460, 460 Mi and 460 Pi

Service Manual

P/N 361507-01
Revision: AA, October 2003
 Copyright 2003, Videojet Technologies Inc. (herein referred to as Videojet). All rights reserved.

This document is the property of Videojet Technologies Inc. and contains confidential and propri-
etary information owned by Videojet. Any unauthorized copying, use or disclosure of it without the
prior written permission of Videojet is strictly prohibited.

Videojet / Willett
1500 Mittel Boulevard Phone: 1-800-843-3610 Offices - USA: Atlanta, Chicago, Los Angeles, Philadelphia
Wood Dale, IL Fax: 1-800-582-1343 INT’L: Canada, France, Germany, Ireland, Japan, Spain,
60191-1073 USA Int’l Fax: 630-616-3629 Singapore, The Netherlands,The United Kingdom
[Link] Distributors Worldwide
Compliance Information
For Customers in the U.S.A.
This device complies with Part 15 of the FCC Rules. Operation is subject to
the following two conditions: 1) this device may not cause harmful
interference, and 2) this device must accept any interference received,
including interference that may cause undesired operation.

Warning
Changes or modifications to this unit not expressly approved by the
party responsible for compliance could void the user’s authority to
operate the equipment.

This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to Part 15 of the FCC Rules. These limits
are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the
instruction manual, may cause harmful interference to radio
communications. Operation of this equipment in a residential area is likely
to cause harmful interference in which case the user will be required to
correct the interference at his own expense.
Shielded cables must be used with this unit to ensure compliance with
Class A FCC limits.
The user may find the following booklet prepared by the Federal
Communications Commission helpful: How to Identify and Resolve
Radio-TV Interference Problems. This booklet is available from the U.S.
Government Printing Office, Washington, DC 20402, Stock No. 004-00-
00345-4.
This equipment has been tested and certified for compliance with U.S.
regulations regarding safety and electrical emissions.

For Customers in Canada

This digital apparatus does not exceed the Class A limits for radio noise
emissions from digital apparatus set out in the Radio Interference
Regulations of the Canadian Department of Communications.
This equipment has been tested and certified for compliance with
Canadian regulations regarding safety and electrical emissions.

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Willett 460 Inkjet Printer Service Manual

Pour la clientèle du Canada

Le present appareil numerique n’emet pas de bruits radioelectriques
depassant les limites applicales aux appareils numerique de las class A
prescrites dans le Reglement sur le brouillage radioelectrique edicte par le
ministere des Communications du Canada.
Cet équipement est certifié CSA.

For Customers in the European Union

This equipment displays the CE mark to indicate conformance to the
following legislation:
• EN55022: 1998 Class B Emissions
• EN61000-4-2: 1995 ESD Requirements
• EN61000-4-3: 1997 Radiated Susceptibility
• EN61000-4-4: 1995 Electrical Fast Transient Burst Requirement
• EN60950:2000 Clause 4.4.8 Safety standards of Information
Technology (IT) equipment.
In addition to the above list, the 460 Pi has been found to comply with the
following legislation:
• EN61000-4-6: 1996 Conducted Susceptibility
• EN50082-1: 1995 Electromagnetic Compatibility
• EN50082-2: 1995 Electromagnetic Compatibility

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Support and Training
Contact Information
If you have any questions or need assistance, please contact Willett at 1-
800-843-3610 (for all customers within the United States). Outside the U.S.,
customers should contact their Willett distributor or subsidiary for
assistance.

Willett
1500 Mittel Boulevard
Wood Dale, IL 60191-1073 U.S.A.
Phone: 1-800-843-3610
Fax: 1-800-582-1343
International Fax: 630-616-3629
Web: [Link]

Service Program
About Tot al Source Commitment
Tot al Source® TOTAL SERVICE PLUS RELIABILITY, is the Willett
commitment to provide you - our customer - the complete service you
deserve.

The Tot al Source Commitment

The Willett Tot al Source® Service Program is an integral part of our
business in providing marks, codes, and images where, when, and how
often customers specify for packages, products, or printed materials. Our
commitment includes:
• Applications support.
• Installation services.
• Maintenance training.
• Customer response center.
• Technical support.
• Field service.
• Extended hours phone assistance.
• Parts and supplies.
• Repair service.

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Willett 460 Inkjet Printer Service Manual

Customer Training
If you wish to perform your own service and maintenance on the printer,
Willett highly recommends you complete a Customer Training Course on
the printer.

Note: The manuals are intended to be supplements to (and not replacements for)
Willett Customer Training.

For more information on Willett Customer Training Courses, call 1-800-

843-3610 (within the United States only). Outside the U.S., customer
should contact a Willett subsidiary office or their local Willett distributor
for further information.

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Table of Contents
Compliance Information
For Customers in the U.S.A.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
For Customers in Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Pour la clientèle du Canada. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
For Customers in the European Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

Support and Training

Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Service Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Customer Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

Table of Contents

Chapter 1 — Introduction
About this Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
Installation and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Hazard Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4

Chapter 2 — Installation
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
Required Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
Clean Start/Stop Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–15
Jet Start and Stop Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–16
Setting the Print Speed for 460 Pi. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–20
Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–23
Setting up Shifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–24
Production Line Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–25
Throw Distance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–26
Shaft Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–26
Product Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–28

Chapter 3 — Consumables
Selecting Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
Ink and Solvent Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1

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Chapter 4 — Firmware Download

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
Windows [Link] Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
Windows 95/98/2000 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5
Boot Monitor Recovery Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–9

Chapter 5 — Calibration and Testing

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
Earth Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
Machine Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
Pressure Zero Offset Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
Cooling Fan Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5
I/O Board LED Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6
Gutter Fault and Charge Error Disable . . . . . . . . . . . . . . . . . . . . . . . . . 5–8
Voltage Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9
Calibrate 285 V Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9
Reset Run Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–10
Set EHT Trip Level (for printhead setup only). . . . . . . . . . . . . . . . . . 5–11
About the Low Fluid Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13
Fill Mixer Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14
Entering Fluid Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–16
Manually Priming the Flush Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–17
VMS Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–19
Nozzle Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–20
Strobe LED Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–20
Ink Jet Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–21
Head Heater Temperature and Ink Pressure . . . . . . . . . . . . . . . . . . . 5–22
Modulation Calibration (Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–23
Phase Profile Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–26
Phase Offset Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–27
Print Charge Value Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–28
Setting EHT Tables for Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–29
Clean Start / Clean Shutdown Check . . . . . . . . . . . . . . . . . . . . . . . . . 5–30
Set EHT Trip Level (Normal Operation) . . . . . . . . . . . . . . . . . . . . . . . 5–31
EHT Trip Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–32
Print Height Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–33
Backup Calibration Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–34
Restore Calibration Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–34
Enable Gutter Detect and Charge Check. . . . . . . . . . . . . . . . . . . . . . . 5–35

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Chapter 6 — Technical Description

Main Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6
Electronics System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–10
Control Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–15
PSU Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–62
Electronics Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–64
Ink System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–66
Printhead Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–77
Ink System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–80

Chapter 7 — System Software

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
Messages Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
Editor Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4
User Fields Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5
Print Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–6
Password Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–7
System Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8
Configure Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–11
Calibrate Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–13
Data Logging Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–15

Chapter 8 — Assembly / Disassembly

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
Electronic Board Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2
Pump Motor Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
I/O Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
CPU Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–6
Levels Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–7
Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–8
LCD Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–11
Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–12
Top Up Reservoir Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–13
Mains Cable Gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–15
Fluid Management System (FMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–17
Ink System Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–20
Main Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–22
Flush Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–24
Solenoid Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–26
Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–28

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EHT Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–29

Head Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–30
Phase Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–32
EHT Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–34
Nozzle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–36
Umbilical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–38
Gutter Pump (460 Pi only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–42
460 Pi Pressure Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–44
FMS and Ink Tank Stirrers (460 Pi only) . . . . . . . . . . . . . . . . . . . . . . . 8–46

Chapter 9 — Maintenance Schedule

Chapter 10 — Troubleshooting
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–3
Display Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–7
Display Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–9

Chapter 11 — Cleaning and Adjustment

Valve Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–1
VMS Inlet Restrictor Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–2
VMS Outlet Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–3
Umbilical Purge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–5
Printhead Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–7

Chapter 12 — Illustrated Parts List

How to Use This Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–1
Optional Parts and Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–1
460 Ink Jet Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–2
Stands and Lamp Stacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–9
Encoders and Encoder Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . 12–10
Product Detectors and Detector Accessories . . . . . . . . . . . . . . . . . . 12–11
Networking Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–11
Other Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–12
Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–12
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–13
Outer Door Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–14
Inner Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–16
Printhead Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–17
FMS Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–20

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460 Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–23

Ink and Top-Up Filler Caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–27
PSU Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–28
Ink and Top-up Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–29
Electronics Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–31

Chapter 13 — Tools and Spare Part Kits

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–1
Spare Parts Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–3

Appendix A — Circuit Diagrams

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1
Foldout 1: CPU Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–3
Foldout 2: I/O Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–5
Foldout 3: Pump Motor Control Board . . . . . . . . . . . . . . . . . . . . . . . . A–7
Foldout 4: Expansion Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–9
Foldout 5: Levels Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–11

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Willett 460, 460Mi and 460Pi Service Manual

x Rev AA
Introduction
1
About this Guide
Welcome to the Service Manual for the Willett 460, 460 Mi and 460 Pi ink
jet printers.
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.

Writing Conventions

Positional References
Unless stated to the contrary, positions and directions such as left, right,
front, rear, clockwise and counter-clockwise are given with respect to the
printer when viewed from the front.

Units of Measurement
This handbook uses metric units of measurement. The equivalent English
measures are included in parenthesis.

Associated Publications
The following publications are related to this document:
• Willett 460, 460Mi and 460Pi Instructions for Use, Part Number:
361506

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Willett 460, 460Mi and 460Pi Service Manual

Language Codes
When ordering manuals, be sure to add the 2-digit language code to the
end of the part number. For example, the Spanish version of this manual is
part number 361507-04.

Code Language Availability (see note)

01 English (US) * +
02 French
03 German
04 Spanish
05 Portuguese
06 Japanese
07 Russian
08 Italian
09 Dutch
10 Chinese (Simplified)
11 Arabic
12 Korean
13 Thai
14 Icelandic
15 Norwegian
16 Finnish
17 Swedish
18 Danish
19 Greek
20 Hebrew
21 English (UK) * +
23 Polish

Note: Initial availability of the Instructions for Use is indicated by an asterisk (*).
Availability of the Service Manual is indicated by a plus sign (+). For more
information, consult your Willett distributor or subsidiary.

