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• Page 1
  430 Ink Jet Printer Service Manual THE WORLD’S CODING AND LABELLING COMPANY…

• Page 2: Table Of Contents

  Contents ONTENTS PREFACE…………………………..VII Introduction…………………………… vii Conventions …………………………. vii Positional References……………………….. vii Units of Measurement ………………………. vii Typography…………………………vii Applicable Standards ……………………….vii Installation and Inspection……………………..viii Mains Power Supply……………………….viii Grounding …………………………viii Restrictions…………………………..ix Acknowledgements ……………………….. ix Associated Publications ……………………….ix Contact Information ………………………..

• Page 3
  430 Ink Jet Printer Service and Maintenance Manual I/O Board LED Check ……………………….27 Voltage Checks…………………………28 Reset Run Hours …………………………. 28 Gutter Fault and Charge Error Disable………………….29 Set EHT Range (preliminary settings for printhead and EHT table setup)…………29 Set EHT Trip Level (for printhead setup only) ………………..
• Page 4
  Contents Ink System…………………………..80 General …………………………..80 Solenoid Valves…………………………81 V1 Solvent Top-up Valve (located at the solvent top-up reservoir) …………81 V2 Ink Top-up Valve (located at the ink reservoir)………………81 V3 VMS Diverter Valve (located on the FMS ink system) …………….81 V6 Feed Valve (located on the FMS ink system)………………81 V7 Flush Valve (located on the FMS ink system) ………………81 V8 Gutter Valve (located on the FMS ink system)………………82 V11 Jet Valve (located in the printhead)…………………82…
• Page 5
  430 Ink Jet Printer Service and Maintenance Manual I/O Board …………………………… 110 Removal …………………………. 110 Installation …………………………111 Calibration …………………………111 CPU Board…………………………. 112 Removal …………………………. 112 Installation …………………………112 Power Supply Unit ……………………….113 Removal …………………………. 113 Installation …………………………113 PSU Module Fuse Replacement……………………
• Page 6
  Base Moulding and Cabinet ……………………..177 Mains Plate Assembly ……………………….179 Ink System…………………………..181 APPENDIX B …………………………..1 Earlier 430 Model …………………………1 Ink System…………………………..1 General …………………………..1 Flush Tank…………………………..2 Removal…………………………..2 Installation……………………………2 Earlier 430 Illustrated Parts List ………………………3 Ink System …………………………..3 Issue 2 Part No. 306-0430-102…
• Page 7
  430 Ink Jet Printer Service and Maintenance Manual Issue 2 Part No. 306-0430-102…

• Page 8: Preface

  The names of menu options are presented in bold typeface. Cross-references are presented on bold, italic typeface. Applicable Standards Willett Limited is a BS5750/ISO9000 approved company (certification number FM14003 dated 9 December 1991). The 400 Series Continuous Ink Jet (CIJ) printers conform to the following legislation: EN55022: 1987 — Emissions.

• Page 9: Installation And Inspection

  430 Ink Jet Printer Service and Maintenance Manual Installation and Inspection The equipment described in this handbook must be installed and subsequently inspected at the recommended intervals by qualified service and maintenance personnel. Mains Power Supply Ensure that the mains electrical supply is within the range indicated by the label adjacent to the mains inlet on the printer.

• Page 10: Restrictions

  Copyright © Willett Limited 2001. Printed in the UK. March 2001. Acknowledgements The Willett name and Willett logo are trademarks of Willett Limited. Associated Publications Willett 430 Ink Jet Printer Instructions for Use Part Number 306-0430-101.

• Page 11: Labelling

  430 Ink Jet Printer Service and Maintenance Manual Labelling The following labels appear on the 430 Ink Jet printer: W A R N I N G SERIAL No. DESIGNED AND MANUFACTURED BY WILLETT SYSTEMS LTD. CORBY ENGLAND TEL: 01536 400777…

• Page 12: Hazard Information

  Preface Hazard Information This section contains important hazard notices. You must read these notices before using the printer. The hazard information is prioritised into typographically distinct warning and caution notices as follows: WARNING NOTICES Warning notices denote a potential hazard to the health and safety of users. These notices clearly state the nature of the respective hazard and the means by which it can be avoided.

• Page 13
  430 Ink Jet Printer Service and Maintenance Manual WARNING — RISK OF PERSONAL INJURY To avoid spillage of ink or top-up, do not remove the foil seal from the bottle prior to replenishing the ink or top-up reservoir. WARNING — FIRE AND HEALTH HAZARD The ink, solvent and top-up are volatile and flammable.

• Page 14: Caution Notices

  Caution — Degraded Performance Machine functions that only Willett trained personnel can access are set at Password Level 3 (MASTER password), these functions must not be given as customer options.

• Page 15
  430 Ink Jet Printer Service and Maintenance Manual Caution — Electrostatic Sensitive Devices The printed circuit boards contain static sensitive devices. A suitably grounded, antistatic wrist strap must be worn when working on or handling printed circuit boards. Caution — False Readings To avoid the risk of false readings, the pump zero offset should only be calibrated when there is no ink in the system and the pump is off.
• Page 16
  Preface Caution — Equipment Damage To avoid the risk of overfilling or spillage, never replenish ink or top-up unless the relevant low icon is shown. Ensure that ink bottle is completely empty before removing. Caution — Equipment Damage Do not fit or remove any connector on the printer whilst power is on, otherwise the printer may be damaged.
• Page 17
  430 Ink Jet Printer Service and Maintenance Manual Issue 2 Part No. 306-0430-102…

• Page 18: Installation

  Caution — Equipment Damage Only Willett trained personnel may carry out installation and maintenance work. Any such work undertaken by unauthorised personnel may damage the printer and will invalidate the warranty. Issue 2…

• Page 19: Unpacking

  430 Ink Jet Printer Service and Maintenance Manual Unpacking (1) Left-hand Insert (2) Right-hand Insert (3) Carton (4) Umbilical (5) Printhead » Figure 1 Unpacking the Printer Open the top flaps of the carton and gently pull the complete machine and inserts (1 and 2) upwards from the carton.

• Page 20: Commissioning

  Installation: Commissioning Commissioning Access Tighten the two top cover fasteners (1) until they release the top cover catches (the top cover (2) will raise slightly). Unscrew both top cover fasteners, leaving them captive. Raise the top cover until the spring loaded locating pins on the extender legs slot into their respective locating holes.

• Page 21: Preparation For Use

  430 Ink Jet Printer Service and Maintenance Manual Preparation for Use (1) Filler Plug (2) Ink Mixer Bowl (3) Filler Tubes Figure 3 Ink Mixer Bowl Filler Plug Location Remove and retain the black rubber shipping cap from the breather tube.

• Page 22
  Installation: Commissioning (1) On/Off switch (2) Supply fuse holder PRINT TRIGGER 1 SHAFT ENCODER COMM 1 (3) Mains inlet socket Mains Voltage Fuse Rating 110 V AC 230 V AC 3.15 A Figure 4 Connector Panel and Fuse Ratings Connect the mains electrical supply to the mains inlet socket (3) and set the On/Off switch (1) to I (On). The printer PSU will automatically detect and adjust to the mains voltage.
• Page 23
  430 Ink Jet Printer Service and Maintenance Manual 12 Push in the locating pins on each of the extender legs and lower the top cover (Figure 2 (2)) into position. It will be necessary to exert a small amount of pressure to locate the cover properly.
• Page 24
  Installation: Commissioning 28 From the Configure menu, select Photocell Levels and set the state of the photocell 1 level to Active high or Active Low as required. 29 The printer should now be printing continuously. Let the printer complete a minimum of 250 000 prints. Use the counter to monitor the number of messages printed.
• Page 25
  430 Ink Jet Printer Service and Maintenance Manual To remove trapped air, proceed as follows: Remove the front and rear covers from the printhead. Slacken the jet valve (V11) screws. Place tissue paper around the printhead and jet valve to absorb solvent when the priming procedure commences.

• Page 26: Passwords

  Set the Passwords for Levels 1 and 2. Caution — Degraded Performance Machine functions that only Willett trained personnel can access are set at Password Level 3 (MASTER password), these functions must not be given as customer options.

• Page 27: Production Line Setup

  430 Ink Jet Printer Service and Maintenance Manual Production Line Setup Typical Installation A typical installation is shown in Figure 6, where the printer (7) is mounted on a printer stand (6). The printhead (4) is configured to print vertically via a clamp (2) and bracket (3) assembly. A lamp stack (1) is fitted to the printer stand.

