WILLETT 430 User manual

430 Ink Jet Printer

Service Manual

THE WORLD'S CODING AND LABELLING COMPANY

Contents

Issue 2 i

Part No. 306-0430-102

CONTENTS

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 ............................................................................................................................................. ix

Labelling ...............................................................................................................................................................x

Hazard Information.............................................................................................................................................. xi

Warning Notices .............................................................................................................................................. xi

Caution Notices ............................................................................................................................................. xiii

INSTALLATION.......................................................................................................................................................1

Introduction...........................................................................................................................................................1

Unpacking ............................................................................................................................................................2

Commissioning.....................................................................................................................................................3

Access ..............................................................................................................................................................3

Preparation for Use ..........................................................................................................................................4

Passwords ........................................................................................................................................................9

Setting up Shifts ...................................................................................................................................................9

Production Line Setup........................................................................................................................................10

Typical Installation ..........................................................................................................................................10

Throw Distance ..................................................................................................................................................11

Shaft Encoder.....................................................................................................................................................11

Internal Source ...............................................................................................................................................11

External Source ..............................................................................................................................................11

Product Sensors.................................................................................................................................................13

CONSUMABLES...................................................................................................................................................15

Ink and Solvent Storage.....................................................................................................................................15

FIRMWARE DOWNLOAD ....................................................................................................................................17

Introduction.........................................................................................................................................................17

Requirements .....................................................................................................................................................17

Windows 3.xx Procedure ...................................................................................................................................17

Checking the Communications Link ...............................................................................................................17

Windows 95/98 Procedure .................................................................................................................................18

Checking the Communications Link ...............................................................................................................18

Using Microsoft Windows 3.xx to Download Firmware ..................................................................................20

Using Microsoft Windows 95 or 98 to Download Firmware............................................................................21

Boot Monitor Recovery Procedure .................................................................................................................23

SYSTEM CALIBRATION AND TEST ...................................................................................................................25

Introduction.........................................................................................................................................................25

Earth Continuity Test..........................................................................................................................................25

Machine Power-Up.............................................................................................................................................26

Pump Zero Offset Calibration.............................................................................................................................26

Cooling Fan Check.............................................................................................................................................26

430 Ink Jet Printer Service and Maintenance Manual

ii Issue 2

Part No. 306-0430-102

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) ................................................................................................... 29

Filling the Ink System......................................................................................................................................... 30

Fluid Identification Number (FIN)....................................................................................................................... 31

Fill Mixer Tank ................................................................................................................................................... 31

Calibrate 285 V Rail........................................................................................................................................... 32

VMS Calibration................................................................................................................................................. 32

Nozzle Flush ...................................................................................................................................................... 33

Strobe LED Check ............................................................................................................................................. 33

Ink Jet Alignment ............................................................................................................................................... 33

Head Heater Temperature and Ink Pressure .................................................................................................... 34

Modulation Calibration (Manual)........................................................................................................................ 35

Phase Profile Adjustment .................................................................................................................................. 37

Phase Offset Calibration.................................................................................................................................... 37

Print Charge Value Calibration .......................................................................................................................... 37

Setting EHT Tables for Printing ......................................................................................................................... 38

Clean Shutdown Check ..................................................................................................................................... 38

Set EHT Trip Level (Normal Operation) ............................................................................................................ 39

EHT Trip Test .................................................................................................................................................... 39

Print Height Test ................................................................................................................................................ 39

Restore Calibration Parameters ........................................................................................................................ 40

Enable Gutter Detect and Charge Check .......................................................................................................... 40

Ink Viscosity Measurement................................................................................................................................ 41

Temperature/Viscosity Graphs ...................................................................................................................... 41

CIJ MK 390ID Black....................................................................................................................................... 41

CIJ MK 3903F Red ........................................................................................................................................ 42

CIJ MK 3930F Black ...................................................................................................................................... 42

CIJ EA 3969H Black ...................................................................................................................................... 43

TECHNICAL DESCRIPTION................................................................................................................................ 45

Main Assemblies................................................................................................................................................ 46

Cabinet .............................................................................................................................................................. 46

Top Cover ...................................................................................................................................................... 46

Side Covers.................................................................................................................................................... 47

Base ............................................................................................................................................................... 47

Printhead ........................................................................................................................................................... 48

Construction ................................................................................................................................................... 49

Electronics System ............................................................................................................................................ 51

Control Panel ................................................................................................................................................. 51

Connector Panel ............................................................................................................................................ 53

Control Electronics............................................................................................................................................. 55

General .......................................................................................................................................................... 55

CPU Board ..................................................................................................................................................... 56

I/O Board........................................................................................................................................................ 62

Ink Pump Motor Driver Board ........................................................................................................................ 74

PSU Board......................................................................................................................................................... 77

General Specification..................................................................................................................................... 77