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 Willett 460, 460Mi and 460Pi Service 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. 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.

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Willett 460, 460Mi and 460Pi Service Manual

Hazard Information
This section contains important hazard notices. You must read these
notices before using the printer.
The hazard information is prioritized into typographically distinct
warning and caution notices as follows:

Warning
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.
Warning notices, together with the warning symbol shown on the
left, appear in full in the preliminary pages and at their points of
application in the manual. They are presented in the typographical
style of this notice.

Caution
Cautionary notices denote a potential hazard to the physical
integrity of equipment/software but not a danger to personnel.
These notices clearly state the nature of the hazard and the means by
which it can be avoided.
Cautionary notices appear in full in the preliminary pages and at
their points of application in the manual. They are presented in the
typographical style of this notice.

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 Willett 460, 460Mi and 460Pi Service Manual

Warning Notices

Warning
LETHAL VOLTAGES. Lethal voltages are present within this
equipment when it is connected to the mains electrical supply. Only
trained and authorized 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.

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. It is also
advisable to wear safety glasses when carrying out maintenance.
Apply barrier hand cream before handling ink.
If ink or top-up contaminates the skin, wash immediately with soapy
water. DO NOT use washdown or solvent to clean ink stains from
the skin.

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.

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Willett 460, 460Mi and 460Pi Service 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.
Immediately after use remove any tissue or cloths that become
saturated with these substances. Dispose of all such items in
accordance with local regulations.
In the event that any ink, solvent or top-up container is not
completely empty after use, it should be resealed. Only full bottles
are recommended for use when replenishing ink or top ups;
partially filled bottles should be disposed of in accordance with local
regulations.

Warning
WASTE INK. When setting up the nozzle, direct the ink stream into
a beaker or suitable container. To avoid contamination of the ink
supply in the printer, do not re-use any ink collected in this way.
Dispose of all waste ink in accordance with local regulations.

Warning
VAPOR HAZARD. Prolonged breathing of top-up or cleaning fluid
vapor may cause drowsiness and/or effects similar to alcoholic
intoxication. Use only in open, well-ventilated areas.

Warning
FUSES FIRE HAZARD. To ensure continued protection against the
risk of fire, replace fuses only with the specified type and rating.

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 Willett 460, 460Mi and 460Pi Service Manual

Warning
TOXIC HAZARD. The cleaning agent is poisonous if taken
internally. Do not drink. Seek medical attention immediately if
ingested.

Warning
HANDLING CLEANING AGENT. The cleaning agent is irritating to
the eyes and respiratory system. To prevent personal injury when
handling this substance:
Always wear protective rubber gloves and clothing.
Always wear goggles with side-shields or a face mask. It is also
advisable to wear safety glasses when carrying out maintenance.
Apply barrier hand cream before handling ink.
If cleaning agent contaminates the skin, rinse off with running water
for at least 15 minutes.

Warning
FIRE AND HEALTH HAZARD. The cleaning agent is volatile and
flammable. It must be stored and handled in accordance with local
regulations.
Do not smoke or use a naked flame in the vicinity of the cleaning
agent.
Immediately after use remove any tissue or cloths that become
saturated with cleaning agent. Dispose of all such items in
accordance with local regulations.

Warning
PERSONAL INJURY. Airborne particles and substances are a health
hazard. Do not use high pressure compressed air for cleaning
purposes.

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Willett 460, 460Mi and 460Pi Service Manual

Warning
EARTH CONTINUITY. To ensure safe earthing the resistance
between the mains lead earth wire and the test points must be less
than 1Ω.

Warning
HANDLING INK, SOLVENT AND TOP-UP. A high AC voltage is
present at the inverter and backlight.
Extreme caution is required when diagnosing failure in these areas.

Warning
LETHAL VOLTAGES. Under no circumstances must mains voltages
be switched directly from these contacts. If mains voltage is required
to be switched by these relays, An intermediate relay must be used.

Caution Notices

Caution
EQUIPMENT DAMAGE. Only Willett-trained personnel my carry
out installation and maintenance work. Any such work undertaken
by unauthorized personnel may damage the printer and will
invalidate the warranty.

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.

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 Willett 460, 460Mi and 460Pi Service 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.

Caution
PRINT QUALITY. To ensure high print quality, ink viscosity must
be checked and must be correct prior to attempting modulation
calibration.

Caution
INCORRECT MEASUREMENT. If the temperature compensation
factor is not used, the end result could be incorrect by as much as
40%.

Caution
EQUIPMENT DAMAGE. Ensure that ink comes from a sealed bottle
and that at least one of the bottles from the same batch has been
tested to ensure that the viscosity is correct.

Caution
DAMAGE TO CHARGE ELECTRODE. Take care not to deform the
charge electrode slot when rotating the charge electrode.

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Willett 460, 460Mi and 460Pi Service Manual

Caution
CHARGE CABLE. Ensure that the charge cable is not pulled out of
its position in the rear face of the deflector block assembly.

Caution
EQUIPMENT DAMAGE. Never attempt to bend the gutter. It is in a
fixed position.

Caution
EQUIPMENT DAMAGE. The I/O Board LEDS connector must not
be used to drive anything other than LEDs as specified otherwise
damage may occur.

Caution
EXCESSIVE USE OF TOP-UP OR SOLVENT. As solvent is used
during the stop cycle, repeatedly stopping and starting the printer
can lead to excessive use of top-up or solvent and may lead to a
Mixer Tank High error.

Caution
QUICK STOP. After a Quick Stop, the machine should not be left in
this state for any length of time as drying ink may make restarting
difficult.

Caution
EQUIPMENT DAMAGE. To avoid the risk of overfilling or spillage,
never replenish ink or top-up unless the relevant low icon is shown
pr the LED adjacent to the filler cap is illuminated.
Ensure that ink bottle is completely empty before removing.

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 Willett 460, 460Mi and 460Pi Service Manual

Caution
EQUIPMENT DAMAGE. Do not fit or remove any connector on the
printer whilst power is on, otherwise the printer may be damaged.

Caution
CLEANING MATERIALS. To avoid damage to the printer
components use only soft brushes and lint free cloths for cleaning.
Do not use high pressure air, cotton waste or abrasive materials.

Caution
EQUIPMENT DAMAGE. Ensure that the cleaning agent is
compatible with the ink used before carrying out printhead cleaning
otherwise the printhead may be damaged.

Caution
EQUIPMENT DAMAGE. The printhead must be completely dry
before attempting to start the printer otherwise the printhead may
be damaged.

Caution
PRINTER OVERHEATING. Report all overheating incidents to a
maintenance engineer.

Caution
RISK OF DATA LOSS. Ensure the correct message name is selected
for message deletion as no message selection confirmation prompt is
given.

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Willett 460, 460Mi and 460Pi Service Manual

Caution
RISK OF DATA LOSS. All messages apart from the TEST MESSAGE
will be deleted.

Caution
RISK OF DATA LOSS. The Clear Message option, when selected,
does not ask for confirmation to clear the message.

Caution
RISK OF DATA LOSS. The Delete user field option does not ask for
confirmation to delete a User Field.

1-12 Hazard Information Rev AA

Installation
2
Introduction
The printer is tested prior to dispatch to the customer. The
“Commissioning” section in this chapter contains the necessary
instructions for setup and additional testing at the customer site.
Each installation must be approached on an individual basis due to
variations in production line build specifications. Supposedly identical
production lines can vary significantly due to customer requirements or
modifications.
Each installation must be preceded by a site survey to establish the
necessary information relevant to the production line and printer. In some
cases it may be impossible to install a printer; it is therefore of vital
importance that all the installation criteria are met before attempting
installation. The site survey form must be completed as fully as possible by
the sales engineer.
Missing or ambiguous information should be clarified by telephone or fax
prior to the installation procedure.

Warning
LETHAL VOLTAGES. Lethal voltages are present within this
equipment when it is connected to the mains electrical supply. Only
trained and authorized 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.

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Willett 460, 460Mi and 460Pi Service Manual

Caution
EQUIPMENT DAMAGE. Only Willett-trained personnel may carry
out installation and maintenance work. Any such work undertaken
by unauthorized personnel may damage the printer and will
invalidate the warranty.

Required Items
You will need the following items to complete this procedure:
• the Service Tool Kit listed in Chapter 13
• 1 liter of ink
• 1 liter of suitable top-up
• 1 liter of suitable wash down

Commissioning

Unpacking and Inspecting the Printer

1 Open the box and visually inspect the machine for transit damage.
2 Check the contents of the box against the packing list.
3 Check that the correct keypad overlay is supplied with the machine. If
correct, remove the LCD protection film and fit the keypad overlay to
the front of the keypad.
4 Attach the bezel adhesive strip to the back of the keypad bezel. Fit the
bezel over the keypad.

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 Willett 460, 460Mi and 460Pi Service Manual

5 Ensure that the correct fuses (Item 2 in Figure 2-1) are fitted for the
local mains electrical supply.

3
Mains Voltage Fuse Rating
2
110 V AC 5A

230 V AC 3.15 A

1) Mains cable gland

2) Fuses
3) Mains Switch

Figure 2-1. Electrical Panel and Fuse Ratings

6 Verify that the correct type of nozzle is fitted to the printhead tray and
that the nozzle is mechanically and electrically fitted:
• A 60-micron nozzle for the 460 Si (P/N 200-0430-141) should have
orange and black wires. Its serial number should begin with an S.
• A 60-micron nozzle for the 460 Pi (P/N 200-0466-143) should have
orange and black wires. Its serial number should begin with an P.
• A 43-micron nozzle for the 460 Mi (P/N 200-0467-141) should have
yellow and black wires. Its serial number should begin with an M.
If the incorrect nozzle is fitted or the nozzle needs replacing, refer to
“Nozzle Assembly” on page 8-41 for instructions on installing a new
nozzle.

Important: Ensure that the nozzle tubes are not yet connected.

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Willett 460, 460Mi and 460Pi Service Manual

Preparation for Use

(1) Retainer screws
(2) FMS tray

Figure 2-2. Beginning the commissioning process

Start up calibration and testing

7 Using the key supplied, unlock and open the cabinet door as shown in
Figure 2-2.
8 Loosen the quarter turn retainer screws (Item 1 in Figure 2-2) and lift
the FMS tray (2) forwards and out of the printer.
9 Disconnect the electrical connector cap from the V1 solvent top-up
valve. On a 460 Pi, also remove the cap from the feed valve (V6).
10 Disconnect the condenser power cable from the levels PCB (JP102).

