operation, shutdown,
and other maintenance sequences.
The smaller, secondary circuit provides additional suction on the printhead gutter to return
surplus ink to the ink tank.
The motor controller circuit on the pump motor provides the drive signal for pressure
control of the pump. The requested pressure (Set Pressure) signal and the output signal
from the pressure transducer (Actual Pressure), on connector PL3 of the IPM PCB, are used
to create the drive signal for the pump motor.
Magnetic coupling from the motor to the pump provides separation of the ink from the
electrical drive parts.
The primary ink circuit pump has an external pressure relief valve (PRV), which is
connected across the pump inlet and outlet ports. The PRV is set to a maximum pressure of
5.8 bar (84 p.s.i.).
In the following illustration, the primary circuit ink flow is indicated by the large arrows
and the secondary circuit ink flow is indicated by the small arrows.

68776

Figure A-8. Dual-circuit pump ink flows

A.3.4.2 Printhead positive air pump

Read this section in conjunction with the section ‘Printhead positive air pump’ in
Chapter 3: ‘Technical Description’.
The addition of a positive air pump to the 7900 Food Grade printer provides a significant
improvement in startup reliability in very high humidity conditions. High humidity can
occur over a wide range of temperatures, so positive air provides improved performance at
all times of the year.

FA69398–1
Oct 2013 A—16 Linx 7900 Maintenance Manual
 A.3.5 Electronics and software
A.3.5.1 IPM PCB
Read this section in conjunction with the section ‘IPM PCB’ in Chapter 3: ‘Technical
Description’.

Test points and links

The IPM PCB in the 7900 Food Grade printer is identical to that fitted to the standard 7900
printer, but link LK7 has two additional functions.

Minimum run time

When Link LK7C is fitted, the minimum run time calculated by the printer is disregarded
and the shutdown delay is reduced to 1 minute. This link is used for production testing.
CAUTION: The minimum run time is an important factor in achieving reliable operation of the
printer and must not be routinely overridden.
The default setting for link LK7C is ‘not fitted’.
This link can be fitted to aid fault diagnosis but must remain not fitted when the printer is in
normal use.

Food grade ink options

When link LK7F is fitted, the printhead type (MidiEC) and the ink types that are available
on the Printhead Type and the Ink/Solvent pages are limited to those used by the 7900 Food
Grade printer.

FA69398–1
Linx 7900 Maintenance Manual A—17 Oct 2013
A.4 System Options
A.4.1 Option availability
Read this section in conjunction with the ‘System options availability table’ in the
section ‘Option availability’ in Chapter 4: ‘System Options’.
The Power Down page of the 7900 Food Grade printer has no Delayed power down options.
The Ink/Solvent page has an additional Calibrate 6xxx Ink option.

A.4.2 Line Setup page

A.4.2.1 Power Down
Read this section in conjunction with the section ‘Power Down’ in Chapter 4: ‘System
Options’.
Because the delayed power down options are not applicable to the 7900 Food Grade printer,
the appearance of the Power Down page is as shown below.
69568

Figure A-9. Power Down page

FA69398–1
Oct 2013 A—18 Linx 7900 Maintenance Manual
 A.4.3 Installation page
A.4.3.1 Printhead
Read this section in conjunction with the section ‘Printhead’ in Chapter 4: ‘System
Options’.
The following Printhead page shows example settings for a 7900 Food Grade printer that is
using Linx Red Food Grade ink 6100.
69569

Figure A-10. Printhead page

Printhead Type
The 7900 Food Grade printer uses one printhead type—the MidiEC. This printhead is the
only one that is displayed on the Printhead Type page and is shown as ‘Midi’.

Conduit Length
There is only one conduit length available on the Conduit Length page—2 metres.

Printhead Code
The default Reference Modulation Voltage for the MidiEC printhead is 125 volts. This is
suitable for operation over a temperature range of 0 °C to +40 °C and applies to all 7900
Food Grade printer configurations (including egg coding applications).
Where ambient temperatures are likely to regularly exceed +35 °C, the installation
technician must enter a value 10 volts less than the Reference Modulation Voltage for the
printhead. Also see the note for Linx Blue Food Grade ink 6220 in the ‘Ink type dependent
parameters’ table for the MidiEC printhead on page 3—37 (Chapter 3: ‘Technical
Description’ > Ink system > Ink type dependent parameters).

FA69398–1
Linx 7900 Maintenance Manual A—19 Oct 2013
 A.4.3.2 Ink/Solvent
Read this section in conjunction with the section ‘Ink/Solvent’ in Chapter 4: ‘System
Options’.
The Ink/Solvent page provides a facility for automatically calibrating the Reference
Pressure for food grade inks, as a diagnostic aid. The appearance of the Ink/Solvent page is
therefore as shown below.
69570

Figure A-11. Ink/Solvent page

Calibrate 6xxx Ink

The Ink/Solvent page has an additional Calibrate 6xxx Ink option, which is only enabled at
security access Level E (Service 2) and when the jet is running.
When the Calibrate 6xxx Ink option is selected, the printer uses the Actual Pressure and the
current printhead temperature to calculate the true Reference Pressure for the ink. When
the calibration is completed, the internal alarm tone (buzzer) is activated once.
NOTE: The calibrate function is primarily for use by Linx during the manufacturing
process and is not intended for normal use by maintenance personnel.

FA69398–1
Oct 2013 A—20 Linx 7900 Maintenance Manual
A.5 Maintenance
A.5.1 Jet Functions
A.5.1.1 Overriding the minimum run time delay
Read this section in conjunction with the section ‘Jet Test – Stop’ in
Chapter 5: ‘Maintenance’.
There are two methods that can be used to override the minimum run time delay and stop
the jet immediately:
 By using the key combination [ctrl] + [stop].
 By using the key combination [shift] + [stop].
The first method operates in the same way as on a standard 7900 printer, that is, it initiates
an immediate quick stop of the jet.
The second method initiates a normal 7900 Food Grade shutdown sequence instead of a
quick stop, but again it overrides the minimum run time.
In both cases, the printer first displays the following advisory message.
69572

Figure A-12. Advisory message for minimum run time override

The procedure can be stopped at this point by pressing the Cancel key.
IMPORTANT: The minimum run time is an important factor in achieving reliable printer
operation and must not be routinely overridden. Operators must not be
informed that these override methods exist.
Using [ctrl] + [stop] produces the System Warning “3.00 Shutdown Incomplete” when the
jet has stopped, and the shutdown is recorded in the Event Log as “4.01 Jet Test Stop”.
Using [shift] + [stop] does not produce this System Warning, and the shutdown is recorded
in the Event Log as a normal shutdown. (Note that a comparison of startup and shutdown
times in the Event Log can be used to track overuse or unauthorized use of this shutdown
method.)

FA69398–1
Linx 7900 Maintenance Manual A—21 Oct 2013
 A.5.2 Monitor Jet
A.5.2.1 Modulation
Read this section in conjunction with the section ‘Modulation’ in ‘Monitor Jet’ in
Chapter 5: ‘Maintenance’.

REF (Reference Modulation)

The Reference Modulation Voltage is manually set according to the expected ambient
operating temperature. Refer to ‘Printhead Code’ on page A—19 of this appendix for more
information.

Automatic Tracking
Automatic Modulation Tracking is not used on the 7900 Food Grade printer.

A.5.3 Maintenance Times

A.5.3.1 Easi-Change code
Read this section instead of the section ‘Easi-Change code’ in ‘Maintenance Times’ in
Chapter 5: ‘Maintenance’.
The Easi-Change® process does not apply to the 7900 Food Grade printer.

A.5.4 Maintenance instructions

Read this section in conjunction with the relevant maintenance instructions in
Chapter 5: ‘Maintenance’.

A.5.4.1 Purge and Gutter Valves Tests

Note that although the Gutter valve is connected differently on the 7900 Food Grade printer,
the Maintenance Instruction ‘Purge and Gutter Valves Tests’ can also be used without
alteration for the 7900 Food Grade printer.

A.5.4.2 Printer installation

Installation parameters
On the Printhead Code page (Installation > Printhead > Printhead Code), set the Reference
Modulation Voltage to the appropriate value for the expected ambient operating
temperature range.
Refer to ‘Printhead Code’ on page A—19 of this appendix for more information.

FA69398–1
Oct 2013 A—22 Linx 7900 Maintenance Manual
A.6 System Events
A.6.1 Print Failures
A.6.1.1 “2.01 EHT Trip”
Read this section in conjunction with the section ‘“2.01 EHT Trip”’ in Chapter 6: ‘System
Events’.
An additional feature of the 7900 Food Grade printer is the inclusion of a 10-second EHT
flash test on the printhead before each startup. This means that, unlike the standard 7900
printer, the 7900 Food Grade printer can report an EHT failure before the jet is started.
If this failure occurs, turn off the printer and clean the printhead, using the cleaning
procedure in the ‘MidiEC Printhead Cleaning’ maintenance instruction in Chapter 5:
‘Maintenance’.

A.6.1.2 “2.03 Time Of Flight Failure”

Read this section in conjunction with the section ‘“2.03 Time Of Flight Failure”’ in
Chapter 6: ‘System Events’.
If this failure occurs, turn off the printer and clean the printhead, using the cleaning
procedure in the ‘MidiEC Printhead Cleaning’ maintenance instruction in Chapter 5:
‘Maintenance’.

A.6.2 System Warnings

A.6.2.1 “3.28 Printhead requires cleaning at shutdown”
Read this section in conjunction with the section ‘“3.28 Printhead requires cleaning at
shutdown”’ in Chapter 6: ‘System Events’.
If this failure occurs, a different cleaning procedure is recommended for the 7900 Food Grade
printer to the standard procedure stated for this event in Chapter 6: ‘System Events’. Turn
off the printer and clean the printhead, using the cleaning procedure in the ‘MidiEC
Printhead Cleaning’ maintenance instruction in Chapter 5: ‘Maintenance’.

A.7 Troubleshooting
A.7.1 First steps
Read this section instead of the section ‘First steps’ in Chapter 7: ‘Troubleshooting’.
For the 7900 Food Grade printer, the first flow chart in the series is ‘Troubleshooting Start’
(provided overleaf), for which the reference is ‘FC001—6900/7300/7900 Food Grade Printer
Only’. This flow chart must always be followed first no matter what the fault. It ensures
that all the parameters are set for the troubleshooting session.
The flow chart also includes a check for printhead cleanliness. Cleaning the printhead can
often clear failures, such as:
 “2.01 EHT Trip”.
 “2.03 Time of Flight Failure”.
 “3.28 Printhead requires cleaning at shutdown”.
If the printhead requires cleaning, use the cleaning procedure in the ‘MidiEC Printhead
Cleaning’ maintenance instruction in Chapter 5: ‘Maintenance’.

FA69398–1
Linx 7900 Maintenance Manual A—23 Oct 2013
 FC001 Troubleshooting Start

FC001—6900/7300/7900 Food Grade Printer Only

Troubleshooting
Start

Check the installation data

on the Installation page.
Enter this data on the Flow
Chart Record Sheet.

Load the maximum size

test pattern and, if
possible, start the jet and
take a print sample.

Note any printer failures or Read the explanation of the

warnings on the Flow event message in the
Chart Record Sheet. Maintenance Manual.

If the printer displays a

failure code, shut down
and turn off the printer.

Clean the printhead. Turn on the printer and set

This action is only required Line Setup menu > Trigger
if ink deposits are visible menu > Print Trigger menu
or Print Failure 2.01, Print > Leading Edge Primary.
Failure 2.03, or System Line Setup menu > Speed
Warning 3.28 have menu > Speed Selection
occurred. menu > Fixed Speed.

Select: Maintenance menu

> Jet Functions menu >
Jet Test – Start.

Go to the appropriate
Troubleshooting Flow Chart
Figure A-13. FC001 7900 Food Grade printer Troubleshooting Start

FA69398–1
Oct 2013 A—24 Linx 7900 Maintenance Manual
A.8 Training Course Guides
Read this section in conjunction with Chapter 8: ‘Training Course Guides’.

A.8.1 Course One: Printer Operation (Level C & Level A)

Throughout the course, the special features of the 7900 Food Grade printer must be pointed
out and, where appropriate, demonstrated. In particular, make sure that trainees are
familiar with the following points.

A.8.1.1 Warm-up delay

To ensure reliable operation, the operator must turn on the printer at least 5 minutes before
it is to be used. This is most important where the ambient temperature is less than +5°C.
The software does not allow the jet to be started until at least 5 minutes after the printer has
been turned on.

A.8.1.2 Cleaning procedures

The correct procedures must be used to clean the MidiEC printhead, which are described in
the ‘MidiEC Printhead Cleaning’ maintenance instruction in Chapter 5: ‘Maintenance’.

A.8.1.3 Delayed shutdown feature

This delay is an important factor in achieving reliable operation, and operators must not be
informed of the methods available to override the delay.

A.8.1.4 Humidity and condensation

The water content of the ink used in the 7900 Food Grade printer can create a humid
environment around the components inside the printhead cover. This condition can cause
condensation if the temperature falls. It is important to note that condensation can occur
even in warm environments and with small temperature changes. Condensation in the
printhead can cause EHT trip failures during printing, and to avoid this the 7900 Food Grade
printer performs an EHT flash test before starting the jet. (See ‘Starting up and shutting
down’ in the section ‘Printhead theory of operation’ on page A—2 of this appendix.)

A.9 Illustrated parts list

Read this section in conjunction with the parts list on ExtraLinx or the Linx 7900 Service
Information CD.

A.9.1 Introduction
The following table identifies the few parts that are different from the standard 7900 printer
and specific to the 7900 Food Grade printer.

Part Num. Description Qty Availability Comments

FA74203 DUAL HEAD PUMP ASSY 1 EX-STOCK Used in 7900FG printer.