Output Specification....................................................................................................................................... 77

Electronics Modules........................................................................................................................................... 78

EHT Module ................................................................................................................................................... 78

Electronics Compartment Cooling Fan .......................................................................................................... 78

Ink System Pump........................................................................................................................................... 78

Mains Input Circuit ......................................................................................................................................... 79

Contents

Issue 2 iii

Part No. 306-0430-102

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

V12 Bleed Valve (located in the printhead) ................................................................................................82

Top Up and Ink Reservoirs.............................................................................................................................82

Ink System Filters ...........................................................................................................................................82

Main System Filter (located inside the filter compartment).........................................................................82

Pre Pump Filter (located inside the filter compartment) .............................................................................83

Pre Head Filter (located below the FMS printhead connection manifold) ..................................................83

Nozzle Filter (located behind the nozzle in the printhead)..........................................................................83

Flush Filter (located near flush pump) ........................................................................................................83

VMS Filter (located inside FMS top box) ....................................................................................................83

Fluid Management System (FMS)..................................................................................................................84

Viscosity Monitoring System (VMS) Chamber (located inside the FMS top box).......................................84

Venturi (Jet Pump) (located inside the FMS top box) .................................................................................85

Pressure Transducer (located on the FMS connect manifold) ...................................................................85

Ink System Pump (located in the base of the machine) .............................................................................85

Flush Pump (located close to the FMS)......................................................................................................85

Printhead Operation ...........................................................................................................................................86

Ink Jet Information ..........................................................................................................................................86

Droplet Charging ............................................................................................................................................86

Droplet Deflection ...........................................................................................................................................87

Ink System Operation.........................................................................................................................................88

Function ..........................................................................................................................................................88

Operation........................................................................................................................................................88

Viscosity Monitoring System Sequence .........................................................................................................89

Clean Start Jet Sequence...............................................................................................................................91

Quick Start Jet Sequence...............................................................................................................................93

Clean Stop Jet Sequence...............................................................................................................................94

Quick Stop Jet Sequence ...............................................................................................................................96

Nozzle Flush ...................................................................................................................................................96

Ink Addition to Mixer Tank ..............................................................................................................................97

Top Up Addition to Mixer Tank .......................................................................................................................98

SYSTEM SOFTWARE...........................................................................................................................................99

Introduction.........................................................................................................................................................99

Using the Menus.............................................................................................................................................99

Messages Menu ...............................................................................................................................................100

Editor Menu ......................................................................................................................................................101

User Fields Menu .............................................................................................................................................101

Print Menu ........................................................................................................................................................102

Password Menu................................................................................................................................................102

System Menu ...................................................................................................................................................103

Configure Menu................................................................................................................................................105

Calibrate Menu .................................................................................................................................................106

Data Logging Menu ..........................................................................................................................................108

DISASSEMBLY AND ASSEMBLY.....................................................................................................................109

Introduction.......................................................................................................................................................109

430 Ink Jet Printer Service and Maintenance Manual

iv Issue 2

Part No. 306-0430-102

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.................................................................................................................. 114

LCD and Backlight ........................................................................................................................................... 115

Removal ....................................................................................................................................................... 115

Installation .................................................................................................................................................... 116

Keypad............................................................................................................................................................. 116

Removal ....................................................................................................................................................... 116

Installation .................................................................................................................................................... 116

Ink and Top Up Reservoir Sensor ................................................................................................................... 117

Removal ....................................................................................................................................................... 117

Installation .................................................................................................................................................... 117

Exchanging the Sensor and LED................................................................................................................. 117

Mains Inlet Connector...................................................................................................................................... 119

Removal ....................................................................................................................................................... 119

Installation .................................................................................................................................................... 120

Mains Switch.................................................................................................................................................... 120

Removal ....................................................................................................................................................... 120

Installation .................................................................................................................................................... 120

Fluid Management System (FMS)................................................................................................................... 121

Removal ....................................................................................................................................................... 121

Installation .................................................................................................................................................... 122

Ink System Pump............................................................................................................................................. 123

Removal ....................................................................................................................................................... 123

Installation .................................................................................................................................................... 124

Main Filter ........................................................................................................................................................ 125

Removal ....................................................................................................................................................... 125

Installation .................................................................................................................................................... 125

Flush Pump...................................................................................................................................................... 126

Removal ....................................................................................................................................................... 126

Installation .................................................................................................................................................... 126

Solenoid Valves ............................................................................................................................................... 127

Removal ....................................................................................................................................................... 127

Installation .................................................................................................................................................... 127

Fan................................................................................................................................................................... 128

Removal ....................................................................................................................................................... 128

Installation .................................................................................................................................................... 128

Fan Failure Card.............................................................................................................................................. 129

Removal ....................................................................................................................................................... 129

Installation .................................................................................................................................................... 129

EHT Module..................................................................................................................................................... 130