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 Willett 460, 460Mi and 460Pi Service Manual

11 If a positive air pump is to be installed (standard on the 460 Pi,

optional on other units), install it now by following these steps:
a. If the positive air pump has not already been mounted in the
electronics compartment, fasten it to the PSU bracket as shown in
Figure 2-3.

(1) PSU bracket

(2) Positive air pump
(3) Tube adapter
(4) Yellow-striped tube

Figure 2-3. Mounting the positive air pump

b. Remove the dust caps from the positive air pump in the electronics
compartment and the yellow tube in the printhead. Set the caps
aside for possible use in later steps.
c. Fit the black rubber tube adapter onto the end of the yellow-striped
tube in the electronics compartment.
d. Fit the other end of the tube adapter onto the outlet port (marked
“P”) of the positive air pump.
e. Attach the red wire (power) from the positive air pump to pin 2 of
the I/O board FAN_FAIL connector. Attach the black wire
(ground) to pin 5 . The connector is oriented as shown below.

1 3 5 (0V)

2 (+5 V) 4 6

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Willett 460, 460Mi and 460Pi Service Manual

12 If the mains power cord does not already have an AC plug attached,
attach the proper plug now according to the following table:

Wire Color Description

Brown +

Blue -

Green/Yellow Ground

13 Insert the mains power cord in an appropriate electrical outlet and set
the mains power switch to I (on). The printer PSU will automatically
detect and adjust to the mains voltage.
The quick screen is displayed on the LCD panel.

14 If nothing is visible on the LCD display, press f3 , then press ctrl

and L. This will cause the LCD to repeatedly cycle through the
complete range of contrast values. Press any key when the LCD is at
the most visible point in the cycle. This locks the contrast at the chosen
value.
15 Select Enter Password from the Password menu (Alt + W). Enter the
Master password.
16 Perform a full system reset to clear any erroneous configuration
information. To do this, select Full System Reset from the Configure
menu. Select All Messages Deleted.
17 Re-enter the master password (as in step 15).
18 Perform the following checks and calibration procedures located in
Chapter 5:
a. “Pressure Zero Offset Calibration” on page 5-4
b. “Cooling Fan Check” on page 5-5
c. “I/O Board LED Check” on page 5-6
d. “Gutter Fault and Charge Error Disable” on page 5-8
e. “Reset Run Hours” on page 5-10
f. “Set EHT Trip Level (for printhead setup only)” on page 5-11
g. Select Set Time/Date from the Configure menu. Enter the correct
details and then press the enter key.
Be sure to follow these procedures in the order listed above.

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 Willett 460, 460Mi and 460Pi Service Manual

Filling the ink system

19 Disconnect the vent fitting (Item 2 in Figure 2-4).
20 Prime the mixer bowl (3) with approximately 250 ml of the correct ink
using a syringe and a length of 40 mm x 6 mm tube. The Mixer Tank
Low icon will cease to be displayed when approximately 250 ml has
been added to the mixer bowl.
(1) FMS tray
(2) Ink system vent
fitting (to condenser)
(3) Mixer tank

Figure 2-4. Ink mixer tank and vent fitting location

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Willett 460, 460Mi and 460Pi Service Manual

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. It is also
advisable to wear safety glasses when carrying out maintenance.
Apply barrier hand cream before handling ink.
If ink or top-up contaminates the skin, wash immediately with soapy
water. DO NOT use washdown or solvent to clean ink stains from
the skin.

21 Ensure that the complete 250 ml is added before proceeding.

22 Re-connect the vent fitting (2) to the top of the FMS. Then, replace the
FMS tray (1) and tighten the quarter turn screws.

Caution
INCORRECT CALIBRATION. Do not forget to re-insert the FMS
tray in the printer. Leaving the FMS tray out will cause the
calibrations performed later to be incorrect (the FMS must be level).

23 Pour the remaining ink into the ink reservoir (black cap on top of the
printer). Verify that the ink low icon on the LCD is no longer present
and that the yellow LED near the filler cap is extinguished.
24 Fill the top-up reservoir (white cap on top of the printer) with one liter
of the appropriate top-up solvent. Verify that the top-up low icon on
the LCD is no longer present and that the yellow LED near the filler
cap is extinguished.

25 From the System menu, select Fill Mixer Tank and press enter . The
pump will start and the mixer tank will fill. The pump will stop
automatically when the ink level is satisfactory.
26 Enter the appropriate information about the ink and top-up being
used (see “Entering Fluid Information” on page 5-16).

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 Willett 460, 460Mi and 460Pi Service Manual

Removing trapped air

27 Remove the front and rear printhead covers and the nozzle seal (retain
the seal for refitting if the machine has to be transported).
28 Slacken the jet valve (V11) screws.
29 Place tissue paper around the printhead and jet valve to absorb
solvent when the priming procedure commences.

Warning
HANDLING CLEANING AGENT. The cleaning agent is irritating to
the eyes and respiratory system. To prevent personal injury when
handling this substance:
Always wear protective rubber gloves and clothing.
Always wear goggles with side-shields or a face mask. It is also
advisable to wear safety glasses when carrying out maintenance.
Apply barrier hand cream before handling ink.
If cleaning agent contaminates the skin, rinse off with running water
for at least 15 minutes.

30 From the System menu, select System Flush Purge.

31 Press enter .
32 Press Y to confirm or N to cancel the operation.

The machine starts and the flush pump is actuated. During the
actuation of the flush pump, solvent is ejected from beneath the jet
valve.

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33 Allow the machine to run for approximately 30 seconds before

pressing F1 (Abort Flush.).
34 Tighten the jet valve (V11) screws and dry the printhead.

Note: The majority of air should now have been removed. However, if a
significant amount of air remains trapped in the flush system, you can
remove it by manually priming the flush pump. See “Manually Priming the
Flush Pump” on page 5-17 for instructions.
35 Replace the V6 electrical connector if it was removed earlier.
36 Select Umbilical Purge from the System menu. Enable the purge using
the right arrow key.
37 Leave the machine running and check for leaking tubing and fittings.
38 Disable the umbilical purge using the right arrow key.

Verifying functionality of the gutter detect system

39 Perform an EHT trip test. See “EHT Trip Test” on page 5-32.
40 Start the jet by selecting Quick Start from the System menu. Once
running, enable gutter detect by selecting Gutter Detect from the
System menu and then using the right arrow key to select Enable. Press
the Enter key when you are finished. After a few seconds, the machine
should shut down with a gutter error. Verify that the gutter error icon
is showing on the display.
41 Disable gutter detect by selecting Gutter Detect from the System menu
and then using the right arrow key to select Disable. Press Enter.
Restart the jet by selecting Quick Start from the System menu. When
the machine is in running mode, shut it down by selecting Clean Stop
from the System menu or by Pressing F1. Verify that the machine
indicates that it cannot do a clean stop because of a charge error or a
gutter fault and carries out a quick stop instead.

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 Willett 460, 460Mi and 460Pi Service Manual

Connecting the nozzle

42 Extend the nozzle PTFE tubes forwards across the head heater as
shown below. Cut the tubes off at the length required to reach the rear
end of the head heater. It is best if the tubes are cut exactly at the edge
of the manifold.

(1) Nozzle PTFE tube

(2) Bleed barb
(3) Feed barb
(4) Cut line

43 Connect the nozzle tubes to the print head heater as follows:

a. Fit the clear PTFE tube to the feed barb (3). On the 460 Si and 460
Mi, the last chance filter should be fitted to this tube. On the 460 Pi,
the filter should not be fitted.
b. Fit the black line PTFE tube to the bleed barb (2).
44 Perform a nozzle flush operation to clean any debris out of the
printhead (see “Nozzle Flush” on page 5-20).
45 Align the printhead (see “Printhead Alignment” on page 11-7).

VMS calibration
46 Wait 20 minutes to allow the system temperature to stabilize.

47 Press the information key on the bottom left of the keypad.

48 Observe “visc set” and “visc actual.” If these two numbers are more
than three seconds apart, wait until the difference drops to three
seconds (or less).
49 Once “visc set” and visc actual” are within +/- 3 seconds of one
another, select VMS chamber calibration from the Calibration menu.
50 Ensure that Automatic is selected and press enter.
51 Wait for the printer to confirm that calibration of the VMS has been
completed.
52 Press the information key again and verify that “visc set” and visc
actual” are now identical.

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53 Replace the electrical connector removed from valve V1.

Final configuration and testing

54 Set the throw distance for the clean start/stop , modulation and
charge tests. For 460 Si and Pi, the throw distance should be 14mm.
For the 460 Mi, it should be 6mm.
55 Place a clean sheet of paper under the printhead.
56 Press F1 to stop the jet.
57 When the jet has completely stopped, press F1 to start the jet again.
58 Compare the ink left on the sheet of paper to the pass and fail criteria
shown in “Clean Start/Stop Standards” on page 2-15. If the sample
does not pass this criteria, refer to “Jet Start and Stop Diagnostics” on
page 2-16 for help in troubleshooting the problem.
59 Perform the following checks and calibration procedures located in
Chapter 5:
c. “Strobe LED Check” on page 5-20
d. “Modulation Calibration (Manual)” on page 5-23
e. “Phase Profile Adjustment” on page 5-26
f. “Phase Offset Calibration” on page 5-27
g. Select Auto Modulate from the Calibrate menu and then wait until
the printer informs you that it has finished
h. “Print Charge Value Calibration” on page 5-28
i. “Setting EHT Tables for Printing” on page 5-29
j. “Set EHT Trip Level (Normal Operation)” on page 5-31
k. “Print Height Test” on page 5-33
l. “Enable Gutter Detect and Charge Check” on page 5-35
These procedures must be done in the order shown above.

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Test print
60 Input a message. The message must contain a six-digit incrementing
counter.
61 Place an earthed print collector dish under the printhead.
62 Select the created message for printing.
63 Select Continuous Print mode:
a. From the Print menu, select Continuous Print.
b. From the Continuous print sub-menu, set Continuous mode to Time
Mode and Time Mode Delay to 50.

64 From the Configure menu, select Photocell Levels and set the state of the
photocell 1 level to Active High or Active Low as required.