FA13582 SPECTRUM PRESSURE RELIEF 1 EX-STOCK For Spectrum & Food Grade printers.
VALVE–CALIBRATED

FA22061 PRINTHEAD ASSEMBLY MK7 MIDI 1 EX-STOCK —

EC

FA74202 MK7 MIDI EC NOZZLE ASSY (FG 1 EX-STOCK For Midi EC printhead.
INK 6100)

Table A-1. 7900 Food Grade printer parts

FA69398–1
Linx 7900 Maintenance Manual A—25 Oct 2013
A.10 On-farm egg coding
A.10.1 Introduction
The 7900 Food Grade printer can be used for applications in environments that are subject to
wide temperature and humidity variations, and short printing runs, principally egg coding
on farms.
There are some additional features that are required for the normal 7900 Food Grade printer
to allow it to work effectively in the harsher conditions of egg coding environments.
These additional features are described in the following sections. Read these sections in
conjunction with, or instead of (as indicated), the related sections earlier in this ‘7900 Food
Grade Printer’ appendix or in other chapters of the manual.

A.10.2 Configuration code

Read this section in conjunction with the section ‘Printer Configuration Code’ in
Chapter 4: ‘System Options’.
A configuration code is required if the 7900 Food Grade printer is to be used in an egg coding
environment. This configuration code changes the warm-up delay time (see the following
‘Warm-up delay’ description).

A.10.3 Warm-up delay

Read this section instead of the section ‘Warm-up delay’ earlier in ‘Starting up and
shutting down’ in this appendix.
To ensure reliable operation, the operator must turn on the printer at least 30 minutes
before it is to be used. This is most important where the ambient temperature is less than
+5 °C.
In conditions of high humidity, condensation can cause any dried ink deposits on the
printhead components to become conductive, which can cause EHT trip failures. To avoid
this, the 5-minute warm-up time after the printer is switched on is increased to 30 minutes.
This increased delay allows the printhead heater more time to disperse any condensation
before the software allows the jet to start (see ‘Configuration code’ above).
During the warm-up time, the jet cannot be started with the [start] key. The jet starts
automatically at the end of the warm-up time, unless the [stop] key is pressed first to cancel
the automatic startup.

A.10.4 Maintenance Times

A.10.4.1 Maintenance Finished
Read this section in conjunction with the section ‘Maintenance Finished’ in
Chapter 5: ‘Maintenance’.
When the 7900 Food Grade printer is used in egg coding environments, the scheduled
maintenance interval is 2400 hours/14 months.

FA69398–1
Oct 2013 A—26 Linx 7900 Maintenance Manual
 APPENDIX B: 7900 SPECTRUM
PRINTER
B.1 Introduction
The Linx 7900 Spectrum printer is a special version of the standard 7900 printer that uses
only pigmented inks. The two products are very similar, with some differences in operation
and design. Where the 7900 Spectrum is different from the standard 7900 printer described
in this manual, the alternative information is provided in this appendix. Cross-references
are shown in bold typeface to sections in other chapters of the manual and have one of the
following statements:
 Read this section in conjunction with …
 Read this section instead of …

B.2 B.2 Summary of differences

The following is a summary of the 7900 Spectrum printer differences from the standard 7900
printer.

B.2.1 Hardware
 The 7900 Spectrum printer uses only the Midi plus and Ultima plus printheads.
 The ink system has a more robust pump, which has a higher resistance to the abrasive
characteristics of some pigmented inks.
 Unlike the pump in the standard 7900 printer, the pump fitted in the 7900 Spectrum
printer ink system does not have an internal pressure relief valve (PRV). Instead, an
external PRV is fitted across the inlet and outlet ports of the pump.
 The ink system has a conically-shaped, stainless steel ink tank, which helps to mix all
pigmented inks before use.
 The ink system uses the original (Mk1) venturi manifold.
 A different type of damper is used in the ink system.
 An additional Ink Mixing valve is used in a sequence that mixes the pigmented ink in
the tank before printing is started.

B.2.2 Configuration
 A software link must be fitted to configure a standard 7900 printer to a 7900 Spectrum
printer. When the software link is fitted, the printhead types, ink types, and other
software options that are used by the 7900 Spectrum printer are enabled.

B.2.3 Software
 The damper Easi-Change® process does not apply to the 7900 Spectrum printer.

FA69398–1
Linx 7900 Maintenance Manual B—1 Oct 2013
B.3 Technical Description
B.3.1 Ink system
B.3.1.1 General description
Read this section instead of the section ‘General description’ in ‘Ink system’ in
Chapter 3: ‘Technical Description’.
NOTE: All specified filter sizes are nominal ratings.
The ink system is contained in a stainless steel enclosure, which is part of the base unit of
the cabinet. The cabinet top cover has two openings through which the ink and solvent
tanks are filled, by internal filler tubes. The filler tubes are sealed by removable protective
caps. Both the filler tubes and protective caps are colour coded—black for ink and white for
solvent. Adhesive identification labels for the ink and solvent types are supplied with the
printer, which can be attached to the protective caps.
The ink system contains the following main components (refer to Figure B-1 on page B—4,
‘Static ink system—7900 Spectrum printer’):
 Ink tank
 Ink pick-up tube
 Pump and motor assembly
 Pressure relief valve (PRV)
 10 µm (nominal) main ink filter
 Small ink manifold assembly, which includes the pressure transducer and venturi
 Damper
 Solvent tank
 Solvent pick-up tube that includes a 20 µm stainless steel in-line filter
 Six solenoid-operated valves
 Interconnecting pipes
NOTE: The symbol ‘µm’ stands for micrometre, which is the SI unit of length and formerly
called the micron.
The 7900 Spectrum printer has a stainless steel, conically-shaped ink tank and a
polyethylene solvent tank with nominal capacities of 1400 ml. Both tanks are fitted with
fluid level sensors (float switches) to detect when the level of ink or solvent is below a set
point. If either sensor detects a low fluid level, a System Warning message is displayed
(“3.03 Ink Low” or “3.04 Solvent Low”).
If, during a print run, the low ink condition is allowed to continue, the system reports the
Print Failure “2.05 Ink Tank Empty” after 6 hours. If, during a print run, the low solvent
condition is allowed to continue, the system reports the Print Failure “2.06 Solvent Tank
Empty” after 12 hours. This response prevents the ink or solvent from running out
completely.
The ink system pump used in the 7900 Spectrum printer has an external pressure relief valve
(PRV) connected across the pump inlet and outlet ports. The pump and motor assembly is
controlled by a 0 volts to +5 volts drive signal (which depends on the requested pressure)
supplied by the IPM PCB.
The pump draws the pigmented ink from the tank through the ink pick-up tube. The ink
then flows through the pump and a 4-way connector, and then to the Ink Mixing valve. A
smaller tapping from the 4-way connector also routes ink back in through the base of the
ink tank, where it mixes with the main body of ink. This action helps to keep the pigment in
the ink in suspension. The fourth tapping from the 4-way connector connects the external
PRV from the outlet to the inlet of the pump.

FA69398–1
Oct 2013 B—2 Linx 7900 Maintenance Manual
 The ink is fed through the Ink Mixing valve to the 10 µm main ink filter, which provides the
primary filtration within the ink system. The filter removes any remaining particles before
the ink reaches the venturi manifold and the printhead. From the main ink filter, the ink is
fed through the venturi manifold, damper, open Feed valve, back through the manifold and
then out to the printhead. The damper minimizes any ink pressure fluctuations within the
primary circuit, and isolates the printhead from pressure fluctuations.
Ink is fed to and from the printhead through the feed, purge, and gutter lines, and a 3-way
fluid connector, which connects the printhead to the ink system. This connector is within
the ink system enclosure and contains a 35 µm filter in the feed line. The ink system and
printhead interconnecting pipes are colour-coded: red stripe for the feed line, blue stripe for
the purge line, and no stripe for the gutter line.
The main ink filter, 3-way fluid connector filter, and Printhead Feed valve filter are replaced
at every scheduled maintenance. The damper is replaced annually. All of these items must
be replaced according to the ‘Scheduled Maintenance’ procedure provided in Chapter 5:
‘Maintenance’.
The venturi in the manifold provides suction to return surplus ink from the printhead
gutter to the ink tank through the Gutter valve. This suction also draws solvent from the
solvent tank as required.
During solvent addition, solvent is drawn from the tank through the solvent pick-up tube,
which includes a 20 µm in-line filter. The solvent is then drawn through the de-energized
Solvent Flush valve, energized Solvent Add (Solvent Top-up) valve and the venturi to the
ink tank.
During a solvent flush, solvent is drawn from the tank through the solvent pick-up tube.
The solvent is then drawn through the de-energized Solvent Add (Solvent Top-up) valve,
energized Solvent Flush valve, venturi manifold, and out to the printhead along the feed
line.
During the ink Mixing sequence, ink is drawn from the tank through the ink pick-up tube
and the pump to the energized Ink Mixing valve. From the valve, the ink is fed back in
through the base of the tank, where the ink mixes with the main body of ink. The
continuous circulation of the ink during the sequence completely mixes the ink in the tank,
which keeps the pigment in suspension, in preparation for printing.

FA69398–1
Linx 7900 Maintenance Manual B—3 Oct 2013
 Gun Printhead Printhead Feed valve and PIPE FLUID KEY
chamber Purge valve 35 µm filter assembly
Ink
Purge line Ink with air bubbles
OFF Feed line Gutter restrictor Solvent

Oct 2013
Printhead (2-metre Ultima plus and
Gutter line Midi plus 75 µm
printheads only) 68579_01_Stat

Pipe size
3-way fluid connector and 35 µm adaptor
10 µm main ink Damper in-line feed filter assembly
filter

7 25 1

21
Venturi
24 19 20

14 OFF 15 OFF 16 OFF 17 OFF 18 OFF 23 OFF

B C A 8
Pressure
transducer
9 3 10 4 11 5 12 6 13 26 27
Feed Purge Gutter Solvent Solvent Ink
valve valve valve Add Flush Mixing
valve valve valve

B—4
Pump
22
Vent Vent

20 µm in-line
Ink return filter fitted in
tube INK Ink SOLVENT solvent
pick-up pick-up tube
tube

Pressure
relief
valve

Figure B-1. Static ink system—7900 Spectrum printer

FA69398–1
Linx 7900 Maintenance Manual
 B.3.1.2 Venturi manifold assembly
Read this section instead of the section ‘Venturi manifold assembly’ in
Chapter 3: ‘Technical Description’.
The central part of the ink system is the manifold assembly, which manages the ink and
solvent distribution in the system. Three components are used to perform these
processes—the manifold block, vacuum venturi, and pressure transducer, all of which are
part of the complete manifold assembly.
The main component is the manifold block, which has moulded internal interconnecting
bores. These bores enter and exit the manifold block at ports to which are fitted the vacuum
venturi, pressure transducer, and interconnecting ink and solvent pipes.
The manifold assembly is fitted through the right side-wall of the ink system enclosure
behind the ink system pump and motor assembly. The fluid connections of the manifold are
on the inside of the enclosure, and the electrical connections of the pressure transducer are
on the outside. This arrangement isolates the electrical and fluid connections from each
other.
The 7900 Spectrum printer is fitted with the original (Mk1) venturi manifold and the Mk4
venturi. The following illustration shows the manifold assembly, ink system valves, and the
cableform for the valves and pressure transducer.

Festo Fitting

Venturi
Venturi
Manifold Block

Solvent Flush
Valve (5) Ink Mixing
Valve (6)
68592
Gutter
Valve (3) Solvent Add
Valve (4)
Feed
Valve (1) Purge Pressure
Valve (2) Transducer

Bl
ac
Vi k
ole
t
Blu
e
Gree
Yell n
ow
Re
d

Ink System Cableform

(connector SK1)
Figure B-2. Mk1 venturi manifold assembly and valves—7900 Spectrum printer

FA69398–1
Linx 7900 Maintenance Manual B—5 Oct 2013
 B.3.1.3 Valves
Read this section instead of the section ‘Valves’ in Chapter 3: ‘Technical Description’.
There are six valves in the 7900 Spectrum ink system enclosure. These solenoid-operated
valves control the flow of ink and solvent through the system. The valves are sealed and
cannot be disassembled.
The following gives the type of valve and its function:
 2-way Feed valve
 3-way Purge valve
 3-way Gutter valve
 3-way Solvent Add (Solvent Top-up) valve
 3-way Solvent Flush valve
 3-way Ink Mixing valve
The six valves are fitted through the front wall of the ink system enclosure. The fluid
connections are on the inside of the enclosure and the electrical connections are on the
outside. This arrangement isolates the electrical and fluid connections from each other.

B.3.1.4 Damper
Read this section instead of the section ‘Damper’ in Chapter 3: ‘Technical Description’.
The 7900 Spectrum printer is fitted with the type of damper shown in Figure B-3. The
damper minimizes any ink pressure fluctuations within the primary circuit, and isolates the
printhead from pressure fluctuations.
A drain fitted to the bottom of the damper allows the ink system to be easily emptied.
NOTE: The damper Easi-Change® process described in the section ‘Damper’ on
page 3—29 of Chapter 3: ‘Technical Description’ does not apply to the 7900
Spectrum printer.