• Page 28: Throw Distance

  Installation: Throw Distance Throw Distance The optimum throw distance from the printhead to the product is 8 mm. Shaft Encoder Internal Source If no external shaft encoder is to be fitted then set the Shaft Encoder Source to Internal, via the Configure menu.

• Page 29
  430 Ink Jet Printer Service and Maintenance Manual (1) Input/Output board (2) Sensor 2/Quadrature shaft encoder jumper JB2 (3) Print trigger 1 and 2 jumper JB1 Figure 7 Input/Output Board Product Sensor and Shaft Encoder Jumper Location Issue 2 Part No. 306-0430-102…

• Page 30: Product Sensors

  Installation: Product Sensors Product Sensors Figure 6 shows a photocell (8) connected via a cable (5) to PRINT TRIGGER 1 on the connector panel. The printer can be configured to use two product sensors (PRINT TRIGGER 1 and PRINT TRIGGER 2). Note: The PRINT TRIGGER 2 option requires the use of non-standard system software.

• Page 31
  430 Ink Jet Printer Service and Maintenance Manual Issue 2 Part No. 306-0430-102…

• Page 32: Consumables

  Consumables: Ink and Solvent Storage ONSUMABLES The table below lists the available ink, top-up, washdown and FIN numbers for the 430 Series. Top-Up Washdown Fluid Identification No. MK 3901D BLACK 201-0001-601 201-0001-401 201-0001-702 110/110/47/32/35 MK 3903F RED 201-0001-603 201-0001-402 201-0001-705…

• Page 33
  430 Ink Jet Printer Service and Maintenance Manual WARNING — FIRE AND HEALTH HAZARD The ink, solvent and top-up are volatile and flammable. They must be stored and handled in accordance with local regulations. Do not smoke or use a naked flame in the vicinity of these substances.

• Page 34: Firmware Download

  It is possible to download new versions of the same software but it is not possible to install different language firmware or firmware from a different machine variant. A security feature of the 430 prevents the download of any firmware other than an up-grade of the firmware, which was originally supplied.

• Page 35: Windows 95/98 Procedure

  Before attempting to download new software check the communications link between the PC and the printer. Using a pre-configured connection cable, connect Com1 of the PC to COMM1 of the 430 Printer. On the PC run the HyperTerminal program. The Connection Description window opens requesting a title and an icon for the new connection.

• Page 36
  If required, this set up can be saved for future use by selecting Save As from the File menu and saving the communications set up as, for example, 430.trm. Ensure that port COMM1 on the printer is set to corresponding baud rate, data bits, stop bits and parity settings.

• Page 37: Using Microsoft Windows 3.Xx To Download Firmware

  430 Ink Jet Printer Service and Maintenance Manual 13 To confirm that the communications link is effective press enter on the PC. The prompt MON> should appear a second time, e.g.: MON> MON> 14 Press X and then enter on the PC to return the printer to normal control.

• Page 38: Using Microsoft Windows 95 Or 98 To Download Firmware

  Firmware Download: Windows 95/98 Procedure 13 To select the new operating software file from the Send Text File Window, proceed as follows: From the Drives: menu, select a:. From the List Files of Type menu, select All files [*.*]. enter Select the relevant file e.g.

• Page 39
  430 Ink Jet Printer Service and Maintenance Manual 15 After approximately 20 minutes the Terminal Window displays MON>. 16 At the terminal MON> prompt, type: SET#4000#3ffff#0 and press 17 At the terminal MON> prompt, type: SET#1000#37ff#0 and press 18 At the terminal MON> prompt, type: SET#200#400#0 and press…

• Page 40: Boot Monitor Recovery Procedure

  Firmware Download: Windows 95/98 Procedure Boot Monitor Recovery Procedure If a data communications error occurs whilst downloading a new software Flash File or the system memory becomes corrupted, the system may “lock-up”. If this situation occurs, use the following recovery procedure: Switch off the 400 Series unit.

• Page 41
  430 Ink Jet Printer Service and Maintenance Manual Run the PC in Windows Terminal Mode and establish communication. At the PC type ER. Switch off the printer and remove the test lead from the CPU. 10 Switch on the printer and download new software using the download procedure.

• Page 42: System Calibration And Test

  System Calibration and Test: Introduction YSTEM ALIBRATION AND Introduction The system calibration and test procedures described below should be performed as necessary to commission the machine after repairs have been carried out. All or part of the procedure may be required, as indicated in the failure diagnosis and repair instructions at the beginning of this section.

• Page 43: Machine Power-Up

  430 Ink Jet Printer Service and Maintenance Manual Machine Power-Up Ensure that the correct fuses are fitted for the local mains supply voltage. The correct values are listed below: 110 V supply — 5 A fuse. 240 V supply — 3.15 A fuse.

• Page 44: I/O Board Led Check

  System Calibration and Test: I/O Board LED Check I/O Board LED Check Remove the cabinet side covers. Check that LEDs 1, 3, 4 and 5 on the I/O board are illuminated and that LED2 is dimly illuminated. The LEDs represent the following voltage rails: LED1 (green) +12 V customer’s isolated supply for shaft encoder/photocell.

• Page 45: Voltage Checks

  430 Ink Jet Printer Service and Maintenance Manual Voltage Checks Check the voltages on the POWER connector, situated at the bottom right-hand corner of the I/O board. Use Pin 2 as the 0 V reference. 0 is a representation of the POWER connector with the voltages shown for each pin.

• Page 46: Gutter Fault And Charge Error Disable

  System Calibration and Test: Gutter Fault and Charge Error Disable Gutter Fault and Charge Error Disable From the System menu select Charge Error Shutdown. enter Press Select Charge error and toggle to Disable. Select Gutter fault and toggle to Disable. enter Press to disable both functions.

• Page 47: Filling The Ink System

  Note: A list of part numbers (for ink and top up) and FINs appears in Table 2, 430 Range of Inks, page 15. If the Ink Level Low icon is displayed, pour the remaining ink into the ink reservoir with the black filler cap (4-slot spider).

• Page 48: Fluid Identification Number (Fin)

  Note: Refer to Table 2, 430 Range of Inks on page 15 for a list of ink, Top-up and FIN part numbers. If the FIN number does not correspond with the ink and top-up being used with the machine, press…

• Page 49: Calibrate 285 V Rail

  430 Ink Jet Printer Service and Maintenance Manual Calibrate 285 V Rail To calibrate the 285 V supply, proceed as follows: Remove the electrical connectors to the Feed Valve (V6) on the FMS and the Top-up Addition Valve (V1) on the top-up reservoir.

• Page 50: Nozzle Flush

  System Calibration and Test: Nozzle Flush Nozzle Flush Slacken the knurled screw on top of the printhead and remove the front cover. Support the printhead in a suitable stand and place a container underneath to catch any surplus solvent. From the System menu select Nozzle Flush. Press  enter The nozzle orifice should be irrigated with washdown to clear…

• Page 51: Head Heater Temperature And Ink Pressure

  430 Ink Jet Printer Service and Maintenance Manual Head Heater Temperature and Ink Pressure From the Calibrate menu select Diagnostics screen. enter Press Check that Ink pressure and Head temperature are set to the correct values. Notes: The correct values are part of the FIN and should have been set automatically when the FIN was entered in the Fluid Identification Number (FIN), page 31.

• Page 52: Modulation Calibration (Manual)

  System Calibration and Test: Modulation Calibration (Manual) Modulation Calibration (Manual) Caution — Print Quality To ensure high print quality, ink viscosity must be checked and must be correct prior to attempting modulation calibration. Disable the Rolling Phase: From the System menu select Rolling Phase Disable. Press enter enter…

• Page 53
  430 Ink Jet Printer Service and Maintenance Manual NOZZLE CHARGE CHARGE ELECTRODE ELECTRODE LIGAMENT LIGAMENT SATELLITE SATELLITE VERY LOW GOOD HIGH VERY HIGH Figure 16 Inkjet Break-off Point enter 12 When a good break-off point is achieved, press . Enable the Rolling Phase:…

• Page 54: Phase Profile Adjustment

  System Calibration and Test: Phase Profile Adjustment Phase Profile Adjustment Ensure that the phase detector is approximately 1 mm from the ink jet. If not, align the printhead as described in Printhead Alignment , page 161. From the Calibrate menu select Diagnostics screen. enter Press Check that the Phase profile is 8 ±1.