65 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. Monitor the printer to ensure that the
system functions correctly.
66 At regular intervals access the Calibrate menu and select the
Diagnostics Screen. Monitor the machine parameters and check that
they remain stable. Typical Diagnostics Screen values are shown in
Table 2-1.

Note: The values provided are typical. The exact figures will vary slightly for
each machine depending on the model, ink type and ambient conditions.

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Willett 460, 460Mi and 460Pi Service Manual

Machine Parameter Typical Value (see Note above) Dependency

Ink Pressure 28 (standard print mode) Ink type, Pressure set value.
32 (fast print mode)

Cabinet Temperature 35 Ambient temperature.

Viscosity Set Point 34 Ink type, Ambient temperature.

Phase Angle Any value (must be stable) Correct Jet Break-up.

Ink Temperature 25 Ambient temperature

Head Temperature 35 Ink type, heater set point.

Viscosity Actual 29 Indicated value ±1 compared to

Viscosity Set Point = correct
viscosity.

Phase Profile 08-09 (Ideal) Phase charge, charge value,

Phase pick-up position

Ink (Reservoir Tank) „ Covered Level Detect covered - OK

… Low Level Detect uncovered - LOW

Sol (Top-up Reservoir) „ Covered Level Detect covered - OK

… Low Level Detect uncovered - LOW
or EMPTY

VMS … „ Full … … VMS chamber Sequence

„ Filling „ „ Emptying … Empty
Mix MIXER TANK CONDITION
… … … „ High High - Tank level too High
… … „ On „ On - Tank level OK
Low - Tank level too Low
… Empty„ Low „ „
Table 2-1: Typical diagnostics screen values

67 After 250,000 prints have been satisfactorily completed, press f1

and ensure that the printer performs a clean shutdown.

Note: If the machine does not provide an adequate clean start-up or

shutdown during these procedures, refer to “Jet Start and Stop Diagnostics”
on page 2-16 for help in troubleshooting the problem.
68 Once you are satisfied with the current configuration of the printer,
save it as a “known good” configuration (see “Backup Calibration
Parameters” on page 5-34).

2-14 Commissioning Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Clean Start/Stop Standards

The following illustrations show the minimum acceptable standards for
clean start and clean stop. Compare these to samples obtained by placing a
sheet of blank paper directly under the printhead.

(samples are shown

actual size)

Typical clean
start-up/shutdown

Typical dirty
start-up/shutdown

Minimum standard
required

Figure 2-5. Clean start/stop test illustrations

Rev AA Clean Start/Stop Standards 2-15

Willett 460, 460Mi and 460Pi Service Manual

Jet Start and Stop Diagnostics

Use the flow charts in this section to diagnose problems with dirty jet
starts and stops.

Quick Start Diagnostics

Figure 2-6. Quick start diagnostics flowchart

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 Willett 460, 460Mi and 460Pi Service Manual

Clean Start Diagnostics

Figure 2-7. Clean start diagnostic flowchart, sheet 1

(Continued on next page)

Rev AA Jet Start and Stop Diagnostics 2-17

Willett 460, 460Mi and 460Pi Service Manual

Figure 2-8. Clean start diagnostics flowchart, sheet 2

2-18 Jet Start and Stop Diagnostics Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Clean Stop Diagnostics

Figure 2-9. Clean stop diagnostics

Rev AA Jet Start and Stop Diagnostics 2-19

Willett 460, 460Mi and 460Pi Service Manual

Setting the Print Speed for 460 Pi

It is possible to set the printer to print at either standard speed or fast
speed. The printer is factory set for standard speed, which delivers better
print resolution. The following steps configure the printer for applications
in which the faster print speed is required:
1 Move the W2 link on the CPU board to the 1-2 position (See “CPU
Board” on page 6-16).
2 Exchange the standard 64 kHz printhead nozzle (P/N 200-0466-163)
for the fast 76.8 kHz printhead nozzle (P/N 200-0468-157).
3 Set the ink pressure to 3.2 bar (see “Head Heater Temperature and Ink
Pressure” on page 5-22).
Table 2-2 and Table 2-3 display the maximum printing speed of each
printing mode at typical print resolutions.

Note: This feature is only available on the 460 Pi Mark III. You cannot set the
print speed on the other variants of the printer or on Pi printers prior to Mark III.

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 Willett 460, 460Mi and 460Pi Service Manual

Font High Printed Print Speed Resolution Line Speed

(h x w) Speed Drops (cps/line) (cpi)
m/s fpm

Single Line 5x5 Off 5 1778 10 4.45 889

7x5 Off 7 1333 10 3.33 666

9x6 On 9 914 8 2.85 571

9x6 Off 9 508 8 1.58 317

12x8 Off 12 296 6 1.23 245

16x11 On 16 167 4 1.05 209

16x11 Off 16 137 4 0.85 171

19x14 Off 19 63 3 0.51 105

24x17 Off 25 45 3 0.38 76

Twin Line 5x5 Off 12 444 10 1.11 222

7x5 On 14 508 10 1.26 254

7x5 Off 16 273 10 0.68 136

9x6 Off 25 117 8 0.36 73

12x8 Off 26 82 6 0.33 68

Three Line 5x5 Off 19 157 10 0.38 78

7x5 On 21 222 10 0.55 111

7x5 Off 25 137 10 0.35 68

Four Line 5x5 Off 26 122 10 0.30 61

Table 2-2: 460Pi standard print speed

Rev AA Setting the Print Speed for 460 Pi 2-21

Willett 460, 460Mi and 460Pi Service Manual

Font High Printed Print Speed Resolution Line Speed

(h x w) Speed Drops (cps/line) (cpi)
m/s fpm

Single Line 5x5 Off 5 2133 10 5.33 1067

7x5 Off 7 1600 10 4 800

9x6 On 9 1097 8 3.43 686

9x6 Off 9 609 8 1.9 380

12x8 Off 12 355 6 1.48 296

16x11 On 16 200 4 1.25 250

16x11 Off 16 164 4 1.01 205

19x14 Off 19 75 3 0.61 125

24x17 Off 25 55 3 0.45 91

Twin Line 5x5 Off 12 533 10 1.33 267

7x5 On 14 609 10 1.51 305

7x5 Off 16 400 10 1 200

9x6 Off 25 140 8 0.43 88

12x8 Off 26 98 6 0.41 82

Three Line 5x5 Off 19 188 10 0.46 94

7x5 On 21 264 10 0.66 133

7x5 Off 25 164 10 0.41 82

Four Line 5x5 Off 26 147 10 0.36 73

Table 2-3: 460Pi fast print speed

2-22 Setting the Print Speed for 460 Pi Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Passwords
Liase with the customer and find out which machine functions they want
available to relevant personnel and which passwords they want to use. 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.

Notes: You must be at Password Level 3 to set Password Levels. Do not divulge
the master password to the customer.

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Willett 460, 460Mi and 460Pi Service Manual

Setting up Shifts
Liase with the customer to confirm shift requirements (if any). The
example below show how to set a shift system where the day is split into
three shifts with each shift numbered from 1 and shift 1 starting at 0700.
1 From the Configure menu, select Set Shifts. The Set Shifts sub-menu is
displayed.

2 Set the shift parameters as follows:

Start hour of shift 1 = 7
Start minutes of shift 1 = 0
Character for shift 1 = 1
Shift length (hours) = 8
Shift length (minutes) = 0

Notes: You must delete the Character for shift 1 using the Backspace or
Delete key before entering a new value.
Once you enter a start time and length, the other shifts are calculated
automatically.
3 Using the Shift criteria defined above, the insertion of a shift at
approximately 15:00 would provide a shift number of 2.

07:00 07:00+8=15:00 07:00+8+8=23:00

SHIFT 1

SHIFT 2

SHIFT 3

00h 08:00 16:00 23:59

Figure 2-10. Shift Setting Diagram

2-24 Setting up Shifts Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Production Line Setup

Typical Installation
A typical installation is shown in Figure 2-11, where the printer (7) is
mounted on a printer stand (8). The printhead (1) is configured to print
vertically via a clamp (3) and bracket (2) assembly. A lamp stack (4) is
fitted to the printer stand.

(1) Printhead
(2) Bracket
(3) Clamp
(4) Lamp stack
(5) Shaft encoder
(6) Photocell
(7) Printer
(8) Printer stand
(9) Mains cable
(10) Shaft encoder cable
(11) Photocell cable

Figure 2-11. Typical Production Line Installation

Rev AA Production Line Setup 2-25

Willett 460, 460Mi and 460Pi Service Manual

Throw Distance
The optimum throw distance from the printhead to the product is 14 mm
for the 460Pi and 460Si. It is 6mm for the 460Mi.

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. However, if the line speed varies then a
shaft encoder must be fitted in order to maintain constant message width.
A Width (Message Parameters) of 1 will provide the fastest print that the
printer can achieve in each font using the Internal Shaft Encoder option.
The message width is increased by approximately 3% for each increment.

External Source
If an external shaft encoder is fitted then set the Shaft Encoder Source to
External, via the Configure menu.
Figure 2-11 shows an external shaft encoder (5) connected via a cable (10)
to the SHAFT ENCODER connector on the connector panel.
The printer can be configured to accept two shaft encoder (quadrature)
outputs. This allows the printer to compensate for changes in direction of
the production line.

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.

Note: The expansion board is optional on the 460, 460Mi and 460Pi printers.
This board adds the External Message Selection and Time of Flight Compensation
options as well as relay and opt-isolated outputs, additional serial communication
ports and modem power.

If a quadrature shaft encoder is to be used you must do the following:

1 Set jumper JB2 (Item 2 in Figure 2-12) to position B.

2-26 Throw Distance Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

2 Download the appropriate special software to the printer.

3 Set the Message Length value to 1.
4 Disable Print Trigger 2.

Note: Using quadrature shaft encoders to determine changes of direction disables

the width function (i.e. it must be set to 1). If width control is required, an
external divider box must be provided.

Rev AA Shaft Encoder 2-27

Willett 460, 460Mi and 460Pi Service Manual

Product Sensors
Figure 2-11 on page 2-25 shows a photocell (8) connected via a cable (7) 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.