79089

Figure B-3. Damper

FA69398–1
Oct 2013 B—6 Linx 7900 Maintenance Manual
 B.3.1.5 Ink system connections
Read this section instead of the section ‘Ink system connections’ in Chapter 3: ‘Technical
Description’.
The pipe connections to the venturi manifold are made with barb or Festo fittings. The
barbs are sealed by interference-fit to the manifold and cannot be removed, and so cannot
be replaced.
The following illustration shows the original (Mk1) venturi manifold assembly and ink
system valves used in the 7900 Spectrum printer, and provides information about the ink
system pipe connections. Refer to the static ink system diagram (Figure B-1 on page B—4)
with the following illustration.
22

Spectrum venturi manifold Mk1

21
A 25
8
24 20 19

23 18 17 16 15 14
C 7 1

26 6 5 4 3 2
27 13 12 11 10 9

Ink Mixing Solvent Flush Solvent Add Gutter Purge Feed

(6) (5) (4) (3) (2) (1)
73071
7300 AND 7900 SPECTRUM PRINTER—INK SYSTEM PIPE CONNECTIONS
From To Pipe lengths
Port 1 (venturi) Damper inlet (bleed cap end) 400 mm natural pipe (1/8 in. o.d.)
Port 2 not used — —
Port 3 (Purge valve) 3-way fluid connector (purge) 360 mm blue stripe pipe (1/8 in. o.d.)
Port 4 (Gutter valve) Port 8 (venturi) 240 mm natural pipe (1/8 in. o.d.)
Port 5 (Solvent Add valve) Port 6 (Solvent Flush valve) 160 mm natural pipe (1/8 in. o.d.)
Port 9 (Feed valve) Port A (venturi manifold) 260 mm red stripe pipe (1/8 in. o.d.)
Port 10 (Purge valve) Ink tank 360 mm natural pipe (1/8 in. o.d.)
Port 12 (Solvent Add valve) Port 7 (venturi) 220 mm yellow stripe pipe (1/8 in. o.d.)
Port 13 (Solvent Flush valve) Port B (venturi manifold) 160 mm natural pipe (1/8 in. o.d.)
Port 15 (Purge valve) Port 11 (Gutter valve) 160 mm natural pipe (1/8 in. o.d.)
Port 16 (Gutter valve) 3-way fluid connector (gutter) 360 mm natural pipe (1/8 in. o.d.)
Port 17 (Solvent Add valve) 19 (Y-piece connector) 90 mm natural pipe (1/8 in. o.d.)
Port 18 (Solvent Flush valve) 20 (Y-piece connector) 90 mm natural pipe (1/8 in. o.d.)
Port 21 (Y-piece connector) 22 (solvent tank pick-up tube) 260 mm natural pipe (1/8 in. o.d.)
Port 23 (Ink Mixing valve) pipe size adaptor 100 mm natural pipe (1/8 in. o.d.)
Port 24 (venturi) Ink tank (ink return line) 110 mm natural pipe (6 mm o.d.)
Main ink filter outlet Port 25 (venturi & pressure transducer) 300 mm natural pipe (6 mm o.d.)
Port C (venturi manifold) 3-way fluid connector (feed) 360 mm red stripe pipe (1/8 in. o.d.)
Damper outlet Port 14 (Feed valve) 360 mm red stripe pipe (1/8 in. o.d.)
Pipe size adaptor Main ink filter inlet 75 mm natural pipe (6 mm o.d.)
Ink pick-up tube T-piece connector 55 mm natural pipe (6 mm o.d.)
T-piece connector Pump inlet 250 mm natural pipe (6 mm o.d.)
Pump outlet 4-way connector 90 mm natural pipe (6 mm o.d.)
4-way connector Port 26 (Ink Mixing valve) 90 mm natural pipe (6 mm o.d.)
Port 27 (Ink Mixing valve) Ink tank bottom inlet 9 coils natural pipe (6 mm o.d.)
4-way connector Ink tank bottom inlet 1.7 m looped natural pipe (1/8 in. o.d.)
4-way connector PRV inlet 42 mm natural pipe (6 mm o.d.)
PRV outlet T-piece connector 42 mm natural pipe (6 mm o.d.)
Ink tank Solvent tank (vent) 300 mm natural pipe (3/16 in. o.d.)
Solvent tank Ink tray (vent) 480 mm natural pipe (3/16 in. o.d.)

Figure B-4. Ink system pipe connections—7900 Spectrum printer

FA69398–1
Linx 7900 Maintenance Manual B—7 Oct 2013
 B.3.1.6 Ink and solvent flows
Read this section instead of the section ‘‘Ink and solvent flows’ in Chapter 3: ‘Technical
Description’.
Read the following ink and solvent flow descriptions with the ink and solvent flow
diagrams on the following pages.
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 B-5 on page B—9)

The ink flow in the primary circuit is from the pigmented ink tank through the ink pick-up
tube to the pump and a 4-way connector. The ink is then fed under pressure from the pump
through the de-energized Ink Mixing valve and the main ink filter to the venturi manifold.
The pressurized ink within the manifold passes the pressure transducer, which sends an
electrical feedback signal to the electronics system. This signal is an indication of the Actual
Pressure at which the pump is operating, and is used to control the pump speed to set the
required pressure. After the pressure transducer, the ink flows through the venturi, where
the vacuum is generated, and then returns to the ink tank.
A smaller tapping from the 4-way connector also routes ink back in through the base of the
ink tank, where it mixes with the main body of ink. This action helps to keep the pigment in
the ink in suspension. The fourth tapping from the 4-way connector connects the external
PRV from the outlet to the inlet of the pump.

Secondary circuit (Figure B-6 on page B—10)

The secondary ink flow circuit operates when the Ink System Feed valve and the Printhead
Feed valve are opened. A fluid connection within the manifold feeds the ink from the
primary circuit at the venturi out to the damper and the open Feed valve. This valve allows
the pressurized ink to be fed along the feed line, through the manifold and the in-line feed
filter in the 3-way fluid connector The ink continues along the feed line to the printhead,
and then passes through the open Printhead Feed valve to the printhead nozzle, which
creates the jet.
Drops of ink that are not used for printing enter the gutter. The venturi vacuum action on
the gutter draws the surplus ink back into the system through the 3-way fluid connector
and the de-energized Gutter valve. The ink is then returned to the ink tank through the
venturi.

FA69398–1
Oct 2013 B—8 Linx 7900 Maintenance Manual
 Gun Printhead Printhead Feed valve and PIPE FLUID KEY
chamber Purge valve 35 µm filter assembly
Ink
Purge line Ink with air bubbles
OFF Feed line Gutter restrictor Solvent
Printhead (2-metre Ultima plus and

FA69398–1
Gutter line Midi plus 75 µm
printheads only) 68579_02_Pri

Pipe size
3-way fluid connector and 35 µm adaptor
10 µm main ink Damper in-line feed filter assembly
filter

7 25 1

21
Venturi
24

Linx 7900 Maintenance Manual

19 20

14 OFF 15 OFF 16 OFF 17 OFF 18 OFF 23 OFF

B C A 8
Pressure
transducer
9 3 10 4 11 5 12 6 13 26 27
Feed Purge Gutter Solvent Solvent Ink
valve valve valve Add Flush Mixing
valve valve valve

B—9
Pump
22
Vent Vent

20 µm in-line
Ink return filter fitted in
tube INK Ink SOLVENT solvent
pick-up pick-up tube
tube

Pressure
relief
valve

Figure B-5. Primary circuit—7900 Spectrum printer

Oct 2013
 Gun Printhead Printhead Feed valve and PIPE FLUID KEY
chamber Purge valve 35 µm filter assembly
Ink
Purge line Ink with air bubbles
OFF Feed line Gutter restrictor Solvent

Oct 2013
Printhead (2-metre Ultima plus and
Gutter line Midi plus 75 µm
printheads only) 68579_03_Sec

Pipe size
3-way fluid connector and 35 µm adaptor
10 µm main ink Damper in-line feed filter assembly
filter

7 25 1

21
Venturi
24 19 20

14 OFF 15 OFF 16 OFF 17 OFF 18 OFF 23 OFF

B C A 8
Pressure
transducer
9 3 10 4 11 5 12 6 13 26 27
Feed Purge Gutter Solvent Solvent Ink
valve valve valve Add Flush Mixing
valve valve valve

B—10
Pump
22
Vent Vent

20 µm in-line
Ink return filter fitted in
tube INK Ink SOLVENT solvent
pick-up pick-up tube
tube

Pressure
relief
valve

Figure B-6. Secondary circuit (normal running after a start purge—7900 Spectrum printer

FA69398–1
Linx 7900 Maintenance Manual
 Solvent addition (Figure B-7 on page B—12)
Under normal operating conditions, the Set Pressure is adjusted as the ink viscosity changes
to maintain a regular TOF. For example, as the ink viscosity increases caused by solvent
evaporation, the Set Pressure is increased to maintain a fixed TOF (at the Reference TOF)
with the thicker ink. If the Set Pressure reaches the known Solvent Add Pressure, solvent is
added to the ink to decrease the viscosity and so maintain the Actual TOF at Reference TOF.
A solvent addition occurs only if all of the following conditions apply:
 The pressure check is good (that is, the pressure generation circuits operated correctly
at jet startup and the System Warning “3.18 Low Pressure” has not occurred).
 The Set Pressure is greater than the Solvent Add Pressure.
 The Actual TOF is within ±0.3% of the Reference TOF.
 The warm-up time has expired (that is, the jet has been in operation for 45 minutes).
 The solvent level is acceptable (that is, the printer solvent level is above the minimum
required and the System Warning “3.04 Solvent Low” has not occurred).
NOTE: Solvent is not added if the System Warning “3.18 Low Pressure” occurs, because
this warning indicates that there is a loss of pressure in the system. In this condition
a higher pressure is then required to get the correct TOF, although the ink viscosity
is probably acceptable.
During a solvent addition sequence, the Solvent Add (Solvent Top-up) valve is energized.
The venturi vacuum is now applied through the energized Solvent Add (Solvent Top-up)
valve, as well as the Gutter valve. The venturi vacuum draws solvent from the solvent tank,
through the Solvent Flush valve and the energized Solvent Add (Solvent Top-up) valve to
the venturi. At the venturi, the solvent mixes with the ink that is returning to the ink tank.
The lower viscosity ink that is now in the ink tank is then fed to the printhead.
The Solvent Add (Solvent Top-up) valve is energized for a set time, which is calculated to
allow an exact quantity of solvent to be added in a single ‘solvent add’ sequence. This
Solvent Add Time depends on the ink type and printhead type. Refer to the ‘Ink type
dependent parameters’ tables in the section ‘Ink system’ in Chapter 3: ‘Technical
Description’ for more information.
When solvent is added to the ink in the ink tank, the viscosity of the ink is lowered. This
thinner ink reaches the printhead within 3 minutes, and the jet speed increases. The Set
Pressure is then decreased to maintain the jet speed at the Reference TOF. If after
20 minutes (the Viscosity Settle Time), the Set Pressure value remains above the Solvent Add
Pressure value, more solvent is added to the ink tank.
After solvent is added, further solvent additions are prevented for the Viscosity Settle Time.
This time allows the solvent to mix in the ink tank, and for the effects of the solvent addition
to begin to be seen at the printhead.

FA69398–1
Linx 7900 Maintenance Manual B—11 Oct 2013
 Gun Printhead Printhead Feed valve and PIPE FLUID KEY
chamber Purge valve 35 µm filter assembly
Ink
Purge line Ink with air bubbles
OFF Feed line Gutter restrictor Solvent

Oct 2013
Printhead (2-metre Ultima plus and
Gutter line Midi plus 75 µm
printheads only) 68579_04_SolvAdd

Pipe size
3-way fluid connector and 35 µm adaptor
10 µm main ink Damper in-line feed filter assembly
filter

7 25 1

21
Venturi
24 19 20

14 OFF 15 OFF 16 OFF 17 OFF 18 OFF 23 OFF

B C A 8
Pressure
transducer
9 3 10 4 11 5 12 6 13 26 27
Feed Purge Gutter Solvent Solvent Ink
valve valve valve Add Flush Mixing
valve valve valve

B—12
Pump
22
Vent Vent

20 µm in-line
Ink return filter fitted in
tube INK Ink SOLVENT solvent
pick-up pick-up tube
tube

Pressure
relief
valve

Figure B-7. Solvent addition—7900 Spectrum printer

FA69398–1
Linx 7900 Maintenance Manual
 Ink mixing (Figure B-8 on page B—15)
Brilliant White Ink 1305 and 1306 are ultra-white, very pigmented inks that have been
created to be chemically stable, but this attribute does not prevent the pigment from
settling. Unless the fluid is mixed and the pigment redistributed, the opacity of the ink is
lost.
A special conically-shaped ink tank is used in the 7900 Spectrum printer to help to mix all
pigmented inks before use. The shape of the tank collects the settled pigment in the smallest
area at the bottom, where there is high ink flow velocity when the mixing process is started.
After the printer is turned on, and before printing can occur, the pigmented ink is mixed in
the tank by the action of the Mixing sequence. The duration of the sequence can be between
5 minutes and 15 minutes, and depends on the time since the last ink mix.
NOTE: Ink mixing is disabled for Black Pigmented ink 1009 and Yellow Pigmented ink
1039.
The Mixing sequence has four variables:
 The time each day that the sequence is started, if the sequence is required.
 The ‘pump jog-start’ duration.
 The ink mixing duration.
 The damper purge duration.
The first variable is set by the maintenance technician (see ‘Next Mix’ in the section ‘Ink/
Solvent’ on page B—19 of this appendix). The remaining three variables are calculated by
the software and depend on when the last mix occurred, as shown in the following table.

Time since last Pump jog-start Ink mixing time Damper purge
ink mix time (s) (min) time (min)
Less than 1 week 10 5 1
Less than 2 weeks 20 10 2
Less than 3 weeks 30 15 3
More than 3 weeks 40 15 3

Table B-1. Ink Mixing sequence timings

At the start of the Mixing sequence there is a 60-second delay that allows the maintenance
technician time to disable the sequence, if necessary.

Pump Jog-Start
Pigmented ink can sometimes prevent the pump gears from rotating during a pump start.
Immediately before the start of the ink mixing part of the sequence, a ‘pump jog-start’
routine is performed, which turns the pump on and off continuously for a calculated time
(in seconds). This action helps to prevent the problem at pump start.

Ink Mixing
An additional ink mixing, solenoid-operated valve routes the ink through the mixing
circuit.
During the Mixing sequence, ink is drawn from the tank and fed through the pump to the
energized Ink Mixing valve. From the valve, the ink is fed back in through the base of the
tank, where the ink mixes with the main body of ink. The continuous circulation of the ink
during the sequence completely mixes the ink in the tank, which keeps the pigment in
suspension, in preparation for printing.
NOTE: If the ink level becomes low during the Mixing sequence, the sequence is cancelled.