• Page 55: Setting Eht Tables For Printing

  430 Ink Jet Printer Service and Maintenance Manual enter Set a value of 150. Do not press Take print samples, decreasing the charge value in steps of 10 until the print quality becomes poor. It may be necessary to clean the gutter when poor print quality is produced.

• Page 56: Set Eht Trip Level (Normal Operation)

  System Calibration and Test: Set EHT Trip Level (Normal Operation) Set EHT Trip Level (Normal Operation) Ensure the printhead is clean and dry. Fit the printhead cover. From the Calibrate menu select EHT Trip Level Set. enter Press . The display shows Setting EHT trip level. After approximately one minute the display changes to EHT Trip Test successful.

• Page 57: Restore Calibration Parameters

  430 Ink Jet Printer Service and Maintenance Manual Restore Calibration Parameters To restore the previously calibrated parameters: From the Configure menu select Restore System Settings. enter Press to restore the settings. Enable Gutter Detect and Charge Check From the System menu select Charge Error Shutdown.

• Page 58: Ink Viscosity Measurement

  System Calibration and Test: Ink Viscosity Measurement Ink Viscosity Measurement Note: Before testing viscosity, ensure that the printer is at normal operating temperature. Set up the syringe viscometer over a beaker that contains a thermometer. Using the large syringe supplied, draw out at least 60 ml of ink from the mixer reservoir. Cover the viscometer syringe nozzle, using a gloved finger, and fill until the ink is level with the top of the syringe.

• Page 59: Cij Mk 3903F Red

  430 Ink Jet Printer Service and Maintenance Manual CIJ MK 3903F Red CIJ MK 3930F Black Temperature (deg C) Issue 2 Part No. 306-0430-102…

• Page 60: Cij Ea 3969H Black

  System Calibration and Test: Ink Viscosity Measurement CIJ EA 3969H Black Temperature (deg C) Issue 2 Part No. 306-0430-102…

• Page 61
  430 Ink Jet Printer Service and Maintenance Manual Issue 2 Part No. 306-0430-102…

• Page 62: Technical Description

  Technical Description: Ink Viscosity Measurement ECHNICAL ESCRIPTION This section describes the main components and interconnections. It includes the following tables, which detail connector pin outs: Table 3 CON CPU CON_K Keypad Connector Table 4 CPU CON_232 RS232 Serial Interface Table 5 CPU CON_B I/O Board Interface Table 6 CPU CON_S RID Synchronous Port Table 7 CPU CON_P Power Input Connector Table 8 CPU CON_D Charge Data To I/O…

• Page 63: Main Assemblies

  430 Ink Jet Printer Service and Maintenance Manual Table 36 PSU Board General Specification Table 37 PSU Board Output Specifications Main Assemblies The printer comprises four main assemblies: • Cabinet. • Printhead. • Electronics system. • Ink system. Cabinet (1) Reservoir filler cover…

• Page 64: Side Covers

  Technical Description: Cabinet Side Covers The two side covers (9) are similar, they have different length fasteners fixed to them, thus they require the correct orientation when fitting. The side covers should be fitted with the long fasteners at the opposite side from the printhead umbilical cable.

• Page 65: Printhead

  430 Ink Jet Printer Service and Maintenance Manual Printhead (1) Ground potential deflector electrode (7) Rear cover (13) LED (2) Phase detector (8) Head manifold (14) High voltage deflector electrode (3) Charge electrode (9) Umbilical (15) Gutter (4) Nozzle assembly…

• Page 66: Construction

  Technical Description: Printhead Construction The printhead consists of a chassis on which are mounted the following components: • The nozzle assembly (4) which forms the ink into a stream of droplets as described below: The jet valve (17) delivers ink from the ink system to the nozzle assembly. The bleed valve (18) mounted on the heater module block is normally closed, only opening during purging, flushing of the nozzle and start up and shutdown.

• Page 67
  430 Ink Jet Printer Service and Maintenance Manual Figure 19 Printhead Electrics and Ink System Wiring Diagram Issue 2 Part No. 306-0430-102…

• Page 68: Electronics System

  Technical Description: Electronics System Electronics System The printer electronics system comprises the following: • Control panel. • Connector panel. • Control electronics. • Electronics modules. Control Panel (1) Liquid Crystal Display (LCD) (2) Keypad (3) Function Keys (4) Arrow keys enter (5) Status LEDs «…

• Page 69
  430 Ink Jet Printer Service and Maintenance Manual • Basic printer control is provided by four function keys (3) to the left of the LCD screen: Start or stop the ink jet. Select a message for printing. Access the menu screen.

• Page 70: Connector Panel

  Technical Description: Electronics System Connector Panel PRINT TRIGGER 1 SHAFT ENCODER COMM 1 STATUS O/P (1) On/Off switch (5) Shaft encoder connector (2) Fuse holders (6) COMM1 Connector (3) Mains inlet connector (7) Status O/P connector (option) (4) Print trigger 1 connector Figure 21 Connector Panel The connector panel is a stainless steel pre-drilled plate fitted to the printer base and secured by four screws.

• Page 71
  430 Ink Jet Printer Service and Maintenance Manual Print Trigger 1 Connector The printer provides a 12V 200 mA DC total output for use by a photoelectric Cell (Pec), inductive proximity detector or micro switch. The pin allocation of the print trigger 1 connector (Figure 21 (4)) is as follows:…

• Page 72: Control Electronics

  Technical Description: Control Electronics Control Electronics General (1) PSU module (2) CPU board I/O board Ink pump motor driver board Figure 22 Control Electronics The control electronics in 400 series printers is based on a common Central Processing Unit (CPU) board (2), and an INPUT/OUTPUT (I/O) board (3).

• Page 73: Cpu Board

  430 Ink Jet Printer Service and Maintenance Manual CPU Board The CPU Board circuit diagram is included Appendix A in this manual. (1) CPU board (2) IC U31 (3) IC U40 and U41 (4) IC U38 and U39 (5) IC U19…

• Page 74: Major Components

  • Integrated Circuit (IC) U31 (2) produces keyboard drive signals to determine which key has been pressed. • IC U40 and IC U41 (3) are flash memory devices and are programmed by Willett to hold the following information: application software.

• Page 75
  430 Ink Jet Printer Service and Maintenance Manual Connectors The CPU board connectors shown in Figure 24. Pinout details are given in the tables below. CON_K CON_S (7) CON_L CON_232 (5) CON_P (Interboard connector) (8) Link W3 CON_B (Interboard connector)
• Page 76
  Technical Description: Control Electronics CON_K (Figure 24(1)) is connected to the keypad. Pin No. Signal Function Pin No. Signal Function EMC earth connection Scan line 1 ALT key Scan line 2 Control key Scan line 3 Shift key Scan line 4 Scan line 7 Scan line 5 Return line 0…
• Page 77
  430 Ink Jet Printer Service and Maintenance Manual CON_S (4) is a high speed synchronous port. Pin No. Signal Function Pin No. Signal Function Asynchronous transmit SDATA Synchronous data output Asynchronous receive input SDEN0 Synchronous enable 0 Asynchronous data common…
• Page 78
  Technical Description: Control Electronics CON_LAN (9) is a serial communications port (COM2). The logic level signals at this connector are converted by the optional expansion card for use with a modem, 20 mA current loop or RS485 interface. Pin No. Signal Function Pin No.

• Page 79: I/O Board

  430 Ink Jet Printer Service and Maintenance Manual I/O Board The I/O board Figure 22 (3) is mounted over the CPU board and interfaces the printer to the following: • the ink system; • product sensors; • external devices. The I/O board is connected to the CPU board via interboard connectors CON_B1, CON_D and CON_P0. The I/O Board Circuit Diagram is included Appendix A in this manual.