(1) Input/Output board

(2) Sensor 2/Quadrature shaft encoder jumper JB2
(3) Print trigger 1 and 2 jumper JB1

Figure 2-12. I/O Board, Product Sensor and Shaft Encoder Jumper Location

1 The photocells may be either NPN or PNP devices. Set Jumper JB1
(Item 3 in Figure 2-12) on the I/O board to match the device type.

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 Willett 460, 460Mi and 460Pi Service Manual

Table 2-4 lists the settings for jumper JB1.

Print trigger Device type Jumper 1 Pins Jumper 2 Pins

1 NPN A 1-2 C 3-4

1 PNP B 2-3 D 4-5

2 NPN F 6-7 H 8-9

2 PNP G 7-8 I 9-10

Table 2-4: Jumper JB1 Settings

2 Connect the printer to the mains supply and set the on/off switch to I
(on).
3 Select the Photocell Setup option from the Configure menu.
4 Set the relevant Photocell level(s) to Active high or Active low
dependant upon the device type. (NPN = Active high: PNP = Active
low).

Rev AA Product Sensors 2-29

Willett 460, 460Mi and 460Pi Service Manual

2-30 Product Sensors Rev AA

Consumables
3
Selecting Fluids
A complete range of inks, top-up fluids and cleaning solutions for the 460,
460Mi and 460Pi are available from Willett. These fluids can be ordered
either as individual bottles or as kits that contain several bottles of ink, as
well as the corresponding top-up fluid and cleaning solution.
See the current ink catalog for more information on currently-available
fluids.

Ink and Solvent Storage

You must follow the precautions listed below for ink and solvent storage:
• All inks and solvents should be stored and used in a well-ventilated
area and protected in case of fire.
• Store and ship the inks and solvents out of direct sunlight within the
temperature range 5º C to 50º C (41º F. to 122º F.).
• When shipping inks or solvents, comply with the local laws and
regulations.
• The risk of fire is an important consideration when storing/shipping
inks and solvents. Aqueous inks and solvents present a low fire risk as
they will not burn or support combustion. Inks based on water/
alcohol mixtures may burn if sufficient alcohol is present. Solvent-
based inks pose a greater fire risk. Consult the appropriate product
data sheet on the exact nature of the ink/solvent.
• Use powder or dry foam to extinguish fires and ensure electrical
supply is turned off. A fire blanket may be used to smother small local
fires. If in doubt consult the local fire authority.
• Wipe up any spillage immediately with absorbent material and
dispose of safely. If spillage is large, ventilate the area.
• Dispose of ink and solvents in accordance with the local regulations.
• Do not dispose of inks and solvents into the local drains.

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Willett 460, 460Mi and 460Pi Service Manual

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. It is also
advisable to wear safety glasses when carrying out maintenance.
Apply barrier hand cream before handling ink.
If ink or top-up contaminates the skin, wash immediately with soapy
water. DO NOT use washdown or solvent to clean ink stains from
the skin.

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.
Immediately after use remove any tissue or cloths that become
saturated with these substances. Dispose of all such items in
accordance with local regulations.
In the event that any ink, solvent or top-up container is not
completely empty after use, it should be resealed. Only full bottles
are recommended for use when replenishing ink or top ups;
partially filled bottles should be disposed of in accordance with local
regulations.

Warning
VAPOUR HAZARD. Prolonged breathing of top-up or cleaning
fluid vapor may cause drowsiness and/or effects similar to alcoholic
intoxication. Use only in open, well-ventilated areas.

3-2 Ink and Solvent Storage Rev AA

Firmware Download
4
Introduction
To download new operating software to the flash memory in the printer
use either:
• Microsoft Windows version [Link] Terminal mode in conjunction with
the Debug Monitor option from the System menu.
• Microsoft Windows version 95/98/2000 HyperTerminal mode in
conjunction with LCD option from the System menu.

Notes: It is possible to download new versions of the same software, but it is not
possible to install firmware from a different machine variant. A security feature of
the 460, 460Mi and 460Pi prevents the download of any firmware other than an
upgrade of the firmware which was originally supplied.

Requirements
The following equipment is required:
• An IBM compatible PC (with Microsoft Windows version [Link], 95, 98
or 2000 installed).
• A copy of the new operating software on disk.
• A suitable serial communications cable to connect between the PC and
printer connector COMM1.

Rev AA Introduction 4-1

Willett 460, 460Mi and 460Pi Service Manual

Windows [Link] Procedure

Checking the Communications Link

Before attempting to download new software check the communications
link between the PC and the printer.
1 Using a pre-configured connection cable, connect Com1 of the PC to
COMM1 of the 43s Printer.
2 On the PC, run the Terminal program (Windows Accessories Group).
3 Select the Communications option from the Settings menu and set the
following options:
Baud Rate: 9600
Data Bits: 8
Stop Bits: 1
Parity: None
Flow Control: None
Connector: Com1 (assuming Com1 is the port to be used)
4 Click OK to confirm the settings.
5 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, [Link].
6 Ensure that port COMM1 on the printer is set to corresponding baud
rate, data bits, stop bits and parity settings.
7 From the Data Logging menu, select the Serial Port Functionality option.
8 Set Status to Disable and press.
9 From the System menu select Debug Monitor.
10 Set Com1 to the active port. The prompt MON> should appear in the
PC Terminal Window.

11 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>

12 Press X and then enter on the PC to return the printer to normal

control.

4-2 Windows [Link] Procedure Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

13 From the Data Logging menu, select the Serial Port Functionality
option.
14 Reset Status to Enable.

Using Microsoft Windows [Link] to Download Firmware

1 Connect the serial communications cable between the serial port of the
PC and printer connector COMM1.
2 From the System menu select Debug Monitor.

3 Select LCD and press enter . The printer screen displays MON>.
4 On the PC, double-click on Terminal (normally located in Accessories
group).

Figure 4-1. Windows [Link] Accessories Group

5 Type BO on the printer keypad and press enter .

6 Press the Y key to confirm. The screen display becomes blank and the
Terminal Window displays MON>.

7 On the PC, type ER and press enter to erase the printer flash
EEPROM.
8 The PC Terminal Window displays the message; “Blank check failed,
Erasing Flash.”
9 After approximately 10 seconds the Terminal Window displays the
message, “Blank check passed.”
10 The PC Terminal Window then displays MON>.

Rev AA Windows [Link] Procedure 4-3

Willett 460, 460Mi and 460Pi Service Manual

11 On the PC type DU<SPACE>1 and press enter . 0 (zero) is

displayed in the Terminal Window.

12 On the PC press alt + T (Transfers menu), select Send Text File and
press .
enter

13 To select the new operating software file from the Send Text File
Window, proceed as follows:
a. From the Drives: menu, select a:.
b. From the List Files of Type menu, select All files [*.*].

c. Select the relevant file e.g. [Link] and press enter . The file
downloads to the printer.
An indicator at the bottom on the Terminal Window displays the
progress of the download.
14 After approximately 20 minutes the Terminal Window displays
MON>.
15 At the terminal MON> prompt, type: SET#4000#3ffff#0 and press

enter .
16 At the terminal MON> prompt, type: SET#1000#37ff#0 and press

enter .
17 At the terminal MON> prompt, type: SET#200#400#0 and press

enter .

18 Type RUN on the PC keyboard and press enter to activate and

run the new operating software.
19 Carry out a full system reset (see Configure Menu, page 105).

4-4 Windows [Link] Procedure Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Windows 95/98/2000 Procedure

Checking the Communications Link

1 Before attempting to download new software check the
communications link between the PC and the printer.
2 Using a pre-configured connection cable, connect COM1 of the PC to
COMM1 of the printer.
3 On the PC run the HyperTerminal program.
The Connection Description window opens requesting a title and an
icon for the new connection.
4 Enter the details and click OK.

Figure 4-2. New Connection Menu (Windows 2000)

The Connect To dialog box appears.

Rev AA Windows 95/98/2000 Procedure 4-5

Willett 460, 460Mi and 460Pi Service Manual

5 Change the Connect Using edit box to Com1.

Figure 4-3. Connect To Menu (Windows 2000)

6 When the COM1 properties menu is displayed, ensure the settings are
as follows:
Baud Rate: 9600
Data Bits: 8
Stop Bits: 1
Parity: None
Flow Control: None
Connector: Com1 (assuming Com1 is the port to be used)
7 Click OK to confirm the settings.
8 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, [Link].
9 Ensure that port COMM1 on the printer is set to corresponding baud
rate, data bits, stop bits and parity settings.
10 From the Data Logging menu, select the Serial Port Functionality option
and set Status to Disable.
11 From the System menu select Debug Monitor.
12 Set Com1 to the active port. The prompt MON> should appear in the
PC HyperTerminal Window.

13 To confirm that the communications link is effective press enter

on the PC. The prompt MON> should appear a second time, e.g.:

4-6 Windows 95/98/2000 Procedure Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

MON>
MON>

14 Press X and then enter on the PC to return the printer to normal

control.
15 From the Data Logging menu, select the Serial Port Functionality option
and reset Status to Enable.

Using Windows 95, 98 or 2000 to Download Firmware

To use Microsoft Windows 95, 98 or 2000 for a firmware download,
proceed as follows:
1 Connect the serial communications cable between the serial port of the
PC and printer connector COMM1.
2 Select the System menu.

3 Select LCD and press enter . The printer screen displays MON>.
4 Access Windows HyperTerminal
(normally located by clicking Start/Programs/Accessories/
Communications/HyperTerminal).
5 Follow the instructions for establishing a connection (see “Checking
the Communications Link” on page 4-5).

6 Type BO on the printer keypad and press enter .

7 Press the Y key to confirm. The screen display becomes blank and the
HyperTerminal Window displays MON>.

8 On the PC, type ER and press enter to erase the printer flash
EEPROM.
9 The PC HyperTerminal Window displays the message: “Blank check
failed, Erasing Flash.”
10 After approximately 10 seconds the HyperTerminal Windows
displays the message, “Blank check passed.”
11 The PC HyperTerminal Window displays MON>.

12 On the PC type DU<SPACE>1 and press enter . 0 (zero) is

displayed in the HyperTerminal Window.