FA69398–1
Linx 7900 Maintenance Manual B—13 Oct 2013
 Damper Purge
Ink is drawn from the tank by the pump to the main ink filter, and then through the damper
and the energized Ink System Feed valve to purge the damper. Finally, the Solvent Flush
and Solvent Add (Solvent Top-up) valves are energized for a short period, which draws the
ink back from the printhead along the feed line.
When the Mixing sequence has finished, the jet can be started.
There is an additional function to the Mixing sequence. While the pump is running, a
secondary action of the primary ink circuit is to continuously return ink from the pump to
the bottom inlet of the tank. This circulation of the ink helps to keep the pigment in
suspension.
NOTE: The maximum pressure used in the operating sequences for the 7900 Spectrum
printer is lower than that used in the standard 7900 and the 7900 Food Grade
printers. The Maximum Running Pressure and the Ink Mixing Pressure for the 7900
Spectrum printer are decreased from 4.49 bar (65.00 p.s.i.) to 3.87 bar (56.08 p.s.i.).
Higher operating pressures can cause the Ink Mixing valve to stick.

Normal shutdown (Figure B-9 on page B—16)

During a Normal Shutdown, the ink is removed from the printhead nozzle and the gun by
suction through the feed and purge lines. Before final shutdown, solvent is flushed through
the printhead to clean the gun, and the feed and purge lines. Then, a solvent jet cleans the
nozzle and gutter, which prepares the printer for the next jet startup.
Figure B-9 shows the state of the ink system after successful completion of the Normal
Shutdown sequence.

FA69398–1
Oct 2013 B—14 Linx 7900 Maintenance Manual
 Gun Printhead Printhead Feed valve and PIPE FLUID KEY
chamber Purge valve 35 µm filter assembly
Ink
Purge line Ink with air bubbles
OFF Feed line Gutter restrictor Solvent
Printhead (2-metre Ultima plus and

FA69398–1
Gutter line Midi plus 75 µm
printheads only) 68579_05_InkMix

Pipe size
3-way fluid connector and 35 µm adaptor
10 µm main ink Damper in-line feed filter assembly
filter

7 25 1

21
Venturi
24

Linx 7900 Maintenance Manual

19 20

14 OFF 15 OFF 16 OFF 17 OFF 18 OFF 23 OFF

B C A 8
Pressure
transducer
9 3 10 4 11 5 12 6 13 26 27
Feed Purge Gutter Solvent Solvent Ink
valve valve valve Add Flush Mixing
valve valve valve

B—15
Pump
22
Vent Vent

20 µm in-line
Ink return filter fitted in
tube INK Ink SOLVENT solvent
pick-up pick-up tube
tube

Pressure
relief
valve

Figure B-8. Ink mixing—7900 Spectrum printer

Oct 2013
 Gun Printhead Printhead Feed valve and PIPE FLUID KEY
chamber Purge valve 35 µm filter assembly
Ink
Purge line Ink with air bubbles
OFF Feed line Gutter restrictor Solvent

Oct 2013
Printhead (2-metre Ultima plus and
Gutter line Midi plus 75 µm
printheads only) 68579_06_AfterSdown

Pipe size
3-way fluid connector and 35 µm adaptor
10 µm main ink Damper in-line feed filter assembly
filter

7 25 1

21
Venturi
24 19 20

14 OFF 15 OFF 16 OFF 17 OFF 18 OFF 23 OFF

B C A 8
Pressure
transducer
9 3 10 4 11 5 12 6 13 26 27
Feed Purge Gutter Solvent Solvent Ink
valve valve valve Add Flush Mixing
valve valve valve

B—16
Pump
22
Vent Vent

20 µm in-line
Ink return filter fitted in
tube INK Ink SOLVENT solvent
pick-up pick-up tube
tube

Pressure
relief
valve

Figure B-9. Ink system after a successful normal shutdown—7900 Spectrum printer

FA69398–1
Linx 7900 Maintenance Manual
 B.3.2 Electrical components
B.3.2.1 Ink system pump
Read this section instead of the section ‘Ink system pump’ in Chapter 3: ‘Technical
Description’.
This unit is a pump and DC motor assembly, which is fitted through the front wall of the
ink system enclosure.

79081

Figure B-10. Ink system pump and motor assembly—7900 Spectrum printer
The pump and motor assembly circulates ink around the ink system at different pressures,
as required by the ink system control electronics. These pressure values depend on the
different functions performed by the printer during startup, normal operation, shutdown,
and other maintenance sequences.
The motor controller circuit on the pump motor provides the drive signal for pressure
control of the pump. The requested pressure (Set Pressure) signal and the output signal
from the pressure transducer (Actual Pressure), on connector PL3 of the IPM PCB, are used
to create the drive signal for the pump motor.
Magnetic coupling from the motor to the pump provides separation of the ink from the
electrical drive parts.
The pump and motor assembly used in the 7900 Spectrum printer has gears made from a
material that has a greater resistance to the abrasive characteristics of some pigmented inks.
The 7900 Spectrum pump has an external pressure relief valve (PRV), which is connected
across the pump inlet and outlet ports. The PRV is set to a maximum pressure of 5.8 bar
(84 p.s.i.).

B.3.2.2 Ink system valves and cableform assembly

Read this section instead of the section ‘Ink system valves and cableform assembly’ in
Chapter 3: ‘Technical Description’.
The six valves are fitted through the front wall of the ink system enclosure. The fluid
connections are on the inside of the enclosure and the electrical connections are on the
outside. This arrangement isolates the electrical and fluid connections from each other.
Electrical connections to the valves are provided by the valve cableform assembly, which
has a 24-way Mini-Fit Junior connector (SK1). This connector is fitted to PL1 on the edge of
the 7900 IPM PCB. The cableform also includes electrical connections for the pressure
transducer, fluid level sensors (float switches), and ink spillage detection.
The following Table B-2 provides information about the pin numbers and wire
colour-codes of the valve cableform assembly. Each valve electrical connector has a number
on the top surface for easy valve identification to prevent incorrect connection, and this
information is also provided in the table.

FA69398–1
Linx 7900 Maintenance Manual B—17 Oct 2013
 VALVE CABLEFORM ASSEMBLY (SK1)
Component Pin number Wire colour
Feed valve (1) 13; 14 Black; purple
(red heatshrink)
Purge valve (2) 19; 20 White/yellow; yellow/brown
(yellow heatshrink)
Gutter valve (3) 15; 16 Grey/pink; red/blue
(green heatshrink)
Solvent Add valve (4) 17; 18 White/green; brown/green
(blue heatshrink)
Solvent Flush valve (5) 21; 22 White/grey; grey/brown
(violet heatshrink)
Ink Mixing valve (6) 1; 2 Red; black
(Spectrum printer only) (black heatshrink)
Pressure transducer 6; 7; 8; 9 Brown; green; yellow; grey
(black heatshrink)
Ink spillage detection 10 Pink
(green/yellow heatshrink)
Level sensor—solvent 5; 11 White; blue
Level sensor—ink 12; 24 Red; white/pink

Table B-2. Valve cableform connections

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Oct 2013 B—18 Linx 7900 Maintenance Manual
B.4 System Options
B.4.1 Installation page
B.4.1.1 Ink/Solvent
Read this section instead of the section ‘Ink/Solvent’ in Chapter 4: ‘System Options’.
When the Ink/Solvent option is highlighted on the Installation page and the Select key is
pressed, the following page is displayed.
69167

Figure B-11. Ink/Solvent page

The ink type being used in the printer and related parameters are selected on this page.

Ink/Solvent Type
All the inks available for use in 7900 printers are displayed in a list on the Ink/Solvent Type
page when the Select key is pressed. The inks are identified by their type number followed
by their related solvent-type number. For example, MEK ink ‘Black Water Removable ink
1035’ is identified as ‘1035/1535’, and ‘Black Ethanol ink 2035’ is identified as ‘2035/2500’.
Refer to the ‘Ink Conversion Calibration (Offset Calibration)’ maintenance instruction in
Chapter 5: ‘Maintenance’ for a complete list of inks approved for use in 7900 printers.
The four options Next Mix, Last Mix, Mix Time and Disable Mix are only applicable to the
7900 Spectrum printer, which uses pigmented inks. These options are displayed when both
of the following conditions apply:
 Software link LK7B is fitted on the IPM PCB (which enables the Spectrum printer
options).
 A pigmented ink is selected on the Ink/Solvent Type page.
Refer to Chapter 2: ‘General and Compliance Information’ for the pigmented inks used in
the 7900 Spectrum printer.
When a 7900 Spectrum printer has not been turned on for a period of time, the pigment in
the ink falls to the bottom of the tank. Before the printer is next used, the ink in the tank is
briefly mixed to make sure that the pigment is completely distributed in the ink.
All pigmented inks must be shaken before being added to the printer. An electrical shaker
is used to do this job automatically for Brilliant White inks 1305 and 1306, and
High-Opacity Grey inks 1310 and 1311 to thoroughly mix the ink. More information can be
found in the Linx Ink Shaker User Guide. All other pigmented inks must be hand shaken only
before being added to the printer.

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 Next Mix
This option sets the time (in hours, minutes and seconds) that the next ink premix sequence
is required to be performed. For example, the Next Mix option can be set for a premix to be
performed 30 minutes before printing is planned to start each day. This time is then
displayed in the Next Mix option.
To help customers who use their printers less than every 2 weeks, a standby mode is also
available. This mode is automatically entered if the printer is continuously turned on, but it
is not used to print. The printer enters a 5-minute Mixing sequence every 24 hours in this
mode, which begins at a time set by the maintenance technician.

Last Mix
The Last Mix option is for display only, and shows the time (in hours, minutes and
seconds) and the date that the last ink mix occurred (that is, at jet shutdown). The time and
date is used by the software to calculate the duration of the next ink premix before printing
(see the following ‘Mix Time’ description).
NOTES:
1. The recommended maximum time that the printer is turned off for is:
 Four weeks if the ambient temperature is not more than 35 degrees Celsius.
 Two weeks if the ambient temperature is not more than 45 degrees Celsius.
2. Where possible, Linx also recommends that the printer is turned on and the jet
started for 30 minutes every 2 weeks during a shutdown period.

Mix Time
The Mix Time option is for display only and shows the duration (in minutes and seconds)
of the next ink premix before printing. The Last Mix time and date is used by the software
to calculate the duration of the premix. This time changes between 5 and 17 minutes
according to the length of time from the last jet shutdown.

Disable Mix
A 1-minute delay is included at the start of the Mixing sequence to allow time for the
maintenance technician to disable the sequence at power-up.To disable the sequence when
an ink mix is not required, the Disable Mix option is set to Yes on the Ink/Solvent page.
The state of the Disable Mix function is not remembered when the printer is turned off. The
mix sequence is always enabled at power-up.
When the Disable Mix option is set to No, the software considers the time that the mix
sequence was disabled to calculate when the next ink mix occurs.
When the Disable Mix option is set to Yes, the occurrence is logged in the Event Log as
System Warning “3.27 Mix Disabled”.

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B.5 Maintenance
B.5.1 Maintenance Times
B.5.1.1 Easi-Change code
Read this section instead of the section ‘Easi-Change code’ in ‘Maintenance Times’ in
Chapter 5: ‘Maintenance’.
The Easi-Change® process does not apply to the 7900 Spectrum printer.

B.5.2 Valves
Read this section instead of the section ‘‘Valves’ in Chapter 5: ‘Maintenance’.
The Valves page allows each of the ink system valves to be opened and closed manually to
help fault diagnosis. The state of each valve can also be monitored (to the right of the valve
name) as it opens and closes during any of the operating sequences.
73083

Figure B-12. Valves page

B.5.2.1 Open/Close
When a valve is highlighted in the Valves list and the Open/Close key is pressed, the
selected valve is energized (opened). The valve remains energized until the Open/Close
key is pressed again or the Valve Reset key is pressed (see the following ‘Valve Reset’
description). If a valve is opened and the Exit key is pressed, the valve remains open. The
Valves page must be accessed again to close the valve.
There are seven valves displayed in the Valves list:
 Printhead Feed
 Feed
 Purge
 Gutter
 Solvent Add
 Solvent Flush
 Mix
The 7900 Spectrum printer has an additional Mix valve, which is used during the Mixing
sequence for all Spectrum pigmented inks. This additional valve is not displayed in the
Valves list of a standard 7900 printer or a 7900 Food Grade printer.

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Linx 7900 Maintenance Manual B—21 Oct 2013
 The valves can be manually operated only when the printer is in the ‘Idle’ state (jet off).
When the printer is in the ‘Jet Running’ or ‘Printing’ states, the Open/Close and Valve
Reset keys are dimmed. The Valves page then shows only the current states of the valves
and they cannot be manually operated.
To help with fault diagnosis, the Set Pressure function (Monitor Jet page) can be used with
the options on the Valves page (refer to ‘SET (Set Pressure)’ on page 5—9, in
Chapter 5: ‘Maintenance’).

B.5.2.2 Valve Reset

If more than one valve has been manually opened, all the valves can be closed at the same
time when the Valve Reset key is pressed.

B.6 System Events

The following System Warnings are applicable only to the 7900 Spectrum printer. Refer to
‘System Warnings’ in Chapter 6: ‘System Events’ for descriptions of these warnings.
 “3.21 Ink Low Prevented Mix”
 “3.22 Fault Prevented Mix”
 “3.23 Power Off Occurred During Mixing”
 “3.24 Restart In Progress”
 “3.25 Ink Unmixed For 4 Weeks”
 “3.27 Mix Disabled”

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Oct 2013 B—22 Linx 7900 Maintenance Manual
 INDEX
NOTE: In the following Index, entries contained within double quotation marks are
event messages.