• Page 80
  Technical Description: Control Electronics • IC U20 (2) is a Quadruple Digital to Analogue Converter (QDAC) which converts digital inputs into analogue 0 to +5 volt signals to control functions on the I/O board. • The ink pump motor drive board (3) acts as an interface between the I/O board and the ink system pump motor, it is connected to the I/O board via connectors CON_BM1 and CON_BM2.
• Page 81
  430 Ink Jet Printer Service and Maintenance Manual Connectors » » & » & (1) PEC1 (6) LEVELS (11) CON_BM2 (16) HEAD_1 (21) FAN_FAIL (2) PEC2 (7) CON_B1 (12) PUMP (17) CON_P0 (22) CON_D (3) SENC (8) CON_EX (13) P/TRANS…
• Page 82
  Technical Description: Control Electronics PEC1 (1) — Product sensor 1 via the connector panel Pin No. Signal Function Positive DC supply to sensor EXT PEC 1/2 Input from sensor Common Table 11 I/O Connector PEC1 PEC2 (2) — Product sensor 2 via the connector panel. Pin No.
• Page 83
  430 Ink Jet Printer Service and Maintenance Manual T/LIGHT (5) — Status traffic lights via the connector panel. Pin No. Signal Function Pin No. Signal Function +24 V +24 V DC to all lights Negative supply for green lamp GREEN…
• Page 84
  Technical Description: Control Electronics CON_B1 (7) — Interboard connector to I/O board to the CPU board. Pin No. Signal Function Pin No. Signal Function opto I/O Not used A/D converter output enable pec1 Photocell 1 output 13 to 20 cb0 to Control bus bits 0 to 7 phase Phase detector…
• Page 85
  430 Ink Jet Printer Service and Maintenance Manual PIGS (9) — Will be used in future models for an ink heater/cooler system. Pin No. Signal Function Pin No. Signal Function +24 V BULK HEAT HEATER Heater/cooler on/off +24 V Table 19 I/O Connector PIGS VALVES (10) — Ink system solenoid valves.
• Page 86
  Technical Description: Control Electronics PUMP (12) — Ink system pump. Pin No. Signal Function Pin No. Signal Function B OUT Stator drive B Position signal from Hall effect sensor C A OUT Stator drive A Hall effect sensor -ve supply C OUT Stator drive C Position signal from Hall effect…
• Page 87
  430 Ink Jet Printer Service and Maintenance Manual CON_BM1 (15) — Ink pump motor driver board. Pin No. Signal Function Pin No. Signal Function +24 V Supplies to motor control board ENABLE Enable ink pump motor PRESS TRANS Pressure transducer input…
• Page 88
  Technical Description: Control Electronics POWER (18) — PSU. Pin No. Signal Function Pin No. Signal Function 15 V 15 V DC from PSU +5 V +5 V DC from PSU 0 V from PSU +24 V +24 V DC from PSU +5 V +5 V DC from PSU 0 V from PSU…
• Page 89
  430 Ink Jet Printer Service and Maintenance Manual CON_D (22) — Interboard connector from I/O board to CPU board. Pin No. Signal Function Pin No. Signal Function 1 to 8 dd0 to dd7 Droplet charge data Common Not used 11-20…
• Page 90
  Technical Description: Control Electronics (1) TP9 (2) TP7 » (3) TP6 (4) TP8 (5) LED4 (6) LED3 (7) TP4 (8) TP2 (9) LED2 (10) LED5 (11) LED1 (12) TP3 (13) TP5 (14) TP1 & » Figure 27 I/O Board Test Points and LEDs Issue 2 Part No.

• Page 91: Ink Pump Motor Driver Board

  430 Ink Jet Printer Service and Maintenance Manual Ink Pump Motor Driver Board Figure 28 Ink Pump Motor Driver Board The Ink Pump Motor Driver Board circuit diagram is included Appendix A in this manual. The Ink Pump Motor Driver Board is a separate plug-in PCB, which is based on the Motorola MC33033 controller.

• Page 92
  EMF generated by the gutter valve, and the feed valve, respectively. The 430 motor control PCB contains additional ‘hit and hold’ circuits to control the ‘Feed’ and ‘Bleed’ pico valves mounted within the printhead. These valves require 24 V for about 50 ms for them to open, after which the drive voltage must reduce to 12 V to hold them open without excessive dissipation.
• Page 93
  430 Ink Jet Printer Service and Maintenance Manual 24V SUPPLY TP34 GF1B TO VALVE 100n 280R 360k CONTROL GF1B BSP17 Figure 29 Pico Valve Control Circuit The valve is connected between TO VALVE line and the 24 V SUPPLY line.

• Page 94: Psu Board

  Technical Description: PSU Board PSU Board General Specification The PSU (Figure 22 (1)) is a switch mode power supply with the following general specification: Input voltage 88 VAC to 260 VAC. Input frequency 47 Hz to 63 Hz. Inrush current (cold) 15 A at 115 VAC, 30 A at 230 VAC.

• Page 95: Electronics Modules

  430 Ink Jet Printer Service and Maintenance Manual Electronics Modules (1) Ink system pump (2) Fan failure card (3) Electronics compartment cooling fan (4) EHT module Figure 30 Printer Electronics Modules EHT Module The EHT module (4) generates the extra high tension voltage required by the high voltage deflector electrode.

• Page 96: Mains Input Circuit

  Technical Description: Electronics Modules Mains Input Circuit The AC mains supply (Figure 31) is supplied, via three core cable to the mains connector on the connector panel. At the mains connector the live and neutral lines are fed to the On/Off switch via a filter, the earth line is connected directly to an earth lug on the PSU.

• Page 97: Ink System

  430 Ink Jet Printer Service and Maintenance Manual Ink System General The ink system provides a continuous supply of ink to the printhead at the correct pressure and at the correct temperature/viscosity combination. The ink system is housed in the printer cabinet and the components are interconnected by PTFE tubing.

• Page 98: Solenoid Valves

  Technical Description: Ink System Solenoid Valves The flow of ink in the ink system is controlled by eight solenoid operated spool valves. Except for valves V11 and V12, the valves (see Figure 33) are all of the same design. The valves are single-acting, operated by an electrical actuator (solenoid) with spring return.

• Page 99: V8 Gutter Valve (Located On The Fms Ink System)

  430 Ink Jet Printer Service and Maintenance Manual V8 Gutter Valve (located on the FMS ink system) The gutter valve (4) directs the vacuum generated by the Venturi jet pump. When V8 is energised, vacuum is applied to the printhead gutter, which returns unused ink (non-printed drops) to the FMS mixer tank for recirculation.

• Page 100: Pre Pump Filter (Located Inside The Filter Compartment)

  Technical Description: Ink System Owing to the type of filter media used in the main system filter, which provides a large surface area to catch particulates, it also offers a long service life. The filter has two filtration ratings, which are selected dependant upon the type of ink used for the printing application.

• Page 101: Fluid Management System (Fms)

  The VMS chamber has two ink level detectors, ‘High’ and ‘Low’. These detectors can be of the optical or metal rod conductivity type. The detector type is dependent upon the type of machine. The 430 machine uses the optical type detector.

• Page 102: Venturi (Jet Pump) (Located Inside The Fms Top Box)

  Technical Description: Ink System At the bottom of the VMS chamber is a restrictor orifice (R2), which provides a controlled flow of ink out of the chamber. For operation ( see V3 VMS Diverter Valve (located on the FMS ink system) , page 81). Venturi (Jet Pump) (located inside the FMS top box) The Venturi jet pump provides a partial vacuum (typically –…

• Page 103: Printhead Operation

  430 Ink Jet Printer Service and Maintenance Manual Printhead Operation Ink Jet Information An electrically conductive ink is supplied under pressure by the ink system to the nozzle assembly (Figure 35 (2)) via the ink feed pipe (3). An ink stream is formed as the ink is forced out of the nozzle jet orifice (1). A modulation signal is applied to a ceramic transducer which is clamped to the nozzle assembly.

• Page 104: Droplet Deflection

  Technical Description: Printhead Operation The ink stream and the charge electrode can be considered as the two electrodes of a capacitor. By raising the charge electrode to a specific positive voltage (with a charge pulse) the section of the ink system within the charge electrode will have a negative charge induced on it.

• Page 105: Ink System Operation

  430 Ink Jet Printer Service and Maintenance Manual Ink System Operation Function The functions of the ink system are as follows: • Deliver ink to the nozzle at a constant pressure and temperature. • Ensure sufficient ink and solvent are available.

• Page 106: Viscosity Monitoring System Sequence

  Technical Description: Ink System Operation Viscosity Monitoring System Sequence The viscosity of the ink is checked by the Viscosity Monitoring System (VMS) whenever the jet is running and pressing to STOP JET. This procedure is as follows: Solenoid valve V3 opens directing ink into the VMS chamber, which is an integral part of the FMS (Figure 38).