Rev AA Windows 95/98/2000 Procedure 4-7

Willett 460, 460Mi and 460Pi Service Manual

13 On the PC press alt + T (Transfer menu), select Send Text File and
press .
enter

14 To select the new operating software file from the Send Text File
Window, proceed as follows:
a. From the Look in field, select A.
b. From the Files of Type box, select All files [*.*].
c. Select the relevant file e.g. [Link] and click Open. The file
downloads to the printer.
An indicator at the bottom on the Terminal Window displays the
progress of the download.
15 After approximately 20 minutes the Terminal Window displays
MON>.
16 At the terminal MON> prompt, type: SET#4000#3ffff#0 and press

enter .
17 At the terminal MON> prompt, type: SET#1000#37ff#0 and press

enter .
18 At the terminal MON> prompt, type: SET#200#400#0 and press

enter .

19 Type RUN on the PC keyboard and press enter to activate and

run the new operating software.
20 Carry out a full system reset (see “Configure Menu” on page 7-11).

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 Willett 460, 460Mi and 460Pi Service Manual

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:
1 Switch off the printer.
2 Remove the I/O board to allow access to the CPU (see “I/O Board” on
page 8-3).
3 Connect test point TMR1 to the chassis (0 V) with a test lead. TMR1 is
the test point closest to R12.

(1) CPU board

(2) Test lead
(3) Pillar (0 V)

Figure 4-4. Connection of TMR1 to chassis

4 Replace the I/O board and connections.

5 Connect a PC to the Comms port.
6 Switch on the printer.

Rev AA Boot Monitor Recovery Procedure 4-9

Willett 460, 460Mi and 460Pi Service Manual

7 Run the PC in Windows Terminal Mode and establish

communication.
8 At the PC type ER.
9 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.
The printer will now be operational.

4-10 Boot Monitor Recovery Procedure Rev AA

Calibration and Testing
5
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. The procedures may also be used as an aid to fault finding.

Earth Continuity Test

Warning
EARTH CONTINUITY. To ensure safe earthing the resistance
between the mains lead earth wire and the test points must be less
than 1Ω.

Using the multimeter, test between the earth terminal pin at the mains
plug and the following points:
With the cabinet door closed.
• Cabinet (Item 1 in Figure 5-1)
• Cabinet door (4)
With the cabinet door open.
• Earth wire connection on the PSU (2)
• FMS tray (see Item 1 in Figure 2-4 on page 2-7)
• Earth point on printhead (located under the rear cover).

Note: All printhead metal work, including covers, should equal less than 1Ω.

Rev AA Introduction 5-1

Willett 460, 460Mi and 460Pi Service Manual

(1) Cabinet
(2) Earth wire connection
on PSU
(3) Printhead earth point
(under rear cover)
(4) Cabinet door

Figure 5-1. Earth Continuity Test Points

5-2 Earth Continuity Test Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Machine Power-Up
1 Ensure that the correct fuses are fitted for the local mains supply
voltage. The correct values are listed below:
• 110 V AC supply - 5 A fuse
• 230 V AC supply - 3.15 A fuse
2 Connect the printer to the mains power supply.
3 Set the mains power switch to I (on).

4 If nothing is visible on the LCD display, press f3 , then press ctrl

and L. This will cause the LCD to repeatedly cycle through all possible
contrast values. Press any key when the LCD is at the most visible
point in the cycle. This locks the contrast at the chosen values.
5 Select Enter Password from the Password menu. Enter the Master
password.
6 If there is no ink in the system, verify that the Mixer Tank Low icon is
displayed.

Rev AA Machine Power-Up 5-3

Willett 460, 460Mi and 460Pi Service Manual

Pressure Zero Offset Calibration

Caution
FALSE READINGS. To avoid the risk of false readings, the pressure
zero offset should only be calibrated when there is no ink in the
system and the pump is off.

Calibrate the pressure zero offset as follows:

1 From the Calibrate menu select the Pump Zero Offset option.

2 Press enter .
3 Press Y to confirm or N to cancel the operation.

The ink system pressure is automatically set to zero relative to local

atmospheric pressure. There is no visual indication that the calibration has
been performed.

Note: If you want to confirm that the operation was carried out correctly, check
the Ink Pressure setting in the Diagnostics screen. It should now read “000.”

5-4 Pressure Zero Offset Calibration Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Cooling Fan Check

Check that the three cooling fans are operating correctly:
• The fan located on the left side of the cabinet should blow air into the
electronics compartment.
• The fan located on the bottom of the internal door should blow air
outwards toward the main door.
• The fan located on the inside face of the internal door should blow air
towards the circuit boards.

Rev AA Cooling Fan Check 5-5

Willett 460, 460Mi and 460Pi Service Manual

I/O Board LED Check

Remove the printhead cover. Check that LEDs 1, 3, 4 and 5 on the I/O
board are illuminated and that LED2 is dimly illuminated.

(1) LED 1 (green); +10 V (4) LED 4 (red); -15 V

(2) LED 2 (red); +285 V (5) LED 5 (green); +24 V
(3) LED 3 (yellow); -24 V

Figure 5-2. I/O Board Status LED Location

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 Willett 460, 460Mi and 460Pi Service Manual

The LEDs represent the following voltage rails:

LED 1 (green) +12 V customer's isolated supply for
shaft encoder/photocell.
LED 2 (clear/illuminates red) 285 V (+15 V = dim with printhead
cover off, +285 V = bright with
printhead cover on and jet running).
LED 3 (yellow) -24 V supply.
LED 4 (red) -15 V supply.
LED 5 (green) +24 V valve/pump/heater supply.

Rev AA I/O Board LED Check 5-7

Willett 460, 460Mi and 460Pi Service Manual

Gutter Fault and Charge Error Disable

1 From the System menu select Charge Error Shutdown Disable.

2 Press enter .

3 Select Charge error and toggle to Disable.

(The Idle Mode option

appears only on the 460 Pi)

4 Select Gutter fault and toggle to Disable.

5 460 Pi only: select Idle mode and toggle to Disable.

6 Press enter to disable both functions.

5-8 Gutter Fault and Charge Error Disable Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Voltage Checks
Check the voltages on the POWER connector, situated at the bottom left-
hand corner of the I/O board. Use Pin 2 as the 0 V reference. Figure 5-3 is
a representation of the POWER connector with the voltages shown for
each pin.

Notes: -24 V is generated from the I/O board, not the PSU. Allow ± 5% tolerance
on all voltages except -24V which is allowed at ± !0%. The power connector must
be connected to the I/O board to carry out this check.

PIN 8 PIN 7 PIN 6 PIN 5

-24V 0V +24 V +5 V

PIN 4 PIN 3 PIN 2 PIN 1

-15V +5 V 0V +15 V

Figure 5-3. I/O board POWER connector

Calibrate 285 V Rail

To calibrate the 285 V supply, proceed as follows:
1 Remove the electrical connectors to the Ink Feed Valve (V6) on the
FMS and the Top-up Addition Valve (V1) on the top-up reservoir.

2 Ensure the printhead cover is fitted and press f1 to start the Jet.

Notes: An inkjet will not be produced at the printhead as Valve V6 has been
disabled. The machine will shut down if disable charge and gutter detect
errors are not disabled.
3 On the I/O card connect a DVM, set to measure 285 V, between TP2
(+ve) and TP1 (0 V).
4 Set the 285 V rail to 285 V ±1 by adjusting VR1 on the I/O board.
Disconnect the multimeter.
5 Seal VR1 adjustment screw using a suitable sealing compound. Refit
the electrical connectors to valves V6 and V1.

Rev AA Voltage Checks 5-9

Willett 460, 460Mi and 460Pi Service Manual

Reset Run Hours

If the Service icon is displayed, the time until the next service is due must
be entered to remove it.

Note: the contact information that is displayed on

screen when this icon appears can be configured by
selecting Enter Service Information in the Data
Logging menu.

Proceed as follows:
1 From the Data Logging menu select Reset Run Hours.

2 Press enter .
3 Select Set pump alarm hours. Enter the number of hours until the next
main ink filter change is due. For a new filter, the recommended
interval is 6 months (4368 hours) of continuous use.
4 Set Reset pump run hours to Yes.

5 Configure Set machine alarm hours to the number of hours until the
next air filter inspection is due. The recommended interval is roughly
once a week (168 hours), but that interval should be decreased if
environmental conditions are poor and may be increased in
exceptionally clean environments.
6 Set Reset machine run hours to Yes.

7 Press enter to save the settings.

5-10 Reset Run Hours Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Set EHT Trip Level (for printhead setup only)

Ensure that the printhead is clean and dry before setting the EHT range
and trip level. The preliminary settings ensure that EHT trip is prevented
when setting up the printhead and calibrating the EHT table.
1 Fit the printhead cover.
2 From the Calibrate menu select EHT Range Set.

3 Press enter .

4 Select EHT Value 1 and set the value to 255.

5 Select EHT Value 10 and set the value to 255.

6 Press enter to save the settings.

7 Fit the printhead cover.

8 From the Calibrate menu select EHT Trip Level Set.

Rev AA Set EHT Trip Level (for printhead setup only) 5-11
Willett 460, 460Mi and 460Pi Service Manual

9 Press enter . The display shows “Setting EHT trip level.”

10 After approximately one minute the display changes to “EHT trip set
successful.”

11 Press enter .

5-12 Set EHT Trip Level (for printhead setup only) Rev AA
 Willett 460, 460Mi and 460Pi Service Manual

About the Low Fluid Indicators

There are three low fluid indicators that appear on the display screen.
They have the meanings shown below. See “Display Icons” on page 10-9
for additional troubleshooting information.
If the Mixer Tank Low icon is displayed, prime the mixer
tank according to the instructions in “Fill Mixer Tank” on
page 5-14.

Note: The Mixer Tank Low icon will clear from the display
before all the ink is added to the mixer tank but ensure that the
entire 250 ml of ink is added.

Caution
EQUIPMENT DAMAGE. Ensure that the ink comes from a sealed
bottle and that at least one of the bottles from the same batch has
been tested to ensure that the viscosity is correct.

If the Ink Level Low icon is displayed, fill the ink reservoir by
adding ink at the black filler cap (4-slot spider). Normally, a
full liter should be added. But, if you have just primed the
mixer tank, use the remaining ink in the open bottle.

If the Top Up Level Low icon is displayed, add one liter of

top-up solvent at the white filler cap (3-slot spider).

Rev AA About the Low Fluid Indicators 5-13

Willett 460, 460Mi and 460Pi Service Manual

Fill Mixer Tank

If the ink level in the mixer tank is less than 250 ml then it will be below
the ink pick up pipe. The machine will not reach operating pressure or top
up ink. If this is the case, begin at step 1, below. If there is more than 250
ml in the mixer tank, proceed to step 5.