Symbols
24 volts external alarm
beacon installation 5—195
output 3—61
“300V Power Supply” 3—49, 3—51, 5—6, 6—9, 7—22
3-way fluid connector 3—9, 3—10, 3—23, A—6, B—3
filter 3—23, A—6, B—3
filter replacement 3—23, 5—40, 5—41, 5—65, B—3

A
abbreviations 2—9
Actual Modulation 5—12
Actual Pressure 5—10
Actual TOF 3—8, 3—18, 5—13
additional publications xxviii
After Jet Shutdown (auto power-down option) 4—8
air filter 3—2
replacement 5—42
Alarm and interface upgrade combinations 3—68
alarm PCB 3—61, 3—62
alarms
24 volts external alarm
beacon installation 5—195
output 3—61
dual alarm
installation 5—207
mains (VFC) external alarm
conversion to 5—199
output 3—62, 5—206, 5—215
multi-stage alarm (24 V)
conversion to 5—217
output 3—64, 5—221
multi-stage alarm (VFC)
conversion to 5—223
output 3—64, 5—229
alignment
jet 3—20, 5—103
nozzle 3—20
Always Log option 4—14
amendments iii
antistatic precautions 5—34
approvals, regulatory 2—8
arrow keys 3—4
auto mains power-off bypass kit
installation 5—171
Automatic Tracking
Modulation 5—12
Modulation, Food Grade printer A—22
Pressure 5—10
auxiliary PCB 3—55

B
backing up and restoring data 3—55, 3—68, 5—243
battery 3—49
Block New Events option 4—11
blocked gutter clearance 5—117
Built In Self-Test link 3—51, 6—18

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Linx 7900 Maintenance Manual Index—1 Oct 2013
C
cabinet 3—1
cooling 3—2
CALCHG1 option 5—21
Calendar option 4—24
Calibrate 6xxx Ink option, Food Grade printer A—20
calibrated nozzle replacement (offset calibration) 3—21, 5—139
calibration
charge amplifier 5—77
pressure transducer 5—81
Calibration Mode option 5—20
Calibration Value option 5—21
Cautions (safety) 1—1
CE approval checklist 5—35
Change User Level page 4—26
Charge (Troubleshooting FC004) 7—9
charge amplifier
calibration procedure 5—77
output 3—48
charge calibration factor 3—20, 4—19
Charge Calibration page 5—20
CALCHG1 option 5—21
Calibration Mode option 5—20
Calibration Value option 5—21
EHTPSU1 option 5—21
XCAL125/XCAL255 option 5—21
charge electrode 3—7, 3—15
charge voltage 3—15, 3—48
Clear Event History option 4—13
Conduit Length option 4—18
Food Grade printer A—19
configuration code 3—55, 4—21
egg coding A—26
control panel and keyboard keys xxvii
control panel LEDs 3—4
conventions (used in this manual) xxvii
cooling fan 3—45
correct installation of Mk7 printheads 5—161
“Corrupt Program Data” 6—5
Cover Off Override link 3—50, 6—16
“Cover Override Link Fitted” 3—50, 6—16
Cover Override option 4—19
cover tube magnet, printhead 3—8
Create (test message) option 5—27
cross-references xxvii
Current Date option 4—17
Current Events page 4—10
Current Time option 4—17

D
damper
Food Grade printer A—5, A—8
replacement
Food Grade printer 5—40, A—6
Spectrum printer 5—41, B—3
standard printer 3—23, 5—40
Spectrum printer B—3, B—6
standard printer 3—22, 3—29
Date & Time page 4—17
Current Date option 4—17
Current Time option 4—17
Hijri Date Offset (Days) option 4—18
Hijri Date option 4—18
debounce
primary trigger 3—51, 3—52, 3—57

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Oct 2013 Index—2 Linx 7900 Maintenance Manual
 secondary trigger 3—52, 3—59
Decommission Printhead sequence 5—25
deflector and phase plate (DPP) 3—7
deflector plates 3—7, 3—16
cleanliness 3—16
Delay (auto power-down option) 4—9
Delayed on Idle (auto power-down option) 4—8
Delayed on Jet Running (auto power-down option) 4—9
Delayed on Printing (auto power-down option) 4—9
density, ink 3—8
Disable Mix option B—20
display 3—4
display PCB 3—55
double pole/neutral fusing 1—3, 3—42, 5—33
downloading software 3—56
draining the ink system 5—51
Drop charge 3—15
drop deflection 3—16
Drops item 5—30
D-type connector, correct assembly 3—69
dual alarm 3—63
installation 5—207
dynamic flow control 3—11
module replacement 5—183
printhead replacement (printer with DFC) 5—187

E
Easi-Change® code 3—29, 5—19
Edit Interval option 4—15
Edit Modulation option 5—12
Edit Modulation page
Automatic Tracking (modulation) option 5—12
Automatic Tracking (modulation) option, Food Grade printer A—22
Edit Pressure option 5—9
Edit Pressure page
Automatic Tracking (pressure) option 5—10
egg coding, Food Grade printer A—26
configuration code A—26
maintenance times A—26
warm-up delay A—26
EHT default value 3—43
EHT Deflection (Troubleshooting FC010) 7—15
EHT flash test A—3
EHT power supply unit 2—3, 3—43
“EHT Trip” 5—6, 6—7, 7—19
Food Grade printer A—23
EHTPSU1 option 5—21
electromagnetic compatibility (EMC) compliance 2—8
EMC Directive 2—8
European EMC standards 2—8
USA EMC standards 2—8
EMC compliance 2—8
Empty Tank sequence 5—25
enclosure protection compliance 2—8
engineering units 4—23
environmental compliance 2—8
RoHS Directive 2—8
environmental specification 2—2
Ethernet interface 3—68
Event Filtering page 4—12
Hide/Show Faults options 4—12
Hide/Show Information options 4—12
Hide/Show Warnings options 4—12
Event History page 4—10
Block New Events option 4—11
Clear Event History option 4—13

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Linx 7900 Maintenance Manual Index—3 Oct 2013
 Track New Events option 4—11
Event Log 4—10
Current Events page 4—10
Event Filtering page 4—12
Event History page 4—10
Event Setup page 4—13
Event Setup page 4—13
Always Log option 4—14
Edit Interval option 4—15
Log At Intervals option 4—14
Never Log option 4—14
Reset Count option 4—15
events messages 6—1
extended scheduled maintenance 5—18
external alarms
24 volts external alarm
beacon installation 5—195
output 3—61
dual alarm
installation 5—207
mains (VFC) external alarm
conversion to 5—199
output 3—62, 5—206, 5—215
multi-stage alarm (24 V)
conversion to 5—217
output 3—64, 5—221
multi-stage alarm (VFC)
conversion to 5—223
output 3—64, 5—229
external signals 3—56
alarm output 3—61
dual alarm 3—63
Ethernet interface 3—68
multi-stage alarms 3—64
parallel I/O interface 3—66
primary trigger 3—56
secondary trigger 3—58
serial interface 3—65
shaft encoders 3—59
upgrade combinations 3—68
USB facility 3—68

F
Fail LED 3—4
“Fault Prevented Mix” 6—19, B—22
Feed valve, Ink System 3—22, 3—28, 3—31, A—5, A—10, B—3, B—6, B—8, B—14
testing for leaks 5—87
Feed valve option 5—26, B—21
Feed valve, Printhead 3—9, 3—31, A—10, B—8
filter replacement 5—41, 5—155
testing for leaks 5—83
valve replacement 5—151
filter, air 3—2
replacement 5—42
Filter Purge sequence 5—24
Final Test (Troubleshooting FC999) 7—31
first aid 1—5
eye contact with inks or solvents 1—5
ingestion of inks or solvents 1—5
inhalation of solvent fumes 1—5
skin contact with inks or solvents 1—5
flash memory 3—56
float switches (fluid level sensors) 3—22, 3—44, A—5, B—2, B—17
flow diagrams
after shutdown 3—36
Food Grade printer A—15

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Oct 2013 Index—4 Linx 7900 Maintenance Manual
 Spectrum printer B—16
ink mixing, Spectrum printer B—15
primary circuit 3—32
Food Grade printer A—11
Spectrum printer B—9
secondary circuit 3—33
Food Grade printer A—12
Spectrum printer B—10
solvent addition 3—35
Food Grade printer A—14
Spectrum printer B—12
static ink system 3—24
Food Grade printer A—7
Spectrum printer B—4
fluid connector, 3-way 3—9, 3—10, 3—23, A—6, B—3
filter 3—23, A—6, B—3
filter replacement 3—23, 5—40, 5—41, 5—65, B—3
fluid level control 2—4
fluid level sensors (float switches) 3—22, 3—44, A—5, B—2, B—17
Flush Cycle sequence 5—25
Food Grade ink options link A—17
Food Grade printer
Automatic Tracking (modulation) option A—22
Calibrate 6xxx Ink option A—20
Conduit Length option A—19
differences from standard printer 3—1
egg coding A—26
Configuration Code A—26
maintenance times A—26
warm-up delay A—26
EHT flash test A—3
gutter restrictor A—2
ink and solvent flows A—10
ink options link A—17
ink system A—5
ink type dependent parameters 3—38
ink types 2—5, 5—177, A—1
Ink/Solvent page A—20
IPM PCB links A—17
minimum run time A—4, A—17
link A—17
overriding the shutdown delay A—21
modulation frequency A—3
parts list A—25
positive air pump A—16
Power Down page A—18
printhead cleaning 5—177
Printhead Code option A—19
Printhead page A—19
Printhead Type option A—19
training courses, special features A—25
viscosity control A—3
warm-up delay A—4, A—26
fuses, mains electrical supply 3—42
fusing, double pole/neutral 1—3, 3—42, 5—33

G
“Gate Array Test Mode Active” 6—18
glossary 2—9
Gregorian calendar 4—24
guard drops 3—16
gun chamber 3—7
gutter (clearing a blockage) 5—117
gutter check valve, in-line 3—10
“Gutter Override Active” 3—51, 6—17
gutter restrictor 3—10

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Linx 7900 Maintenance Manual Index—5 Oct 2013
 Food Grade printer A—2
gutter sense 3—47, 3—51, 6—10, 6—17
Gutter Sense Override link 3—51, 6—17
Gutter valve 3—23, 3—28, 3—31, A—6, A—10, B—3, B—6, B—8
testing for leaks 5—90, 5—92
testing for operation 5—92
Gutter valve option 5—26, B—21

H
Hall-effect switch 3—8, 3—15
“Hardware Safety Trip” 6—12, 7—30
Hide/Show Faults options 4—12
Hide/Show Information options 4—12
Hide/Show Warnings options 4—12
High Viscosity Ink (Troubleshooting FC009) 7—14
Hijri Date Offset (Days) option 4—18
Hijri Date option 4—18
historic correction 3—15

I
ID page 4—20
Printer Configuration Code option 4—21
Printer Serial Number option 4—22
UNIC Code option 4—21
imperial units 4—23
important Notes xxviii
ink and solvent identification labels 3—22, A—5, B—2
Ink Bottles item 5—30
ink conversion calibration (offset calibration) 5—135
ink density 3—8
ink flow 3—31
Food Grade printer A—10
Spectrum printer B—8
“Ink Low” 3—22, 6—13, A—5, B—2
ink low (level) 2—4
“Ink Low Prevented Mix” 6—19, B—22
Ink Mixing valve B—2, B—3, B—6, B—8, B—13, B—14
ink mixing—Spectrum printer only B—3, B—13
damper purge B—14
ink mixing B—13
pump jog-start B—13
ink pick-up filter
replacement 3—23, A—6
ink pick-up tube 3—22, A—5, B—2
blockage 6—11, 6—18
filter 3—22, A—5
replacement 3—23, 5—40, 5—61, A—6
Ink Quality (Troubleshooting FC007) 7—12
ink spillage detection 3—44, 6—10, B—17
ink system 2—3, 3—2, 3—22
capacity 2—4
connections
Food Grade printer A—9
Spectrum printer B—7
construction 2—3
draining 5—51
electrical connections 2—3
environmental 2—3
flow diagrams
after shutdown 3—36
Food Grade printer A—15
Spectrum printer B—16
ink mixing, Spectrum printer B—15
primary circuit 3—32
Food Grade printer A—11
Spectrum printer B—9

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 secondary circuit 3—33
Food Grade printer A—12
Spectrum printer B—10
solvent addition 3—35
Food Grade printer A—14
Spectrum printer B—12
static ink system 3—24
Food Grade printer A—7
Spectrum printer B—4
fluid level control 2—4
fluid level sensors (float switches) 3—44
Food Grade printer A—5
ink spillage detection 3—44, 6—10, B—17
IP rating 2—3
maximum surface temperature of valves solenoids 2—4
performance 2—4
pipe connections 3—30
pressure 2—4
primary ink circuit 3—31
Food Grade printer A—10
Spectrum printer B—8
pump/motor assembly 3—22
secondary ink circuit 3—31
Food Grade printer A—10
Spectrum printer B—8
Spectrum printer B—2
valves 3—28, 3—44
Spectrum printer B—6, B—17
ink tank 3—22, A—5
Spectrum printer B—2
capacity 2—4
construction 2—3
removal 5—57
standard and Food Grade printer
capacity 2—4
construction 2—3
“Ink Tank Empty” 3—22, 6—9, 7—23, A—5, B—2
ink type dependent parameters 3—37
Micro printhead 3—39
Midi A printhead 3—38
Midi plus printhead 3—40
Midi printhead 3—37
MidiEC printhead 3—38
Mini printhead 3—39
Ultima A printhead 3—38
Ultima plus printhead 3—40
Ultima printhead 3—37
“Ink Unmixed For 4 Weeks” 6—19, B—22
ink viscosity 3—8, 3—18, 3—19
Ink/Solvent page
all 7900 printers
Ink/Solvent Type option 4—22, B—19
Food Grade printer
Calibrate 6xxx Ink option A—20
Spectrum printer
Disable Mix option B—20
Last Mix option B—20
Mix Time option B—20
Next Mix option B—20
Ink/Solvent Type option 4—22, B—19
in-line feed filter 3—9
in-line gutter check valve 3—10
Installation page 4—16
Date & Time page 4—17
Current Date option 4—17
Current Time option 4—17