• Page 107
  430 Ink Jet Printer Service and Maintenance Manual The ink flows out of the chamber through a large restrictor into the mixer tank until the low level sensor is uncovered. The CPU in the electronics system measures the time that this takes. V3 energises and the chamber starts to fill again (Figure 40).

• Page 108: Clean Start Jet Sequence

  Technical Description: Ink System Operation Clean Start Jet Sequence When the clean start jet sequence is initiated the following automatically takes place: Ink system pressure is set to 4 bar. Wait for 15 seconds to ensure flush pump is full ( Figure 41 ). Gutter valve V8 opens.

• Page 109
  430 Ink Jet Printer Service and Maintenance Manual GUTTER Figure 42 Clean Start Jet Sequence – Pressurise Flush Pump and Eject Solvent out of Nozzle NOZZLE FILTER PRE HEAD FILTER GUTTER Figure 43 Clean Start Jet Sequence – Change from Solvent to Ink Issue 2 Part No.

• Page 110: Quick Start Jet Sequence

  Technical Description: Ink System Operation NOZZLE FILTER PRE HEAD FILTER GUTTER Figure 44 Clean Start Jet Sequence – Jet Running with Ink Quick Start Jet Sequence When the clean start jet sequence is initiated the following automatically takes place: Ink system pressure set to 4 bar. Gutter valve V8 opens Wait 3 seconds — ink pressure valve V6 opens.

• Page 111: Clean Stop Jet Sequence

  430 Ink Jet Printer Service and Maintenance Manual Clean Stop Jet Sequence When the clean stop jet sequence is initiated the following automatically takes place: EHT switched off. Ink system pressure increased to 4 bar ( Figure 45 ). Wait 5 seconds — modulation and phasing switched off.

• Page 112
  Technical Description: Ink System Operation NOZZLE FILTER PRE HEAD FILTER GUTTER Figure 46 Clean Stop Jet Sequence – Stop Ink Supply and Continue with Pure Flush NOZZLE FILTER PRE HEAD FILTER GUTTER Figure 47 Clean Stop Jet Sequence – Stop Ink Supply and Re-fill Flush Pump Issue 2 Part No.

• Page 113: Quick Stop Jet Sequence

  430 Ink Jet Printer Service and Maintenance Manual Quick Stop Jet Sequence When the quick stop jet sequence is initiated the following automatically takes place: Switch off EHT and set ink pressure to 3.5 bar. Bleed valve V12 opens and jet valve V11 closes.

• Page 114: Ink Addition To Mixer Tank

  Technical Description: Ink System Operation Ink Addition to Mixer Tank When the level of fluid in the mixer tank falls below the level OK sensor, the ink top up valve V2 is energised. Ink from the reservoir flows round the system into the mixer tank until the level OK sensor is covered. V2 is then de-energised (Figure 49).

• Page 115: Top Up Addition To Mixer Tank

  430 Ink Jet Printer Service and Maintenance Manual Top Up Addition to Mixer Tank The time taken for the VMS chamber to empty is checked by the software against a reference value. The reference value is derived from a ‘time to empty algorithm’ stored in the CPU memory. It takes into account the type of ink in the machine (entered by the operator during calibration) and the ink temperature as measured by the sensor in the mixer tank.

• Page 116: System Software

  System Software: Introduction YSTEM OFTWARE Introduction This section describes the menus available in the printer control software. The function of each menu option is briefly described below. Using the Menus Using the Arrow Keys To select a menu: Press until the menu is highlighted. enter Press To select an item from a menu:…

• Page 117: Messages Menu

  Displays the Memory Space screen, showing Show Free Message Space message space free, work space free and the largest block of message RAM. Quit Returns to the quick screen. * This function is disabled on the 430 printer. Issue 2 Part No. 306-0430-102…

• Page 118: Editor Menu

  System Software: Editor Menu Editor Menu Editor Menu Menu Option Function Select Font Opens the Select Font menu. The selected font is applied to the selected text in the message. Insert User Field Opens the Select user field menu. The contents of the user field is copied into the message at print time e.g.

• Page 119: Print Menu

  430 Ink Jet Printer Service and Maintenance Manual Print Menu Print Menu Menu Option Function Print Enable Opens the Print Control menu. The PRINT option can be toggled between Enable and Disable. Manual Print Printing is normally triggered from an external device, i.e.

• Page 120: System Menu

  System Software: System Menu System Menu System Menu Menu Option Function Status Displays the fault list, containing the possible faults with current faults highlighted Clean Start Jet The ink jet is started and Starting the jet is displayed. A flush and bleed sequence is performed to eliminate ink splashing and spray before ink is fed to the nozzle.

• Page 121
  430 Ink Jet Printer Service and Maintenance Manual Debug Monitor Monitors the electronic system to detect possible hardware or software faults. This facility should only be used by experienced Willett- trained engineers. Set Jet Start Allows setting of the timing and sequence of the valves in the Sequence ink system for the jet start process.

• Page 122: Configure Menu

  System Software: Configure Menu Configure Menu Configure Menu Menu Option Function Set Time/Date Allows the Real Time Clock (RTC) in the printer to be set to the local time and date. Opens the Set time/date menu. The parameters that can be set are: Day, Month, Year, Day number, Hour, Minutes, Seconds.

• Page 123: Calibrate Menu

  430 Ink Jet Printer Service and Maintenance Manual Full System Reset Opens the System Restart dialogue. This gives three options: Initialise, where the printer is restored to the factory system settings Reset – keep messages, where the backed up system settings are restored and any stored messages are kept.

• Page 124
  System Software: Calibrate Menu Modulation Set Level The modulation voltage can be set manually to achieve optimum jet breakup. Opens the Machine Control dialogue. The Modulation set value can be adjusted between 1 and Auto Modulate This option automatically sets the modulation voltage to achieve optimum jet breakup.

• Page 125: Data Logging Menu

  430 Ink Jet Printer Service and Maintenance Manual Data Logging Menu Data Logging Menu Menu Option Function Software Part No. Displays the software version installed. Compilation Displays the date the software was compiled and the name Date/Author of the author.

• Page 126: Disassembly And Assembly

  Disassembly and Assembly: Introduction ISASSEMBLY AND SSEMBLY Introduction This section contains complete instructions for the removal and installation of the components and sub-assemblies listed below: Component Page Component Page I/O Board Flush Pump CPU Board Solenoid Valves Power Supply Unit PSU Fuses Fan Failure Card LCD/Backlight Assembly…

• Page 127: I/O Board

  430 Ink Jet Printer Service and Maintenance Manual I/O Board » (1) 18 mm stand offs (4) Securing nuts and washers (2) CPU (5) 10 mm stand offs (3) I/O board (6) Ink pump motor driver board Figure 51 I/O Board and CPU Board — Removal and Installation Removal Remove the ink pump motor driver board (Figure 51 (6)) from the I/O board.

• Page 128: Installation

  Installation Note: The 430 uses an issue 3 I/O board identified by a blue PCB as opposed to a green PCB. This board may be used on older 450/460/470 machines. Boards previous to issue 2, however, must not be used on the 430.

• Page 129: Cpu Board

  Installation Note: If the flash Eproms on the new CPU board have not been pre-loaded with the 430 Boot Monitor Program, transfer the flash Eproms from the old CPU board to the new CPU board Set the links on the new CPU board as noted above.

• Page 130: Power Supply Unit

  Disassembly and Assembly: Power Supply Unit Power Supply Unit (1) Baffle plate (2) PSU module securing screws and washers Figure 53 Power Supply Unit Removal Disconnect the DC power cable from the POWER connector on the I/O board. Remove and retain the screws and washers (Figure 53 (2)) that secure the PSU module to the baffle plate (1).

• Page 131: Psu Module Fuse Replacement

  430 Ink Jet Printer Service and Maintenance Manual PSU Module Fuse Replacement To replace PSU module internal fuse, proceed as follows: Remove the PSU module as described above. Remove and retain the cover retaining screws at the base of the PSU and lift off the cover.

• Page 132: Lcd And Backlight

  Disassembly and Assembly: LCD and Backlight LCD and Backlight (1) Keypad (2) LCD panel assembly (3) Keypad plate (4) Securing nuts and washers (5) Securing screw (6) Backlight inverter (7) Top moulding (8) Seal (9) Earth strap » & Figure 54 Top Moulding, Keypad and LCD Panel Removal To remove the LCD and backlight panel assembly, proceed as follows: Disconnect all cables, earth strap and the vent tube from the printer top moulding, noting their position and…

• Page 133: Installation

  430 Ink Jet Printer Service and Maintenance Manual Remove the top moulding from the printer (see Top Cover , page 46). Place the top moulding (Figure 54 (7)) face down on a clean level surface. Protect the keypad membrane (1) from damage and contamination.