(1) FMS tray

(2) Vent fitting
(3) Mixer tank

Figure 5-4. Ink Mixer Tank and Vent Fitting Location

1 Remove the vent fitting (Item 2 in Figure 5-4) from the top of the FMS.
2 Prime the mixer bowl (3) with approximately 250 ml of the correct ink
using a syringe and a length of 40 mm x 6 mm tube. The Mixer Tank
Low icon will cease to be displayed when approximately 250 ml is
added to the mixer bowl.
3 Ensure that the complete 250 ml is added before proceeding.

5-14 Fill Mixer Tank Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

4 Re-attach the vent fitting (2) to the top of the FMS.

5 From the System menu select Fill Mixer Tank.

6 Press enter . The pump starts and the mixer tank fills. When the
level of ink is OK, the pump stops (this may take several minutes).

Rev AA Fill Mixer Tank 5-15

Willett 460, 460Mi and 460Pi Service Manual

Entering Fluid Information

To ensure that the printer has the correct information about the ink and
top-up being used, proceed as follows:

1 From the Calibrate menu select Set Ink Type and press enter .

2 Check that the Fluid ID No. (FIN) displayed corresponds with ink
being used with the machine. If the FIN, Ink Part No. and Top-up Part
No. have previously been entered and are correct, press .
esc

If any of these values do not correspond with the ink and top-up being
used with the machine, enter the correct values and press .
enter

Notes: Refer to the ink bottle for the correct FIN number.
The pressure value contained in the FIN (digits 9 and 10) should be increased
slightly for 460 Pi printers using the 70 micron nozzle. For example, if the
pressure value in the FIN is 28 (which is typical), enter 32 for digits 9 and 10
of the FIN number.
FIN numbers should be entered exactly as they appear on the bottle. Do not
alter the punctuation or add spaces anywhere.
Although the ink and top-up part numbers are not actually used in the
operation of the machine, it is important to enter them anyway. The printer
displays these values for the user when the corresponding fluid is low.
Ideally, this will help avoid mishaps due to the addition of incorrect fluids.

5-16 Entering Fluid Information Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Manually Priming the Flush Pump

In some cases (occurs only rarely), air will remain trapped in the flush
system even after a system flush/purge operation has been completed.
This problem can sometimes by solved by manually priming the flush
pump using the flush pump priming adapter (P/N 2000466246) and a
syringe (P/N 5000118001) from the service tool kit.
1 Unscrew the tube fitting (Item 2 in Figure 5-5) from the end of the
flush filter (1) nearest the flush pump (3).

(1) Flush filter

(2) Flush filter tube fitting
(3) Flush pump
(4) Black omnifit connector

Figure 5-5. Manually priming the flush pump

2 Unscrew the black omnifit connector (4) from the front of the flush
pump. Place the connector and free tube end in a suitable fluid catcher
to catch any ink that drains out.
3 Make sure the syringe plunger is fully inserted in the body of the
syringe. Then, connect the flush pump priming adapter to the syringe.
4 Attach the other end of flush pump priming adapter to the flush
pump.
5 Carefully draw the syringe plunger back until air bubbles begin to fill
the priming adapter tube.
6 Disconnect the syringe from the tube just long enough to break the air
seal between the two.

Rev AA Manually Priming the Flush Pump 5-17

Willett 460, 460Mi and 460Pi Service Manual

7 Once the tube is re-connected to the syringe, carefully return the

plunger to the fully inserted position. (Solvent should squirt out of the
tube that was disconnected from the flush filter).
8 Re-attach the flush filter tube.
9 Disconnect the flush pump priming adapter and re-attach the black
omnifit connector.

5-18 Manually Priming the Flush Pump Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

VMS Calibration

Caution
INCORRECT VISCOSITY. Do not perform this calibration unless
Visc setpoint and Visc actual values displayed in the diagnostics
screen differ by no more than 3.
Ensure that the ink comes from a sealed bottle and that at least one
of the bottles from the same batch has been tested to ensure that the
viscosity is correct.

1 Remove the electrical connector from the top-up addition valve (V1).

2 Start the jet by pressing f1 . Ensure the that machine has been
running for at least 20 minutes before continuing.
3 From the Calibrate menu select VMS Chamber Calibration.

4 Select Automatic.

5 Press enter . The display shows “Calibrating VMS Chamber.”

After approximately 3 minutes this changes to “VMS Chamber
Calibrated.”
6 Refit the coil to the top-up addition valve (V1).

Rev AA VMS Calibration 5-19

Willett 460, 460Mi and 460Pi Service Manual

Nozzle Flush
1 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.
2 From the System menu select Nozzle Flush.

3 Press enter .

4 The nozzle orifice should be irrigated with washdown to clear any

blockages.
The nozzle flush remains operational for 2 minutes but can be aborted at
any time by pressing , Abort Flush.
f1

Strobe LED Check

Check that the red strobe LED (situated behind the charge electrode) is
illuminated.

5-20 Nozzle Flush Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Ink Jet Alignment

1 Press f1 to start the jet.
2 Ensure that the jet is in the correct position in the gutter (see
“Printhead Alignment” on page 11-7) and is passing through the
centre of the charge electrode slot (Figure 5-6) with an equidistant gap
(1) either side. Check also that the jet is parallel to the sides of the
charge electrode slot.

Figure 5-6. Ink Jet Alignment

3 If the inkjet alignment is not correct set up the printhead alignment as

described in “Printhead Alignment” on page 11-7.

Rev AA Ink Jet Alignment 5-21

Willett 460, 460Mi and 460Pi Service Manual

Head Heater Temperature and Ink Pressure

This procedure must be performed with the ink jet running.
1 From the Calibrate menu select Diagnostics screen.

2 Press enter .

3 Check that Ink pressure and Head temperature are reaching 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 Select Ink Type window. See
“Entering Fluid Information” on page 5-16 for more information.
The Head temperature is typically 35 but can vary for some inks. Ensure that the
temperature set point is correct for the ink being used (refer to the last 2 digits of
the FIN).
Ink pressure is typically 28 (32 for a 460 PI with a 70 micron nozzle) but can vary
for some inks. Ensure that the pressure set point is correct for the ink being used
(refer to the 9th and 10th digits of the FIN).
The head heater will not turn on if a gutter fault is present.

5-22 Head Heater Temperature and Ink Pressure Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Modulation Calibration (Manual)

Caution
PRINT QUALITY. To ensure high print quality, pressure, ink
viscosity and temperature must be checked and must be correct
prior to attempting modulation calibration.

Disable the Rolling Phase

1 From the System menu select Rolling Phase Disable.

2 Press enter .

3 Toggle to Disable then press enter .

Adjust the modulation value

4 From the Calibrate menu select Modulation Set Level.

Rev AA Modulation Calibration (Manual) 5-23

Willett 460, 460Mi and 460Pi Service Manual

5 Press enter .

6 View the position of the jet break-off. Adjust the Modulation Set Value
until the modulation level is 5.

7 Observe the jet in the viewing area illuminated by the strobe LED.
8 While observing the jet, slowly increase the modulation until the
satellites start to merge with the main drops.
9 Continue to increase the modulation until all the satellites have just
merged and record this value as Vmin.
10 Continue to increase the modulation until the break up point starts to
move away from the nozzle (turning point) and record this value as
Vtp.
11 Set the modulation voltage, Vset half way between Vmin and Vtp.

Vset = Vmin + Vtp – Vmin

----------------------------
2

NOZZLE

CHARGE CHARGE
ELECTRODE ELECTRODE

LIGAMENT LIGAMENT
SATELLITE SATELLITE

VERY LOW LOW GOOD HIGH VERY HIGH

Figure 5-7. Inkjet Break-off Point

12 When a good break-off point is achieved, press enter .

5-24 Modulation Calibration (Manual) Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Enable the Rolling Phase

13 From the System menu select Rolling Phase Disable and press enter .

14 Toggle to Enable then press enter .

Rev AA Modulation Calibration (Manual) 5-25

Willett 460, 460Mi and 460Pi Service Manual

Phase Profile Adjustment

1 Ensure that the phase detector is approximately 1 mm from the ink jet.
If not, align the printhead as described in “Printhead Alignment” on
page 11-7.
2 From the Calibrate menu select Diagnostics screen.

3 Press enter .

4 Check that the Phase profile is 8 ±1.

If the Phase profile is incorrect, adjust it as follows:

a. Remain in the Diagnostics screen and press alt + L,C.

b. The display shows “Phase Charge.”

c. Press or to adjust the Phase Charge until the correct Phase

profile is displayed then press .
enter

5-26 Phase Profile Adjustment Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

d. Press esc to exit the Diagnostics screen.

Note: Typical Phase Charge value for the 460 Si, 460Mi and the 460 Pi’s fast
printing mode is 112. Typical Phase Charge value for the 460 Pi’s standard
speed is 120.
5 Ensure that the jet is 4 mm ±0.25 mm from the +ve EHT plate. Also
ensure that the 0 V EHT plate is parallel to the jet. If any adjustments
are required, refer to the printhead alignment procedure in
“Printhead Alignment” on page 11-7.

Phase Offset Calibration

Set the phase offset to 9 for the 460 Si and 460 Mi. Set to 12 for the 460 Pi.

Rev AA Phase Offset Calibration 5-27

Willett 460, 460Mi and 460Pi Service Manual

Print Charge Value Calibration

1 Enter a test message that represents the specific customer
requirement.
2 From the Calibrate menu select Charge Value.

3 Press enter .

4 Set a Charge Value of 150 for the standard speed mode, or 130 if using
the fast speed mode on a 460 Pi.

5 Press enter
.

6 Take print samples of typical messages used by this customer. Verify

that the print quality is OK.
If print quality is poor, follow these steps to adjust the charge value.
a. Return to the Phasing menu.
b. Take print samples, decreasing the charge value in steps of 5 until
the print quality becomes poor. It may be necessary to clean the
gutter when poor print quality is produced.
c. Return to a charge value of 150 (or 130) and increase it in steps of 5
until the print quality becomes poor.
d. Adjust the character height as necessary to prevent over or under
deflection.
e. Set the charge value, which gives the best print quality and press

enter .