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Linx 7900 Maintenance Manual Index—7 Oct 2013
 Hijri Date Offset (Days) option 4—18
Hijri Date option 4—18
ID page 4—20
Printer Configuration Code option 4—21
Printer Serial Number option 4—22
UNIC Code option 4—21
Ink/Solvent page B—19
Disable Mix option B—20
Ink/Solvent Type option 4—22, B—19
Last Mix option B—20
Mix Time option B—20
Next Mix option B—20
Ink/Solvent page, Food Grade printer A—20
Calibrate 6xxx Ink option A—20
Locale page 4—23
Calendar option 4—24
Keyboard option 4—24
Language option 4—23
Secondary Keyboard option 4—24
Units option 4—23
Use Language Defaults option 4—23
Photocells page 4—25
Printhead page 4—18
Conduit Length option 4—18
Cover Override option 4—19
Mod Slope option 4—20
Printhead Code option 4—19
Printhead Height option 4—18
Printhead Type option 4—18
Printhead page, Food Grade printer A—19
Conduit Length option A—19
Printhead Code option A—19
Printhead Type option A—19
“Internal Failure” 6—5
“Internal Software Failure” 6—5
“Internal Spillage” 5—6, 6—10, 7—25
IP rating 3—1
ink system 2—3
printer cabinet 2—2
IPM PCB 3—46
charge amplifier calibration procedure 5—77
links 3—49
links, Food Grade printer A—17
links locations 3—54
pressure transducer calibration procedure 5—81
replacement and calibration 3—55
test points 3—47
test points locations 3—54
isolated secondary trigger input 3—52, 3—59

J
Jet (Troubleshooting FC002) 7—7
jet alignment 3—20, 5—103
Jet Functions page 5—5
Jet Test – Start option 5—6
Jet Test – Stop option 5—7
Jet Test – Stop option, Food Grade printer A—21
Start Print option 5—7
Stop Print option 5—7
Test Print option 5—8
Jet Run Time (Present) 5—17
Jet Run Time (Total) 5—17
Jet Sequences page 5—21
Decommission Printhead sequence 5—25
Empty Tank sequence 5—25
Feed Dry sequence 5—24

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Oct 2013 Index—8 Linx 7900 Maintenance Manual
 Filter Purge sequence 5—24
Flush Cycle sequence 5—25
Gutter Dry sequence 5—24
Jet State box 5—22
Nozzle Clear sequence 5—24
Nozzle Flush sequence 5—23
Purge Dry sequence 5—25
Reset Sequence Count option 5—22
Solvent Drain sequence 5—25
Start Sequence option 5—22
Stop Sequence option 5—22
Jet State box 5—22
Jet Test – Start option 5—6
Jet Test – Stop option 5—7
Food Grade printer A—21
jog-start routine B—13

K
keyboard 3—4
Keyboard option 4—24
keys
control panel xxvii
keyboard xxvii

L
Language option 4—23
Last Mix option B—20
LCD (liquid crystal display) 3—4
LEDs 3—4
lethal voltages 1—3
level sensors (float switches) 3—22, 3—44, A—5, B—2, B—17
Line Setup page 4—7
Power Down page 4—7
After Jet Shutdown option 4—8
Delay option 4—9
Delayed on Idle option 4—8
Delayed on Jet Running option 4—9
Delayed on Printing option 4—9
Power Down page, Food Grade printer A—18
link LK7 3—49, A—17, B—19
links
IPM PCB 3—49
IPM PCB default positions 3—53
IPM PCB, Food Grade printer A—17
IPM PCB locations 3—54
Linx Sync (Service Tool) v4.0 procedures 5—235
Locale page 4—23
Calendar option 4—24
Keyboard option 4—24
Language option 4—23
Secondary Keyboard option 4—24
Units option 4—23
Use Language Defaults option 4—23
Log At Intervals option 4—14
“Low Pressure” 3—19, 3—34, 5—10, 6—18, A—13, B—11
Low Pressure (Troubleshooting FC006) 7—11
Low Viscosity Ink (Troubleshooting FC008) 7—13
low voltage power supply unit 2—3, 3—42

M
main ink filter 3—22, 3—28, A—5, B—3
purging 5—41, 5—75
replacement 3—23, 5—41, 5—69, A—6, B—3
mains (VFC) external alarm
conversion to 5—199

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 output 3—62, 5—206, 5—215
mains electrical supply cable 3—41
mains electrical supply cable connector 3—41
mains electrical supply filter 3—42
mains electrical supply fuses 3—42
mains electrical supply switch 3—41
mains power requirements 2—2
Maintenance Due By option 5—17
Maintenance Due Within option 5—17
Maintenance Finished option 5—18
Maintenance Finished option, egg coding A—26
maintenance instructions 5—33
24 Volts Alarm Beacon Installation (Printer Mount) 5—195
3-Way Fluid Connector Filter Replacement 5—65
Auto Mains Power-Off Bypass Kit Installation 5—171
Blocked Gutter Clearance 5—117
Calibrated Nozzle Replacement (Offset Calibration) 5—139
Changing the Orientation of Mk7 Right-Angled P/HDs 5—167
Charge Amplifier Calibration 5—77
Correct Installation of Mk7 Printheads 5—161
Draining the Ink System 5—51
Dual Alarm Installation 5—207
Dynamic Flow Control Module Replacement 5—183
Ink Conversion Calibration (Offset Calibration) 5—135
Ink System Feed Valve Test 5—87
Ink Tank Pick-up Tube Replacement 5—61
Jet Alignment and Nozzle Cleaning 5—103
Linx Sync (Service Tool) v4.0 Procedures 5—235
Main Ink Filter Purge 5—75
Main Ink Filter Replacement 5—69
Mains (VFC) External Alarm Conversion 5—199
MidiEC Printhead Cleaning 5—177
Modulation Range Checks 5—113
Multi-Stage Alarm (24 V) Conversion 5—217
Multi-Stage Alarm (VFC) Conversion 5—223
Parallel I/O Interface Installation 5—231
Positive Air Pump Installation 5—207
Pressure Transducer Calibration 5—81
Printer Installation 5—159
Printhead Cleaning for Pigmented Inks 5—47
Printhead Feed Valve Filter Replacement 5—155
Printhead Feed Valve Replacement 5—151
Printhead Replacement (Printer with DFC) 5—187
Printhead Valves Tests 5—83
Purge and Gutter Valves Tests 5—89
Scheduled Maintenance 5—37
Solvent Add Valve Tests 5—99
Solvent Flush Valve Tests 5—95
Spectrum Ink Tank Removal 5—57
System Flush 5—123
Maintenance options 5—1
option availability 5—3
password access 4—3
Maintenance page 5—5
Charge Calibration page 5—20
CALCHG1 option 5—21
Calibration Mode option 5—20
Calibration Value option 5—21
EHTPSU1 option 5—21
XCAL125/XCAL255 option 5—21
Jet Functions page 5—5
Jet Test – Start option 5—6
Jet Test – Stop option 5—7
Food Grade printer A—21
Start Print option 5—7
Stop Print option 5—7

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Oct 2013 Index—10 Linx 7900 Maintenance Manual
 Test Print option 5—8
Jet Sequences page 5—21
Decommission Printhead sequence 5—25
Empty Tank sequence 5—25
Feed Dry sequence 5—24
Filter Purge sequence 5—24
Flush Cycle sequence 5—25
Gutter Dry sequence 5—24
Jet State box 5—22
Nozzle Clear sequence 5—24
Nozzle Flush sequence 5—23
Purge Dry sequence 5—25
Reset Sequence Count option 5—22
Solvent Drain sequence 5—25
Start Sequence option 5—22
Stop Sequence option 5—22
Jet Sequences page, Spectrum printer B—21
Maintenance Times page 5—16
Jet Run Time (Present) 5—17
Jet Run Time (Total) 5—17
Maintenance Due By option 5—17
Maintenance Due Within option 5—17
Maintenance Finished option 5—18
Maintenance Finished option, egg coding A—26
Power On Time (Present) 5—16
Power On Time (Total) 5—16
Monitor Jet page 5—8
Actual Modulation 5—12
Actual Pressure 5—10
Actual TOF 5—13
Edit Modulation option 5—12
Edit Pressure option 5—9
Phase 5—15
Pressure in p.s.i./bar/bits option 5—11
Reference Modulation 5—11
Food Grade printer A—19, A—22
Reference Pressure 5—10
Reference TOF 5—13
Set Pressure 5—9
Solvent Add Count 5—15
Solvent Add Pressure 5—9
Temp (printhead temperature) 5—15
TOF Mode option 5—14
Print and Consumables History page 5—29
Drops item 5—30
Ink Bottles item 5—30
Messages item 5—30
Recent Drops item 5—30
Recent Ink Bottles item 5—30
Recent Messages item 5—30
Recent Solvent Bottles item 5—30
Reset Recent option 5—30
Solvent Bottles item 5—30
Software Upgrade option 5—30
System Flush option 5—27
Test Message page 5—26
Create option 5—27
Save option 5—27
Valves page 5—25, B—21
Feed valve option 5—26, B—21
Gutter valve option 5—26, B—21
Mix valve option B—21
Open/Close option 5—26, B—21
Printhead Feed valve option 5—26, B—21
Purge valve option 5—26, B—21
Solvent Add valve option 5—26, B—21

FA69398–1
Linx 7900 Maintenance Manual Index—11 Oct 2013
 Solvent Flush valve option 5—26, B—21
Valve Reset option 5—26, B—22
maintenance terminology 5—33
Maintenance Times page 5—16
Jet Run Time (Present) 5—17
Jet Run Time (Total) 5—17
Maintenance Due By option 5—17
Maintenance Due Within option 5—17
Maintenance Finished option 5—18
Maintenance Finished option, egg coding A—26
Power On Time (Present) 5—16
Power On Time (Total) 5—16
Manual Phase option 5—14
maximum fault pressure
Spectrum and Food Grade printers 2—4
standard printers 2—4, 5—11
maximum operating pressure
revised for the Spectrum printer B—14
Spectrum and Food Grade printers 2—4
standard printers 2—4, 5—11
maximum Set Pressure, Spectrum printer 5—34
memory capacity 2—8
“Memory Corrupt” 6—13
Menu page 4—9
Change User Level page 4—26
Event Log 4—10
Maintenance page 4—15
Setup page 4—16
Installation page 4—16
message types 2—6, 3—13, 3—43, 4—21, 5—26
Messages item 5—30
metric units 4—23
micrometre (µm) 3—22
MidiEC printhead cleaning 5—177
minimum run time A—4, A—17
IPM PCB link A—17
overriding the shutdown delay A—21
“Misaligned Ink Jet” 6—10, 7—27
“Mix Disabled” 6—19, B—20, B—22
Mix Time option B—20
Mix valve option B—21
mixing sequence—Spectrum printer only B—13
mixing valve B—2, B—13, B—14
Mod Slope option 4—20
modulation 3—13
Modulation (Troubleshooting FC003) 7—8
modulation frequency 3—14, 3—48
Food Grade printer A—3
modulation range checks 5—113
modulation tracking slope 4—20
modulation voltage 3—14, 3—48
Monitor Jet page 5—8
Actual Modulation 5—12
Actual Pressure 5—10
Actual TOF 5—13
Edit Modulation option 5—12
Edit Modulation page
Automatic Tracking (modulation) option 5—12
Food Grade printer A—22
Edit Pressure option 5—9
Edit Pressure page
Automatic Tracking (pressure) option 5—10
Phase 5—15
Pressure in p.s.i./bar/bits option 5—11
Reference Modulation 5—11
Food Grade printer A—19, A—22

FA69398–1
Oct 2013 Index—12 Linx 7900 Maintenance Manual
 Reference Pressure 5—10
Reference TOF 5—13
Set Pressure 5—9
Solvent Add Count 5—15
Solvent Add Pressure 5—9
Temp (printhead temperature) 5—15
TOF Mode option 5—14
TOF Mode page
Manual Phase option 5—14
TOF Only option 5—14
TOF/Phase option 5—14
multi-stage alarm (24 V)
conversion to 5—217
output 3—64, 5—221
multi-stage alarm (VFC)
conversion to 5—223
output 3—64, 5—229

N
Never Log option 4—14
Next Mix option B—20
next object input 3—48
“No Time Of Flight” 6—18
nozzle alignment 3—20
nozzle assembly 3—7
nozzle cleaning 5—103
hot water wash 5—109
Nozzle Clear 5—105
nozzle soak 5—107
nozzle wash 5—108
solvent wash 5—108
Nozzle Clear sequence 5—24, 5—105
Nozzle Flush sequence 5—23
nozzle realignment 5—111
nozzle replacement 3—21, 5—139
NPN/PNP (triggering devices) 3—56, 3—58

O
Open/Close (valves) option 5—26, B—21
option availability
Maintenance options 5—3
system options 4—5
option plates, external signals 3—68
options
How to select and change options 4—2, 5—1
“Over Speed (Asynchronous Data)” 6—15
“Over Speed (Compensation)” 6—15
“Over Speed (Line Speed)” 6—15
“Over Speed (No Remote Data)” 6—20
“Over Speed (Print Trigger)” 6—14
“Over Speed (Synchronous Data)” 6—14

P
parallel I/O interface 3—55, 3—66, 5—231
installation 5—231
link positions 3—66
pin connections 3—67
parts list, Food Grade printer A—25
password access 4—3
Phase 5—15
Phase (Troubleshooting FC005) 7—10
phase control 3—17
“Phase Failure” 6—8, 7—20
phase packet 3—17
phase positions 3—17