• Page 134: Ink And Top Up Reservoir Sensor

  Disassembly and Assembly: Ink and Top Up Reservoir Sensor Ink and Top Up Reservoir Sensor Removal Cut the four wires (sensor and LED connections). Unscrew the sensor from the threaded receptacle on top of the reservoir and list it out. Installation Screw the level detector into the receptacle in the tank.

• Page 135
  430 Ink Jet Printer Service and Maintenance Manual Place the new sensor and LED in the sensor holder (4). Thread the new sensor and LED leads through the spacer tube. Reinsert the O-ring, lens, sensor holder and spacer into the level detect retainer.

• Page 136: Mains Inlet Connector

  Disassembly and Assembly: Mains Inlet Connector Mains Inlet Connector (1) Mains inlet connector (2) Mains switch Figure 56 Mains Inlet Connector and Mains Switch – Location (1) Connector panel (2) Mains switch (3) Switch cover (4) Mains inlet connector (5) Securing screw (6) Nut and washer Figure 57 Mains Inlet Connector and Mains Switch — Removal and Installation Removal…

• Page 137: Installation

  430 Ink Jet Printer Service and Maintenance Manual Installation Refit the cables, removed at Removal step 2, to the terminals on the rear of the inlet connector (Figure 57 (4)). Fit the inlet connector to the connector panel (1) and secure it with the screws (5), nuts and washers (6) removed at Removal step 1.

• Page 138: Fluid Management System (Fms)

  Disassembly and Assembly: Fluid Management System (FMS) Fluid Management System (FMS) WARNING — HANDLING INK, SOLVENT AND TOP-UP The ink, solvent and top-up are irritating to the eyes and respiratory system. To prevent personal injury when handling these substances: Always wear protective clothing and rubber gloves. Always wear goggles with side-shields or a face mask.

• Page 139: Installation

  430 Ink Jet Printer Service and Maintenance Manual Unplug the in-line temperature sensor connector. The temperature sensor is located next to the level sensors in the base of the mixer tank. Remove and retain the two screws securing the printhead manifold (situated underneath the valves). Pull the manifold clear of the ink system (take care to retain the manifold O-rings).

• Page 140: Ink System Pump

  Disassembly and Assembly: Ink System Pump Ink System Pump (1) T connector (4) Pump feed pipe (2) Baffle plate fixing screw (5) Ink system pump (3) PUMP connector Figure 59 Ink System Pump Removal Removal Disconnect the top of the pump feed pipe (4) from the T connector (1) located closest to Valve V1 (Top up valve).

• Page 141: Installation

  430 Ink Jet Printer Service and Maintenance Manual Withdraw the pump and its sealing gasket. Discard the gasket. Installation Ensure that the pump is the correct type for the machine. Place the pump in position, with a new sealing gasket fitted between the pump and the bulkhead. Ensure that the pump orientation is correct.

• Page 142: Main Filter

  Disassembly and Assembly: Main Filter Main Filter (1) Hinged flap (2) Main filter (3) Feed tube (4) Return tube (5) Label Figure 60 Main Filter Removal Open the hinged flap (1) at the front of the printer to gain access to the filter compartment. Lift out the filter (2) so that the feed (3) and return (4) ink tubes are accessible.

• Page 143: Flush Pump

  430 Ink Jet Printer Service and Maintenance Manual Flush Pump (1) Flush Pump (2) Cross-head screws (2 OFF) (3) Plastic fixing nut (3 OFF) Figure 61 Flush Pump Removal Removal The flush pump (1) is secured by two cross-head screws (2) accessed from underneath the plate. Remove and retain the two screws.

• Page 144: Solenoid Valves

  Disassembly and Assembly: Solenoid Valves Solenoid Valves (1) Electrical connector (2) Circlip (3) Barb (4) Tube (5) Plug (6) Solenoid windings » (7) Valve block (8) Retaining screws & (9) Dual O-ring seal assembly (10) Captive retaining screw & Figure 62 Solenoid Valve Components Removal Remove the electrical connector (Figure 62 (1)) from the body of the valve after slackening the captive retaining screw (10).

• Page 145: Fan

  430 Ink Jet Printer Service and Maintenance Manual Caution — Equipment Damage Take care to ensure that the fan fail sensor is not damaged when removing or installing the filter housing. Removal Disconnect the FAN/EHT plug from the I/O board.

• Page 146: Fan Failure Card

  Disassembly and Assembly: Fan Failure Card Fan Failure Card Removal The fan failure card is located in the electronics compartment, with two temperature sensors protruding into the filter compartment, just below the fan filter. Disconnect the FAN FAIL connector from its location at bottom centre of the I/O board. Remove and retain the nylon screw securing the fan failure card.

• Page 147: Eht Module

  430 Ink Jet Printer Service and Maintenance Manual EHT Module (1) Baffle plate securing screw (3) EHT module (2) Baffle plate assembly (4) EHT connector Figure 64 EHT Module Removal Removal Remove the two screws Figure 64 (1) securing the baffle plate to the base moulding. Move the baffle plate assembly (2) so that it is clear of the EHT module.

• Page 148: Head Manifold

  Disassembly and Assembly: Head Manifold Head Manifold The head manifold incorporates the gutter detect module and the head heater. (1) Knurled screw (4) Electrical connections (7) Feed Valve (2) Rear cover securing screws (5) Rear cover (8) Return valve (3) Ink barb (6) Front cover Figure 65 Head Manifold Removal…

• Page 149: Installation

  430 Ink Jet Printer Service and Maintenance Manual Installation Place the head heater in position on the printhead, with the electrical connections to the rear. Slide a new length of heat shrink on to one side of each of the electrical connections. Resolder the connections (as noted in Removal step 4) and slide the heatshrink over each soldered joint.

• Page 150: Phase Detector

  Disassembly and Assembly: Phase Detector Phase Detector (1) Printhead front cover (6) Rear cover (2) Top deflector plate (7) Phase detector cable (3) Phase detector (8) Phase detector clamping screw (4) Knurled screw (9) Cable clamp screw (x2) (5) Rear cover securing screw Figure 66 Phase Detector Removal and Installation Removal Slacken the knurled screw Figure 66 (4) and slide the front cover off the printhead.

• Page 151: Installation

  430 Ink Jet Printer Service and Maintenance Manual Remove the heatshrink from the connections between the phase detector and the cable loom. Make a note of how the wires are connected and desolder the connections. Slacken the phase detector clamping screw (8) and slide out the detector. If necessary, move the top deflector plate (2) to gain access to the clamping screw.

• Page 152: Eht Block

  Disassembly and Assembly: EHT Block EHT Block (1) Printhead front cover (7) Charge electrode clamping screw (2) 0 V deflector plate fixing screw (8) Phase detector clamping screw (3) Knurled screw (9) EHT block (4) Rear cover securing screw (10) Rear cable clamp (5) Printhead rear cover (11) Front cable clamp (6) Charge electrode cable…

• Page 153: Installation

  430 Ink Jet Printer Service and Maintenance Manual Remove the two cable clamps (10 and 11). Loosen the phase detector clamping screw (8). Slide the phase detector out of the EHT block, through the bottom of the printhead. Loosen the charge electrode clamping screw (7) and pull the charge electrode cable (6) from the EHT block.

• Page 154: Nozzle Assembly

  Disassembly and Assembly: Nozzle Assembly Nozzle Assembly (1) Nozzle assembly (5) Heater manifold (2) Knurled screw (6) Cable/nozzle clamp screw (3) Rear cover securing screw (7) Nozzle adjusting screw (4) Rear cover Figure 68 Printhead Nozzle Removal and Replacement Removal Slacken the knurled screw Figure 68 (2) and slide the front cover off the printhead.

• Page 155: Installation

  430 Ink Jet Printer Service and Maintenance Manual Installation Slide the nozzle assembly into position and secure it using the cable/nozzle clamp screw (6) and the nozzle adjusting screw (7). Tighten the lateral clamping screws (5). Reconnect the ink feed and return tubes to the heater manifold (5).