Removal ....................................................................................................................................................... 130

Installation .................................................................................................................................................... 130

Head Manifold.................................................................................................................................................. 131

Removal ....................................................................................................................................................... 131

Installation .................................................................................................................................................... 132

Phase Detector ................................................................................................................................................ 133

Removal ....................................................................................................................................................... 133

Installation .................................................................................................................................................... 134

Contents

Issue 2 v

Part No. 306-0430-102

EHT Block ........................................................................................................................................................135

Removal........................................................................................................................................................135

Installation.....................................................................................................................................................136

Nozzle Assembly..............................................................................................................................................137

Removal........................................................................................................................................................137

Installation.....................................................................................................................................................138

RS232 Jumper .................................................................................................................................................139

Installation.....................................................................................................................................................139

Removal........................................................................................................................................................139

Umbilical...........................................................................................................................................................141

PREVENTATIVE MAINTENANCE SCHEDULE.................................................................................................143

TROUBLESHOOTING ........................................................................................................................................145

Introduction.......................................................................................................................................................145

Fault Finding.....................................................................................................................................................146

Printer Fails to Initialise ................................................................................................................................146

Display Faults...................................................................................................................................................149

Backlight .......................................................................................................................................................149

Display ..........................................................................................................................................................150

Keypad Faults...............................................................................................................................................150

Display Icons ....................................................................................................................................................151

Mixer Tank Level High..................................................................................................................................155

CLEANING AND ADJUSTMENT........................................................................................................................157

Valve Cleaning .................................................................................................................................................157

VMS Inlet Restrictor Cleaning ..........................................................................................................................158

VMS Outlet Cleaning........................................................................................................................................159

Umbilical Purge ................................................................................................................................................160

Printhead Alignment.........................................................................................................................................161

ILLUSTRATED PARTS LIST..............................................................................................................................165

How to Use This Parts List...............................................................................................................................165

Optional Parts and Accessories .......................................................................................................................165

430 Ink Jet Printer ............................................................................................................................................166

Stand and Traffic Light System ........................................................................................................................167

Options and Accessories .................................................................................................................................168

General Spare Parts and Tools........................................................................................................................169

Documentation .................................................................................................................................................169

Major Sub-Assemblies .....................................................................................................................................170

Top Moulding Ink System Components ...........................................................................................................171

Top Moulding, Keypad and LCD ......................................................................................................................172

Baffle Plate Assembly ......................................................................................................................................174

Printhead Assembly .........................................................................................................................................175

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

430 Ink Jet Printer Service and Maintenance Manual

vi Issue 2

Part No. 306-0430-102

Preface

Issue 2 vii

Part No. 306-0430-102

PREFACE

Introduction

Welcome to the Service Manual for the Willett 430 Inkjet printer.

This manual is intended as a reference guide for trained service personnel and contains the following

information:

•installation and calibration instructions;

•disassembly and reassembly instructions for field-replaceable components;

•a technical description of the principles of operation of the printer;

•a troubleshooting guide;

•a quick reference guide to the control software which describes the function of each menu item.

Conventions

Positional References

Unless stated to the contrary, positions and directions such as left, right, front, rear, clockwise and anticlockwise

are given with respect to the printer when viewed from the front.

Units of Measurement

This handbook uses SI units of measurement and their imperial equivalents.

Typography

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.

IEC801: parts 2 to 6 inclusive - Immunity standards.

Machinery directive 89/392/EEC - Essential health and safety.

BS5304 - Machinery design.

EN60204 (BS2771) - Electrical safety in machinery.

EN292: 1991 - Safety of machinery.

EN60950 - Safety standards of Information Technology (IT) equipment.

430 Ink Jet Printer Service and Maintenance Manual

viii Issue 2

Part No. 306-0430-102

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. If the voltage ratings differ, do not use the printer until you have consulted your local supplier.

Use only the mains power cable supplied with the printer. This cable must terminate in an approved, three-pole,

mains plug which has a protective ground conductor.

Keep electrical power cables, sockets and plugs clean and dry at all times.

Grounding

The equipment must be connected only to an a.c. power supply, which has a protective ground conductor in

accordance with IEC requirements or applicable local regulations. Any interruption of the protective ground

conductor or disconnection of the protective ground terminal may render the apparatus dangerous.

Preface

Issue 2 ix

Part No. 306-0430-102

Restrictions

The information contained herein shall not be reproduced in whole or part without the manufacturer’s prior

written approval.

The manufacturer reserves the right to make changes in specifications and other information contained in this

document without prior notice. The reader should in all cases consult the manufacturer to determine whether

any such changes have been made.

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.

Contact Information

Willett Limited

Cronin Road

Corby

Northamptonshire

NN18 8AQ

England

Phone +(44) 1536 400777

Fax +(44) 1536 400888

http://www.willett.com

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