FA69398–1
Linx 7900 Maintenance Manual Index—13 Oct 2013
phase sensor 3—7, 3—17
phase/TOF during a stalled print 3—18
phasing 3—7, 3—17
Photocells page 4—25
piezoelectric crystal 3—13
pigmented inks, printhead cleaning 5—47
PIO PCB 3—55, 3—66, 5—231
positive air pump 3—45
Food Grade printer A—16
installation 5—145
Power Down page 4—7
After Jet Shutdown option 4—8
Delay option 4—9
Delayed on Idle option 4—8
Delayed on Jet Running option 4—9
Delayed on Printing option 4—9
Power Down page, Food Grade printer A—18
Power LED 3—4
“Power Off Occurred During Mixing” 6—19, B—22
“Power Off Override Active” 3—50, 6—17
Power Off Override link 3—50, 6—17
power on switch 3—41
Power On Time (Present) 5—16
Power On Time (Total) 5—16
pressure conversion figures 5—11
Pressure in p.s.i./bar/bits option 5—11
“Pressure Limit Reached” 6—11, 7—28
“Pressure O/ride Circuit Tripped” 6—12
pressure relief valve, pump 3—22
Food Grade printer A—5
Spectrum printer B—2
pressure transducer 3—27, 3—44, B—17
calibration procedure 5—81
primary ink circuit 3—31
Food Grade printer A—10
Spectrum printer B—8
primary trigger 3—56
primary trigger signal 3—48
Print (Troubleshooting FC011) 7—16
Print and Consumables History page 5—29
Drops item 5—30
Ink Bottles item 5—30
Messages item 5—30
Recent Drops item 5—30
Recent Ink Bottles item 5—30
Recent Messages item 5—30
Recent Solvent Bottles item 5—30
Reset Recent option 5—30
Solvent Bottles item 5—30
Print Failures 6—6
2.00 Printhead Over Temperature 3—8, 5—6, 6—7, 7—18
2.01 EHT Trip 5—6, 6—7, 7—19
Food Grade printer A—23
2.02 Phase Failure 6—8, 7—20
2.03 Time Of Flight Failure 3—18, 6—9, 7—21
Food Grade printer A—23
2.04 300V Power Supply 3—49, 3—51, 5—6, 6—9, 7—22
2.05 Ink Tank Empty 3—22, 6—9, 7—23, A—5, B—2
2.06 Solvent Tank Empty 3—22, 6—9, 7—24, A—5, B—2
2.07 Internal Spillage 5—6, 6—10, 7—25
2.08 Printer Over Temperature 3—45, 6—10, 7—26
2.09 Misaligned Ink Jet 6—10, 7—27
2.11 Pressure Limit Reached 6—11, 7—28
2.12 Viscosity 3—19, 6—11, 7—29
2.13 Hardware Safety Trip 6—12, 7—30
2.14 Pressure O/ride Circuit Tripped 6—12

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Oct 2013 Index—14 Linx 7900 Maintenance Manual
 2.15 Scheduled Maintenance is overdue by 3 months–Please contact your local ... 6—12
2.16 System Configuration Not Recognised 6—12
Print Monitor page 4—1
print quality 3—20
Print Quality (Troubleshooting FC012) 7—17
printer
cabinet 3—1
construction 2—2
dimensions 2—2
weight 2—3
configuration code 3—55, 4—21
configurations 2—1
installation 5—159
models xxviii
Printer Configuration Code option 4—21
“Printer Over Temperature” 3—45, 3—48, 6—10, 7—26
“Printer Requires Scheduled Maintenance” 5—17, 6—16
“Printer Requires Scheduled Maintenance Within One Month” 6—21
Printer Serial Number option 4—22
printhead 2—5
cleaning
for Food Grade inks 5—177
for pigmented inks 5—47
code 3—20
components 3—6
connections 3—10
construction 2—5
correct installation 5—161
cover sensor 3—8
cover tube magnet 3—8
dimensions 2—5
Feed valve filter replacement 5—41, 5—155, B—3
Feed valve replacement 5—151
Feed valve test 5—83
positive air pump 3—45
Food Grade printer A—16
Purge valve test 5—83
replacement 3—21
replacement (printer with DFC) 5—187
right-angled, changing the orientation 5—167
temperature 5—15
temperature sensor 3—8
types 2—5, 3—12
valves 3—9, 3—20
Printhead Code option 4—19
Food Grade printer A—19
“Printhead Cover Off” 3—50, 6—16
Printhead Feed valve
filter replacement 5—41, 5—155, B—3
replacement 5—151
Printhead Feed valve option 5—26, B—21
Printhead Height option 4—18
“Printhead Over Temperature” 3—8, 3—47, 5—6, 6—7, 7—18
Printhead page 4—18
Conduit Length option 4—18
Cover Override option 4—19
Mod Slope option 4—20
Printhead Code option 4—19
Printhead Height option 4—18
Printhead Type option 4—18
Printhead page, Food Grade printer A—19
Conduit Length option A—19
Printhead Code option A—19
Printhead Type option A—19
“Printhead requires cleaning at shutdown” 6—19
Food Grade printer A—23

FA69398–1
Linx 7900 Maintenance Manual Index—15 Oct 2013
printhead to substrate distance 2—7
Printhead Type option 4—18
Food Grade printer A—19
printing performance 2—6
publications, additional xxviii
pump jog-start sequence B—13
pump/motor assembly 3—22, 3—44
Food Grade printer A—5, A—6, A—16
Spectrum printer B—2, B—17
Purge valve, Ink System 3—28, B—6
testing for leaks 5—90
Purge valve option 5—26, B—21
Purge valve, Printhead 3—9
testing for leaks 5—85

Q
quality, print 3—20

R
Read Pressure 3—47
Ready LED 3—4
Recent Drops item 5—30
Recent Ink Bottles item 5—30
Recent Messages item 5—30
Recent Solvent Bottles item 5—30
recommended procedures 5—34
Reference Modulation 3—14, 3—20, 4—19, 5—11
Food Grade printer A—19, A—22
Reference Pressure 3—19, 3—20, 4—19, 5—10
Reference TOF 3—8, 3—18, 5—13
regulatory approvals 2—8
“Remote Error” 6—20
Reset Count option 4—15
Reset Recent option 5—30
Reset Sequence Count option 5—22
“Restart In Progress” 6—19, B—22
Restart sequence 6—6
“Restarted Print Delay” 6—20
RS-232 3—65
cable connections 3—65

S
safety 1—1
first aid 1—5
eye contact with inks or solvents 1—5
ingestion of inks or solvents 1—5
inhalation of solvent fumes 1—5
skin contact with inks or solvents 1—5
inks and solvents 1—4
lethal voltages 1—3
test printing 1—6
Warnings and Cautions 1—1
safety compliance 2—8
European safety standards 2—8
Low Voltage Directive 2—8
safety functions (under fault conditions) 3—55
“Safety Override Active” 3—50, 6—17
Safety Override link 3—50, 6—17
safety recommendation v
Save (test message) option 5—27
scheduled maintenance 5—37
checklist 5—36
extended 5—18
intervals 3—29
“Scheduled Maintenance is overdue by 3 months–Please contact your local ...” 6—12

FA69398–1
Oct 2013 Index—16 Linx 7900 Maintenance Manual
secondary ink circuit 3—31
Food Grade printer A—10
Spectrum printer B—8
Secondary Keyboard option 4—24
secondary trigger 3—58
secondary trigger input 3—47
secondary trigger signal 3—47
security access levels (user levels) 4—26, 5—2
serial interface 3—65
Service level timeout 4—4
Set Pressure 3—8, 3—19, 3—47, 5—9
Setup page 4—16
Installation page 4—16
Date & Time page 4—17
ID page 4—20
Ink/Solvent page 4—22, B—19
Food Grade printer A—20
Locale page 4—23
Photocells page 4—25
Printhead page 4—18
Food Grade printer A—19
shaft encoders 3—59
“Shutdown Incomplete” 6—13
“Shutdown Incomplete (Failure)” 6—13
shutting down 3—19
soft keys 3—4
software 3—56
downloading software 3—56, 5—30
programming—corrupt/faulty software 5—241
programming—normal 5—237
Software Upgrade option 5—30
Solvent Add (Solvent Top-up) valve 3—23, 3—28, 3—34, A—6, A—13, B—3, B—6, B—11, B—14
testing for leaks 5—99
testing for operation 5—100
Solvent Add Count 5—15
Solvent Add Pressure 3—8, 3—19, 5—9
Solvent Add Time 3—34, A—13, B—11
Solvent Add valve option 5—26, B—21
solvent addition 3—23, 3—34, 6—11, A—6, B—3
Food Grade printer A—13
Spectrum printer B—11
Solvent Bottles item 5—30
Solvent Drain sequence 5—25
solvent flow 3—31
Food Grade printer A—10
Spectrum printer B—8
solvent flush 3—23, A—6, B—3
Solvent Flush valve 3—23, 3—28, 3—34, A—6, A—13, B—3, B—6, B—11, B—14
testing for leaks 5—97
testing for operation 5—95
Solvent Flush valve option 5—26, B—21
“Solvent Low” 3—19, 3—22, 3—34, 6—14, A—5, A—13, B—2, B—11
solvent low (level) 2—4
solvent pick-up tube 3—22, 3—23, A—5, A—6, B—2, B—3
blockage 5—96, 5—101, 6—11
filter 3—23, A—6, B—3
solvent tank 3—22, A—5, B—2
capacity 2—4
construction 2—3
“Solvent Tank Empty” 3—22, 6—9, 7—24, A—5, B—2
Spectrum printer
differences from standard printer 3—1
ink and solvent flows B—8
ink system B—2
ink tank removal 5—57
ink types 2—5

FA69398–1
Linx 7900 Maintenance Manual Index—17 Oct 2013
spillage detection, ink 3—44, 6—10, B—17
“Stack Overflow” 6—5
standard printer
ink and solvent flows 3—31
standards 2—8
standby mode—Spectrum printer only B—20
Start Print option 5—7
Start Sequence option 5—22
starting up 3—19
Stop Print option 5—7
Stop Sequence option 5—22
strobe LED 3—7, 3—15
SureFill page 6—13, 6—14
“System Configuration Not Recognised" 6—12
system diagram 3—46
System Event page 6—1
system events 6—1
System Failures 6—4
1.00 Internal Failure 6—5
1.01 Stack Overflow 6—5
1.02 Corrupt Program Data 6—5
1.03 Internal Software Failure 6—5
system flush 5—123
Empty Tank 5—128
Flush Cycle 5—132
precautions 5—128
procedure 5—128
Solvent Drain 5—133
System Flush option 5—27
system options
Line Setup page 4—7
Power Down page 4—7
Food Grade printer A—18
Maintenance page 5—5
Menu page 4—9
option availability 4—5
security access levels 5—2
system software 3—56
downloading software 3—56, 5—30
programming—corrupt/faulty software 5—241
programming—normal 5—237
System Warnings 6—13
2.00 Printhead Over Temperature 3—47
2.08 Printer Over Temperature 3—48
3.00 Shutdown Incomplete 6—13
3.01 Shutdown Incomplete (Failure) 6—13
3.02 Memory Corrupt 6—13
3.03 Ink Low 3—22, 6—13, A—5, B—2
3.04 Solvent Low 3—19, 3—22, 3—34, 6—14, A—5, A—13, B—2, B—11
3.05 Over Speed (Print Trigger) 6—14
3.06 Over Speed (Synchronous Data) 6—14
3.07 Over Speed (Asynchronous Data) 6—15
3.08 Over Speed (Line Speed) 6—15
3.09 Over Speed (Compensation) 6—15
3.10 Under Speed (Line Speed) 6—15
3.11 Printer Requires Scheduled Maintenance 5—17, 6—16
3.12 Printhead Cover Off 3—50, 6—16
3.13 Cover Override Link Fitted 3—50, 6—16
3.14 Power Off Override Active 3—50, 6—17
3.15 Safety Override Active 3—50, 6—17
3.16 Gutter Override Active 3—51, 6—17
3.17 Gate Array Test Mode Active 6—18
3.18 Low Pressure 3—19, 3—34, 5—10, 6—18, A—13, B—11
3.19 Valid UNIC Chip Not Found 6—18
3.20 No Time Of Flight 6—18
3.21 Ink Low Prevented Mix 6—19, B—22

FA69398–1
Oct 2013 Index—18 Linx 7900 Maintenance Manual
 3.22 Fault Prevented Mix 6—19, B—22
3.23 Power Off Occurred During Mixing 6—19, B—22
3.24 Restart In Progress 6—19, B—22
3.25 Ink Unmixed For 4 Weeks 6—19, B—22
3.26 User Data Corrupt–Please contact your local ... 6—19
3.27 Mix Disabled 6—19, B—20, B—22
3.28 Printhead requires cleaning at shutdown 6—19
Food Grade printer A—23
3.29 Over Speed (No Remote Data) 6—20
3.30 Remote Error 6—20
3.31 Restarted Print Delay 6—20
3.35 Printer Requires Scheduled Maintenance Within One Month 6—21

T
technical data 2—1
Temp (printhead temperature) 5—15
temperature sensor, printhead 3—8
test message, creating 5—27
Test Message page 5—26
Create option 5—27
Save option 5—27
test points
IPM PCB 3—47
IPM PCB locations 3—54
Test Print option 5—8
test printing (safety) 1—6
time of flight (TOF) 3—8, 3—18
measurement 3—7
sensor 3—7
signal 3—18
“Time Of Flight Failure” 3—18, 6—9, 7—21
Food Grade printer A—23
timeout, Service level 4—4
TOF
Actual TOF 3—18
Reference TOF 3—18
TOF Mode option 5—14
TOF Mode page
Manual Phase option 5—14
TOF Only option 5—14
TOF/Phase option 5—14
TOF Only option 5—14
TOF/Phase option 5—14
Track New Events option 4—11
training course guides 8—1
Food Grade printer special features A—25
Level A
Module 01 – Introduction 8—13
Module 02 – Continuous ink jet printing 8—14
Module 03 – Getting started and printing 8—15
Module 06 – Stopping print and shutting ... 8—16
Module 07 – Looking after your printer 8—17
Module 09 – Line installation 8—18
Module 10 – Review 8—19
Level C
Module 01 – Introduction 8—3
Module 02 – Continuous ink jet printing 8—4
Module 03 – Getting started and printing 8—5
Module 04 – Navigating the 7900 8—6
Module 05 – Creating and editing messages 8—7
Module 06 – Stopping print and shutting ... 8—8
Module 07 – Looking after your printer 8—9
Module 08 – Routine maintenance 8—10
Module 09 – Line installation 8—11
Module 10 – Review 8—12
transferring data 3—68, 5—245