• Page 156: Rs232 Jumper

  Disassembly and Assembly: RS232 Jumper RS232 Jumper As the printer is not fitted with an external COMM1 port, the RS232 jumper assembly (Part No. 100-0370-158) must be used to make a temporary connection to the CPU when downloading firmware to the printer. Installation Ensure that the printer is disconnected from the mains supply.

• Page 157
  430 Ink Jet Printer Service and Maintenance Manual (1) CPU board (2) CON_232 Figure 69 CON_232 Location Issue 2 Part No. 306-0430-102…

• Page 158: Umbilical

  Disassembly and Assembly: Umbilical Umbilical The umbilical gland is attached to the printer by four retaining screws. (1) Umbilical gland Figure 70 Umbilical Gland Notes for Figure 71 Umbilical Connection Details Fit earth wire supplied with umbilical assembly. Loop the earth wire through the ferrite ring (item 52) six times.

• Page 159
  430 Ink Jet Printer Service and Maintenance Manual Figure 71 Umbilical Connection Details Issue 2 Part No. 306-0430-102…

• Page 160: Preventative Maintenance Schedule

  Preventative Maintenance Schedule: Umbilical REVENTATIVE AINTENANCE CHEDULE The following preventative maintenance schedule must be carried out by a suitably trained maintenance technician. Actual intervals depend on machine running hours. The figures below are based on eight hours usage per day. If the actual usage is higher, the intervals should be reduced.

• Page 161
  430 Ink Jet Printer Service and Maintenance Manual Issue 2 Part No. 306-0430-102…

• Page 162: Troubleshooting

  Troubleshooting: Introduction ROUBLESHOOTING WARNING — LETHAL VOLTAGES Lethal voltages are present within this equipment when it is connected to the mains electrical supply. Only trained and authorised personnel may carry out maintenance work. Observe all statutory electrical safety codes and practices. Unless it is necessary to run the printer, disconnect the printer from the mains electrical supply before removing the covers or attempting any service or repair activity, otherwise death or personal injury may result.

• Page 163: Fault Finding

  430 Ink Jet Printer Service and Maintenance Manual Fault Finding Printer Fails to Initialise Possible Cause Remedial Action No mains supply Check that mains supply is available and switched on. Mains input cable disconnected or Check that mains input cable is connected.

• Page 164
  Troubleshooting: Fault Finding (1) LED 4 (red); -15 V (4) LED 5 (green); +24 V valve/ pump/heater supply (2) LED 3 (yellow); -24 V (5) LED 1 (green); +12 V isolated supply (3) LED 2 (red); 285 V (bright) charge amplifier supply (+15 V (dim);…
• Page 165
  430 Ink Jet Printer Service and Maintenance Manual TP1 — (9) TP2 — (7) TP3 — (8) TP4 — (6) TP5 — (1) TP6 — (5) TP7 — (3) TP8 — (4) TP9 — (2) Figure 73 I/O Board Mk 2 TP Location Issue 2 Part No.

• Page 166: Display Faults

  Troubleshooting: Display Faults Display Faults Backlight WARNING – LETHAL VOLTAGES A high AC voltage is present at the inverter and backlight. Extreme caution is required when diagnosing failure in these areas. Note: Some DVMs may not show the 1000 V AC correctly. Use an oscilloscope fitted with a high voltage probe to measure the voltage.

• Page 167: Display

  430 Ink Jet Printer Service and Maintenance Manual Display Possible Cause Remedial Action LCD contrast not set correctly. Press ctrl + L. When the LCD is readable, press any key to set contrast. Ribbon cable between CPU board and LCD is faulty.

• Page 168: Display Icons

  Troubleshooting: Display Icons Display Icons Icon Name Possible Cause Remedial Action Ink Level Ink top up or solvent top up Top up the empty reservoir with ink or reservoir empty. The part number solvent as necessary (see Filling the Ink System , page 30).

• Page 169
  430 Ink Jet Printer Service and Maintenance Manual VMS level sensor or cable faulty. Check that cable is connected. Replace FMS if sensor faulty (see Fluid Management System (FMS) , page 121), I/O board (see I/O Board , page 110) or CPU board (see CPU Board , page 112).
• Page 170
  Troubleshooting: Display Icons Icon Name Possible Cause Remedial Action Cabinet Environment too hot for printer. Measure ambient temperature. If it is greater Too Hot than 45°C, move the printer to a cooler position or reduce ambient temperature by improving ventilation etc. Printer air inlet or outlet blocked.
• Page 171
  430 Ink Jet Printer Service and Maintenance Manual Charge Dirty printhead Clean printhead (see Umbilical Purge , page 160). Error Viscosity incorrect Refer to the viscosity error icon in this table for possible causes and remedial action. Modulation incorrect Adjust as required (see Modulation Calibration (Manual) ).

• Page 172: Mixer Tank Level High

  Troubleshooting: Display Icons Mixer Tank Level High To determine why the Mixer Tank Level High icon is displayed, proceed as follows: Remove the filler plug (Figure 74 (1)) from the FMS (2). Use a syringe and plastic tube, remove 100 ml of ink from the FMS to uncover the level high sensor. If the icon is no longer displayed, the level high sensor is working If the icon remains on the display, the level high sensor circuit is faulty.

• Page 173
  430 Ink Jet Printer Service and Maintenance Manual Fault Possible Cause Remedial Action Check ink viscosity (see Ink Viscosity Measurement , Mixer Tank Level VMS incorrectly calibrated High-Sensor page 41). If incorrect, drain the mixer tank and refill with new ink (see Fill Mixer Tank , page 31). Recalibrate the Covered VMS (see VMS Calibration , page 32).

• Page 174: Cleaning And Adjustment

  Figure 75 Valve Components Disassemble the internal valve components (Figure 76) noting the orientation of each. Clean all the components in a suitable Willett solvent washdown. Reassemble the internal valve components. Fit the valve plate to the valve block and secure it using the two screws removed at step 2.

• Page 175: Vms Inlet Restrictor Cleaning

  430 Ink Jet Printer Service and Maintenance Manual VMS Inlet Restrictor Cleaning Remove valve V3 from the FMS valve plate (see Fluid Management System (FMS) , page 121). Pull the VMS restrictor block (Figure 77 (3)) away from the valve body (2). Retain the two O-rings from the VMS restrictor block and the two O-rings from the valve body.

• Page 176: Vms Outlet Cleaning

  Cleaning and Adjustment: VMS Outlet Cleaning VMS Outlet Cleaning Remove all screws from the top of the FMS; retain all screws, washers and seals. Remove the top of the FMS. Remove the four retaining screws (Figure 78 (1)) from the top of the VMS chamber (3) remove the lid (2) and sealing gasket located under the lid.

• Page 177: Umbilical Purge

  430 Ink Jet Printer Service and Maintenance Manual Umbilical Purge Carry out an umbilical purge: • to prevent debris from blocking the nozzle if the printer hasn’t been used for a long time; • if contamination of the umbilical is suspected;…

• Page 178: Printhead Alignment

  Cleaning and Adjustment: Printhead Alignment Disconnect the feed and return pipes and reconnect them to the nozzle feed and return pipes. 10 Slide the rear cover back into position on the printhead and secure it using the two screws (4) removed at step 3.

• Page 179
  430 Ink Jet Printer Service and Maintenance Manual (1) Ground potential deflector electrode (2) Securing screw (3) Height adjustment screw (4) Lateral adjustment screw (5) Deflector block adjustment screw (6) Charge electrode clamping screw (7) Phase detector clamping screw Figure 81 Printhead Adjustment Screw Location When ink jet position is correct in the gutter, check the ink jet is flowing through the centre of the charge electrode slot parallel to the sides of the slot (Figure 82).
• Page 180
  Cleaning and Adjustment: Printhead Alignment To centralise the ink jet flow through the charge electrode: Release the deflector block adjustment screw (Figure 81 (5)). Move the block until the jet is in the correct position. Secure the adjustment screw and recheck jet position.
• Page 181
  430 Ink Jet Printer Service and Maintenance Manual Issue 2 Part No. 306-0430-102…

• Page 182: Illustrated Parts List

  How to Use This Parts List The illustrations and the associated tables give ordering information for the available spare parts for the 430 Printer. Where a component is not illustrated the letters ‘NI’ appears against the entry for the item.

• Page 183: 430 Ink Jet Printer

  430 Ink Jet Printer Service and Maintenance Manual 430 Ink Jet Printer Figure 83 430 Ink Jet Printer Part number Description Part number Description 200-0430-101 English keypad 200-0430-108 Czech/Hungarian keypad 200-0430-102 European keypad 200-0430-109 Polish/Latvian/Lithuanian keypad 200-0430-103 Scandinavian/Turkish keypad 200-0430-110…

• Page 184: Stand And Traffic Light System

  Illustrated Parts List: Stand and Traffic Light System Stand and Traffic Light System Figure 84 Stand and Traffic Light System Fig ref. Part number Description Remarks 200-0390-117 460 si Beacon assembly 100-0370-147 Traffic light cable assembly Required for use with Serial 1 (Optional light cable) 200-0390-114 Stand…

• Page 185: Options And Accessories

  430 Ink Jet Printer Service and Maintenance Manual Options and Accessories Not illustrated. Part number Description 200-0042-005 Photocell assembly 3.5m 200-0042-006 Photocell assembly 6.5m 500-0071-112 24 V 5W spare bulbs 527-0001-126 2500 PPR shaft encoder 527-0001-127 5000 PPR shaft encoder…

• Page 186: General Spare Parts And Tools

  200-0390-152 Nozzle adjusting tool Table 49 General Spare Parts and Tools Documentation Not illustrated. Part number Description 306-0430-101 430 Ink Jet Printer Instructions for Use 306-0430-102 430 ink Jet Printer Service Manual Table 50 Documentation Issue 2 Part No. 306-0430-102…

• Page 187: Major Sub-Assemblies

  430 Ink Jet Printer Service and Maintenance Manual Major Sub-Assemblies Figure 85 Major Sub-Assemblies Fig ref. Description Remarks Top moulding ink system components See Figure 86 Top moulding, keypad and LCD See Figure 87 Baffle plate assembly See Figure 88…

• Page 188: Top Moulding Ink System Components

  Illustrated Parts List: Top Moulding Ink System Components Top Moulding Ink System Components Figure 86 Top Moulding Ink System Components Fig ref. Part number Description 500-0031-232 O-ring 100-0470-215 Ink cap 500-0041-101 Bulkhead fitting 200-0390-248 Top mould assy. 100-0470-218 Filler housing, top-up 100-0470-219 Top-up cap 100-0470-254…

• Page 189: Top Moulding, Keypad And Lcd

  430 Ink Jet Printer Service and Maintenance Manual Top Moulding, Keypad and LCD Figure 87 Top Moulding, Keypad and LCD Issue 2 Part No. 306-0430-102…

• Page 190
  Illustrated Parts List: Top Moulding, Keypad and LCD Fig ref. Part number Description Remarks Keypad overlays 100-0470-138 UK/USA 100-0470-167 European 100-0470-168 Turkish/Scandinavian 100-0047-169 Greek 100-0470-170 Japanese 100-0470-171 Russian/Ukranian 100-0470-172 Bulgarian 100-0470-173 Czech/Slovakian/Hungarian 100-0470-174 Polish/Latvian/Lithuanian 100-0470-175 Korean 100-0470-176 Arabic/Farsi 100-0470-177 Hebrew 100-0470-178 Chinese 100-0470-137…

• Page 191: Baffle Plate Assembly

  430 Ink Jet Printer Service and Maintenance Manual Baffle Plate Assembly Figure 88 Baffle Plate Assembly Fig ref. Part number Description Remarks 200-0390-102 PSU — 80 watt with cover 200-0390-111 CPU board 500-0053-363 Unprogramed Flash memory AM29F040-70JC 200-0430-160 I/O board…

• Page 192: Printhead Assembly

  Illustrated Parts List: Printhead Assembly Printhead Assembly Figure 89 Printhead Assembly Issue 2 Part No. 306-0430-102…

• Page 193
  430 Ink Jet Printer Service and Maintenance Manual Fig ref. Part number Description Remarks Fig 83 Printhead assembly 100-0370-196 Front cover 100-0370-231 Lid switch thumbscrew 200-3900-135 Charge electrode/LED assy. 200-0430-141 Nozzle assembly 200-0390-235 Cover switch assy. 200-0430-262 Head heater assy.

• Page 194: Base Moulding And Cabinet

  Illustrated Parts List: Base Moulding and Cabinet Base Moulding and Cabinet 17,18,19 Figure 90 Base Moulding and Cabinet Issue 2 Part No. 306-0430-102…

• Page 195
  430 Ink Jet Printer Service and Maintenance Manual Fig ref. Part number Description Remarks 500-0048-117 ¼ turn fastener 500-0049-101 ¼ turn retainer 500-0048-119 ¼ turn receptacle 100-0370-127 Outer cover 400-0009-145 Rating label 400-0009-132 CE label 400-0009-295 Outlet label 500-0067-116 High voltage warning label 500-0048-118 ¼…

• Page 196: Mains Plate Assembly

  Illustrated Parts List: Mains Plate Assembly Mains Plate Assembly Figure 91 Mains Plate Assembly Issue 2 Part No. 306-0430-102…

• Page 197
  430 Ink Jet Printer Service and Maintenance Manual Fig ref. Part number Description 100-0370-141 RS485/product sensor cable assembly 100-0370-143 Shaft encoder cable assembly 100-0370-142 RS232 cable assembly (optional) 500-0076-133 Blanking plug 500-0082-145 Mains switch 500-0082-120 Mains switch cover 500-0066-134 Fuse holder 500-0066-139 3.15 A HRC A/S fuses…

• Page 198: Ink System

  Illustrated Parts List: Ink System Ink System NOTE ORIENTATION 15,17 12,13 Figure 92 Ink System Issue 2 Part No. 306-0430-102…

• Page 199
  430 Ink Jet Printer Service and Maintenance Manual Fig ref. Part number Description Qty Remarks 527-0001-125 Pressure transducer 500-0031-164 Pressure transducer front O-ring 521-0001-168 Feed valve (hex) 200-0430-144 FMS single head ink system 200-0390-115 Level detect assembly Contains; detector retainer, O-ring,…
• Page 200
  $SSHQGL[ $ &38 %RDUG 33(1′,; &38 %RDUG ,VVXH  3DUW 1R …
• Page 201
  $SSHQGL[ $ ,2 %RDUG ,2 %RDUG 0V CHARGE H E A D _ 1 V C C R 1 8 +300 Volts LID SWITCHES 2 K 7 1 0 0 R R 1 0 6 R 3 8 + 1 5 V U 3 2 B R 7 7 + 1 5 V…
• Page 202
  $SSHQGL[ $ 3XPS 0RWRU &RQWURO %RDUG 3XPS 0RWRU &RQWURO %RDUG ,VVXH  3DUW 1R …

• Page 203: Earlier 430 Model

  PPENDIX Earlier 430 Model This appendix is to be used as reference to the earlier version of the 430 si printer. The earlier version of the 430 si printer incorporated a flush reservoir/tank, which has been removed and superseded by a pre pump filter.

• Page 204: Flush Tank

  (6) Flush pump fixing screws (7) Retaining nuts (8) Hose connectors Figure 94 Earlier 430 Flush Tank and Flush Pump Removal Open the hinged cover at the front of the printer. Remove the circlips from the fixing pin (2) (one above the plate, one below).

• Page 205: Earlier 430 Illustrated Parts List

  Appendix B: Earlier 430 Illustrated Parts List Earlier 430 Illustrated Parts List Ink System NOTE ORIENTATION 14,16 13,14 Figure 95 Earlier 430 Ink System Issue 2 Part No. 306-0430-102…

• Page 206
  430 Ink Jet Printer Service and Maintenance Manual Fig ref. Part number Description Qty Remarks 527-0001-125 Pressure transducer 500-0031-164 Pressure transducer front O-ring 521-0001-168 Ink valve (hex) 200-0430-244 FMS single head ink system 200-0390-115 Level detect assembly Contains; detector retainer, O-ring,…

• Page 207: Service Manual

  Willett Limited Cronin Road Corby Northamptonshire NN18 8AQ England Phone +(44) 1536 400777 Fax +(44) 1536 400888 http://www.willett.com 430 Ink Jet Printer Service Manual 306-0430-102 Issue 2 Copyright © Willett Limited 2001. Printed in the UK March 2001.

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430 Ink Jet Printer

Service Manual

THE WORLD’S CODING AND LABELLING COMPANY