FA69398–1
Linx 7900 Maintenance Manual Index—19 Oct 2013
trigger device types 3—56, 3—58
troubleshooting 7—1
miscellaneous faults
Spectrum printer—no print 7—3
Spectrum printer—printing, but low ink opacity 7—3
Troubleshooting Start (Troubleshooting FC001) 7—6
Food Grade printer A—24

U
“Under Speed (Line Speed)” 6—15
UNIC 3—46, 3—55, 4—21, 6—18
UNIC Code option 4—21
Units option 4—23
upgrade combinations, external signals 3—68
USB facility 3—55, 3—68
Use Language Defaults option 4—23
“User Data Corrupt–Please contact your local ...” 6—19
user interface 3—4
user levels (security access levels) 4—26, 5—2

V
“Valid UNIC Chip Not Found” 6—18
valve cableform assembly 3—44
Spectrum printer B—17
Valve Reset option 5—26, B—22
valves 3—44
Spectrum printer B—6, B—17
Valves page 5—25, B—21
Feed valve option 5—26, B—21
Gutter valve option 5—26, B—21
Mix valve option B—21
Open/Close option 5—26, B—21
Printhead Feed valve option 5—26, B—21
Purge valve option 5—26, B—21
Solvent Add valve option 5—26, B—21
Solvent Flush valve option 5—26, B—21
Valve Reset option 5—26, B—22
venturi
general 3—23, 3—26, A—6, B—3
Mk3 high flow rate 3—27
Mk4 3—25, 3—27, B—5
venturi manifold
general 3—22, A—5, B—3
Mk1 (Spectrum printer) B—5, B—7
Mk4 (Food Grade printer) 3—25, A—9
Mk4 (standard printer) 3—30
Mk5 (standard printer) 3—25
“Viscosity” 3—19, 6—11, 7—29
viscosity control 3—19
Food Grade printer A—3
viscosity, ink 3—8, 3—18, 3—19
Viscosity Settle Time 3—19, 3—34, A—13, B—11

W
warm-up delay A—4, A—26
Warning LED 3—4
Warnings (safety) 1—1
width adjuster unit 3—61

X
XCAL125/XCAL255 option 5—21

Y
Y-piece connector 3—22, 3—23, 3—31, A—5, A—6, A—10

FA69398–1
Oct 2013 Index—20 Linx 7900 Maintenance Manual
 8 7 6 5 4 3 2 1
NOTES MK7 PRINT
1. OPTION BUSS INTERFACE SIGNALS THERMISTOR HEAD INK SYSTEM
NOTE 5
FEED
5V,12V,24V,-16V OPTION BOARD NEXT OBJECT P/CELL VALVE
D[0..7] OPTION BOARD AUXILIARY INPUT
A[28..31] I2CSCL, I2CSDA MODULATION
/A-OE-/GPL-B1, A-WE0-/BS-AB0, /A-RESET /DREQ1, /SDACK1
SMTXD2, AUX-SMRXD2 RASTER-TRIG
IRQ4-AUX0-1
OPTION BOARD SHAFT ENCODER

CHARGE

2. OPTION FUNCTIONS/BOARDS..CONNECTOR DETAILS

GUTTER
VALVE
OPTION CONNECTOR
PHOTO CELL/SHAFT ENCODER SPLITTER 9 WAY D FEMALE
RS232/RS485 1 x 9 WAY D FEMALE + 2 x 9 WAY D FEMALE STACKED
PARALLEL I/O 25 WAY D IP RATED STROBE LED

3. ONLY ONE TYPE OF ALARM MAY BE FITTED

4. HONEYWELL SS21PE PRINTHEAD

HEATER INK TANK

D D
TO UP
5. NTC 10K SIEMENS B57621C103J62 LEVEL SENSOR
VALVE

DPP PLATE
(PHASE/TOF)
7. POSITIVE AIR PUMP TYPE ASF THOMAS BLG 12/02-4

8. FAN TYPE

6800R PAPST 3414 24V 2.4 W GUTTER

6800S COMAIR ROTRON BD24B7 24V 11.5W SENSE
PURGE
VALVE
9. PLUG & SOCKET REVERSED IN 1 POSITION TO DIFFERENTIATE
COVER SENSOR
10. BELLING LEE/SCHAFFNER (HALL EFFECT)
NOTE 6

SOLVENT TANK
LEVEL SENSOR

PRINTHEAD PHFEED 120 MOTOR 070 PUMP FLUSH

FEED VALVE
VALVE
VALVE HITACHI TX14D11VM1CBA
1/4 VGA TFT LCD

320 X 240

SPARE VPOWERS SPAREIV

PHEAD
KEYBOARD/LEDS
/SPAREPH- NOTE 4 VALVE
VALVE LED
BACKLIGHT

SAFETY 24 WAY 8 WAY

EARTH + SUPPLY FLEXIBLE TAIL FLEXIBLE TAIL
40 WAY
FLEXIBLE
24 WAY 8 WAY 40 WAY CABLE
R/A BS STRIP R/A BS STRIP CONNECTOR

+ SIGNAL - SIGNAL
INK SPILL
DETECTOR
PRESSURE
2 WAY MOLEX 2 WAY MOLEX TRANSDUCER PL17 PL18 SK2 SK1
MINIFIT JNR MINIFIT JNR KEYPAD LED'S LED BACKLIGHT LCD
CONDUIT - SUPPLY
2/4 NOTE 12
METRES PL20 7 WAY
INVERTER CONNECTOR

C 40 WAY IDC
CONNECTOR
PL38
K/BOARD IPM

SCAN0-9
C
RETURN0-7
/LCD-ENB
12V, 3.3V, 0V, 0VI
SAFETY
EHT3000 PSU EARTH
MP15007 HIGHVOL EHT PL37
CONNECTOR 18 WAY MOLEX 24 WAY MOLEX 24 WAY MOLEX LCD IPM
0 - 10KV MINIFIT JNR MINIFIT JNR MINIFIT JNR 34 WAY IDC
3 x RADIALL MCX CONNECTOR LD0-8, SHIFT-CLK, LCD-A-C+
SERIES MINI BNC LD0-8, SHIFT-CLK, LCD-A-C-
/CTRL/ALT/SHIFT
/FAIL, WARNING, READY-LED

SK3 SK4 SK5 PL6 PL3 PL1 PL17 7900 DISPLAY PCB
PL7 PHASE CHARGE MOD PRINTHEAD PUMP INK SYSTEM K/BOARD IPM
24V 12 WAY
WAYMOLEX
MOLEX 12 WAY MOLEX EHT / AS13805
PROG MINIFIT JNR
MINIFIT JNR MINIFIT JNR 322V STROBE+ RTHERM 24V VPOWERS NO-INK SCAN0-9
/EHT-EN STROBE- GUTSENSE DRIVE /FEED- NO-SOLVENT RETURN0-7
/322V-EN /COVER 0VCHASSIS 0VP /GUTTER- /SPILL /LCD-ENB
322V 24V VPOWERS 5V /TOPUP- PRESST+ 12V, 3.3V, 0V, 0VI
/EHT-OVER PROG /PHFEED- -10VREF /PURGE- PRESST-
/EHT-EN /SPAREPH- /FLUSH- 5VREF
/322V-EN /SPAREIV- 0V
322V
/EHT-OVER
PL21
LCD IPM
2 WAY MOLEX
POSITIVE MINIFIT JNR PL9 LD0-8, SHIFT-CLK, LCD-A-C+
POS AIR LD0-8, SHIFT-CLK, LCD-A-C-
AIR PUMP 7900 IPM PCB /CTRL/ALT/SHIFT
NOTE 7 12V /FAIL, WARNING, READY-LED
0V AS13800
PL12
PHOTOCELL
SHAFT
PL5 ENCODER
SPLITTER
AUTO 10 WAY IDC
COOLING POWER CONNECTOR
FAN 2 WAY MOLEX OFF
NOTE 8 MINIFIT JNR 24VFD SE-INPUT
24V PRI-IN SEC-IN
POWEROFF- 0VF QSE-INPUT
P-BUSY SEC-IN-ISOL+ 14 WAY IDC
5VFD CONNECTOR
PL25 14 WAY RIBBON
DISPLAY CABLE ASSEMBLY

LOW VOLTAGE PSU RXD2+/-

COUTANT POP111 TXD2+/-
MP10674 0/5/12V

B SK6
ETHERNET

SK7
4 WAY USB B
CONNECTOR

4 WAY USB A
PL14
OPTION
B
ETHERNET CONNECTOR BUSS
50 WAY IDC 50 WAY IDC
PL8 CONNECTOR CONNECTOR
POWER SK8 8 WAY RJ45
5.1V 16 WAY MOLEX 16 WAY MOLEX ETHERNET CONNECTOR NOTE 1
12V MINIFIT JNR MINIFIT JNR 5.1V
L
-16V 12V PL30
N
24V -16V
E PL15 10 WAY IDC
PF 24V
SMC1 CONNECTOR PL27
PF
PL10 2 WAY MOLEX ALARM VFC
PL16 10 WAY IDC 24V ALARM MINIFIT JNR
SMC2 CONNECTOR COM
24V NC1
NO2
L N 14 WAY MOLEX PL19 10 WAY IDC RETURN
NO3
0V TO CHASSIS MINIFIT JNR PL20 SCC3 CONNECTOR
NC4
CONNECTON AUTO POWER OFF
NO4

LIVE-SWRELIN 7900 PIO PCB

NEUTRAL_SWRELIN
LIVE-SWRELOUT AS13834
NEUTRAL_SWRELOUT NOTE 2

MAINS SWITCH PL13 6 WAY MOLEX MULTI STAGE MULTI STAGE

MOMENTARY NO RS232/422 PL11 PL29 MINIFIT JNR
SK9 SK1 SK2 (FLASH VOLT 4 WAY MOLEX 4 WAY MOLEX ALARM 24V ALARM PCB PL1
ALARM PCB
ON 8/8 WAY V RJ45 ETHERNET PHOTOCELL/SHAFT
ENCODER
PHOTOCELL/SHAFT
ENCODER
PROG) FREE
ALARM
MINIFIT JNR MINIFIT JNR PL1 AS13718 COM AS13718
PL1 PL1 24V 24V NC1
TX+-S DCD3 CTS3 NO 24V ALARM1 ALARM1 NO2
TX--S 24VFD SE-INPUT 24VFD SE-INPUT /DSR3 /DTR3 NC RETURN ALARM2 ALARM2 NO3
PRI-IN SEC-IN PRI-IN SEC-IN /RXD3 /R13 NO COM ALARM3 ALARM3 NC4
RX+-S
0VF QSE-INPUT 0VF QSE-INPUT RTS3 RXD3+/- NC ALARM4 ALARM4 NO4
RX--S 4 WAY MOLEX
P-BUSY SEC-IN-ISOL+ P-BUSY SEC-IN-ISOL+ /TXD3 TXD3+/- COM
FUSED ALARM PCB FUSED ALARM PCB
MINIFIT JNR SK10
5VFD 5VFD AS13741 AS13741 PIO 6 WAY MOLEX
MINIFIT JNR
L N
NOTE 10
ROCKER IP RATED BARRIER
MAINS SWITCH
IP45 6800R PRINTER OPTIONAL ETHERNET 9 WAY IP67 RATED 9 WAY IP67 RATED 9 WAY IP67 RATED 3 WAY BULGIN 2 WAY BULGIN OPTIONAL REMOTE OPTIONAL PHOTOCELL/ 25 WAY IP67 RATED 6 WAY BULGIN 7 WAY BULGIN
ON/OFF IP65 6800S PRINTER CONNECTOR (RJ45)
8/8 WAY IP67 RATED
D FEMALE D FEMALE D MALE BUCCANEER
IP67 RATED
BUCCANEER
IP67 RATED
KEYBOARD/DISPLAY
CONNECTOR
SHAFT ENCODER
CONNECTOR
D FEMALE BUCCANEER
IP67 RATED
BUCCANEER
IP67 RATED
PLUG PLUG 15 WAY IP67 RATED 9 WAY IP67 RATED PLUG PLUG
D FEMALE D FEMALE

L N E SAFETY EARTHS ALARM OUTPUT

NOTE 3

IEC MAINS
FILTER / FUSE

A 2 x 4A (T) FUSES THIS DRAWING IS FOR

REFERENCE ONLY.
IT IS NOT AN ASSEMBLY
A
DRAWING

LINX PRINTING TECHNOLOGIES PLC

BURREL ROAD
ST. IVES
CAMBS PE27 3LA
K Barrett R:\01 NPD\Engineering\Projects\Project 7900\System\Sys Drawing\Iss 2
THIS DRAWING IS CONFIDENTIAL AND MUST NOT BE COPIED
IN WHOLE OR PART WITHOUT THE PRIOR WRITTEN CONSENT Title
DRN K Barrett DATE 03/09/13 OF LINX PRINTING TECHNOLOGIES PLC. 7900 ELECTRICAL SYSTEM DIAGRAM
IT MUST ONLY BE USED FOR THE PURPOSES FOR WHICH IT
CHK K Barrett DATE 03/09/13 HAS BEEN SPECIFICALLY SUPPLIED. Size Document Number Rev
IT IS TO BE KEPT SECURELY AND MUST NOT BE DISCLOSED A1 CD13806 2
APPD DATE TO ANY THIRD PARTY.
Date: Tuesday, September 03, 2013 Sheet 1 of 1

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