5-28 Print Charge Value Calibration Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Setting EHT Tables for Printing

The EHT table sets the voltage level for each of the 10 selectable character
heights. The object in configuring this table is to set up a range of character
heights that gradually increase from an allowable minimum (EHT value 1)
to an allowable maximum (EHT value 10).
1 Select Message 1 for printing. Set the Character Height for the currently
selected message to 1.
2 From the Calibrate menu select EHT Range Set.

3 Press enter .

4 Find the minimum setting for EHT Value 1 by following these steps:
a. Set EHT Value 1 to 180.

b. Press enter .

c. Take a print sample.

d. If gutter clipping does not occur, decrease the value by 10 and go to
step b.
e. Once gutter clipping occurs, increase the final value by 10.
5 Clean the +ve EHT plate.
6 Set the Character Height for the currently selected message to 10.

Rev AA Setting EHT Tables for Printing 5-29

Willett 460, 460Mi and 460Pi Service Manual

7 Set EHT Value 10 to 255. Verify that all dots are printed. If there is no
evidence of over deflection at the maximum EHT setting of 255, leave
the setting at 255 (this will be case for the majority of printers).
If over deflection occurs, follow these steps to find the correct EHT
value:
a. Set EHT Value 10 to 200.
b. Increase the value in steps of 10 and take print samples until the
maximum readable character is achieved. Note this value.
c. If there is evidence of over deflection at the noted value, decrease
the final value by 10 and clean the +ve EHT plate before continuing.
8 Fill out EHT values 2 through 9 such that the values in the table
gradually increase from top to bottom.

Tip: The easiest way to accomplish this is to press f2 , which will evenly
space the values from top to bottom. But, you can manually enter custom
values if you wish.
9 After calibration of the EHT table as detailed above, the EHT trip
sensitivity must be recalibrated as instructed in “Set EHT Trip Level
(Normal Operation)” on page 5-31.

Clean Start / Clean Shutdown Check

Place a clean sheet of paper under the printhead. Then, start or stop the jet
by pressing f1 .

Compare the drops produced on the paper to the standards in “Clean

Start/Stop Standards” on page 2-15. If the printer does not exceed the
minimum standards, refer to “Jet Start and Stop Diagnostics” on page 2-16
for possible solutions.

5-30 Clean Start / Clean Shutdown Check Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Set EHT Trip Level (Normal Operation)

1 Ensure the printhead is clean and dry.
2 Fit the printhead cover.
3 From the Calibrate menu select EHT Trip Level Set.

4 Press enter . The display shows “Setting EHT trip level.”

5 After approximately one minute the display changes to “EHT Trip

Test successful.”

6 Press enter .

Rev AA Set EHT Trip Level (Normal Operation) 5-31

Willett 460, 460Mi and 460Pi Service Manual

EHT Trip Test

This procedure must be performed after replacing one or more of the
following components:
• I/O PCB
• EHT block assembly
• EHT module
It should also be performed during the commissioning process.

Warning
FIRE HAZARD. This procedure may cause a spark at the printhead.
Make sure this procedure is conducted in a well-ventilated area that
is free of combustibles such as open ink or top-up containers. Use
only the recommended tools.

1 Open the ink compartment door.

2 Remove the electrical connector from Feed Valve V6. This will prevent
an ink jet being formed at the printhead nozzle.
3 From the Messages menu, select Message Parameters.

4 Press enter .

5 Select Character height.

5-32 EHT Trip Test Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

6 Set the Character height to 10 then press enter .

7 To prevent the machine from shutting down, set the charge/gutter

detect to DISABLE as instructed in “Gutter Fault and Charge Error
Disable” on page 5-8.
8 Fit the modified EHT printhead cover (this cover is included in the
Service Tool Kit described in “Service tool kit” on page 13-1).
9 Perform a Quick start from the system menu.
10 Insert the EHT Trip Tool (this item is also included in the Service Tool
Kit) between the +ve deflection plate and the 0V plate. The point of
the tool should be towards the +ve plate (lower).
11 Ensure that the machine shuts down with an EHT trip indicated on
the LCD.
12 Refit the electrical connector to Valve V6.
13 Close the cabinet door.

Print Height Test

For the 460 Si and Pi, take two print samples with the printhead between
14 mm and 24 mm from the substrate.
• A 5 drop high message should be able to print a message down to a
minimum height of 2 mm.
• A 24 drop high message should be able to print a message up to a
maximum of 9 mm.

For the 460 Mi, take two print samples with the printhead between 2 mm
and 12 mm from the substrate.
• A 5 drop high message should be able to print a message down to a
minimum height of 0.8 mm.
• A 24 drop high message should be able to print a message up to a
maximum of 4.6 mm.

Make sure that the customer’s minimum and maximum print height
specifications are met.

Rev AA Print Height Test 5-33

Willett 460, 460Mi and 460Pi Service Manual

Backup Calibration Parameters

Once you complete printer configuration, it is recommended that you
backup the calibration parameters as a “known good” configuration. To
backup the current calibration data:
1 From the Configure menu select Backup System Settings.

2 Press enter to backup the settings.

Restore Calibration Parameters

If at any time, the printer begins to print poorly, you can use this option to
restore a “known good” configuration saved previously. Follow these
steps to restore saved calibration parameters:
1 From the Configure menu select Restore System Settings.

2 Press enter to restore the settings.

5-34 Backup Calibration Parameters Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Enable Gutter Detect and Charge Check

1 From the System menu select Charge Error Shutdown Disable.

2 Press enter .

3 Select Charge error and toggle to Enable.

4 Select Gutter fault and toggle to Enable.

5 460 Pi only: Select Idle mode and toggle to Enable.

6 Press enter to enable both functions.

Rev AA Enable Gutter Detect and Charge Check 5-35

Willett 460, 460Mi and 460Pi Service Manual

5-36 Enable Gutter Detect and Charge Check Rev AA

Technical Description
6
This section describes the main components and interconnections. It
includes the following tables, which detail connector pin outs:
• Table 6-1 CON CPU CON_K Keypad Connector
• Table 6-2 CPU CON_232 RS232 Serial Interface
• Table 6-3 CPU CON_B I/O Board Interface
• Table 6-4 CPU CON_S RID Synchronous Port
• Table 6-5 CPU CON_P Power Input Connector
• Table 6-6 CPU CON_D Charge Data To I/O
• Table 6-7 CPU CON_L LCD Interface
• Table 6-8 CPU CON_LAN Serial Port
• Table 6-9 I/O Connector PEC1
• Table 6-10 I/O Connector PEC2
• Table 6-11 I/O Connector SENC
• Table 6-12 I/O Connector LEDS
• Table 6-13 I/O Connector T/LIGHT
• Table 6-14 I/O Connector LEVELS
• Table 6-15 I/O Connector CON_B1
• Table 6-16 I/O Connector CON_EX
• Table 6-17 I/O Connector PIGS
• Table 6-18 I/O Connector VALVES
• Table 6-19 I/O Connector CON_BM2
• Table 6-20 I/O Connector PUMP
• Table 6-21 I/O Connector P/TRANS
• Table 6-22 I/O Connector HEAD_2
• Table 6-23 I/O Connector CON_BM1
• Table 6-24 I/O Connector HEAD_1
• Table 6-25 I/O Connector CON_P0

Rev AA 6-1
Willett 460, 460Mi and 460Pi Service Manual

• Table 6-26 I/O Connector POWER

• Table 6-27 I/O Connector CH/MOD
• Table 6-28 I/O Connector EHT/FAN
• Table 6-29 I/O Connector FAN_FAIL
• Table 6-30 I/O Connector CON_D
• Table 6-31 I/O Connector B/LIGHT
• Table 6-32 I/O Board Jumper
• Table 6-33 I/O Board Test Points and LEDs
• Table 6-34 Levels Out Connector JP1
• Table 6-35 Door Switch Connector JP2
• Table 6-36 Reservoir Connector JP4
• Table 6-37 Ink System Connector JP5
• Table 6-38 EHT Connector JP8
• Table 6-39 FAN/EHT Connector JP9
• Table 6-40 Res/LEDs JP10
• Table 6-41 Fans Connector JP11
• Table 6-42 I/O LCD Connector JP12
• Table 6-43 LED Connector JP13
• Table 6-44 Backlight Connector JP14
• Table 6-45 I/O Keyboard Connector JP15
• Table 6-46 Door PCB Connector JP16
• Table 6-47 Condenser Control Connector JP101
• Table 6-48 Peltier Control Connector JP102
• Table 6-49 Stirrers Connector JP103
• Table 6-50 Gutter Pump Connector JP 104
• Table 6-51 Expansion Board Link and Switch Settings
• Table 6-52 Expansion Board Connector PEC1_IN
• Table 6-53 Expansion Board Connector PEC1_OUT
• Table 6-54 Expansion Board Connector SENC_IN
• Table 6-55 Expansion Board Connector SENC_OUT
• Table 6-56 Expansion Board Connector 20mA
• Table 6-57 Expansion Board Connector MSG_A
• Table 6-58 Expansion Board Connector MSG_B

6-2 Rev AA
 Willett 460, 460Mi and 460Pi Service Manual

• Table 6-59 Expansion Board Connector CON_232

• Table 6-60 Expansion Board Connector CON_EX
• Table 6-61 Expansion Board Connector MODEM
• Table 6-62 Expansion Board Connector OPTO_OUT
• Table 6-63 Expansion Board Connector RELAYS
• Table 6-64 Expansion Board Connector CON_LAN
• Table 6-65 Expansion Board Connector RS485
• Table 6-66 Motor Control Board Valve Connectors
• Table 6-67 Motor Control Board I/O Valve Connectors
• Table 6-68 PSU Board General Specification
• Table 6-69 PSU Board Output Specifications

Main Assemblies
The printer comprises four main assemblies:
• Cabinet
• Printhead
• Electronics system
• Ink system

Rev AA Main Assemblies 6-3

Willett 460, 460Mi and 460Pi Service Manual

Cabinet
(1) Control Panel
(2) Printer Cabinet
(3) Connector Panel
(4) Printhead

Figure 6-1. Main printer components

The 460, 460Mi and 460Pi cabinet is constructed of stainless steel.

6-4 Cabinet Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Cabinet Internals
When the door of the printer cabinet is opened, it reveals a compartment
that is split vertically into two halves. The left-hand compartment contains
the control electronics and power supply unit. It is enclosed by a panel
(Item 3 in Figure 6-2), on which is mounted two cooling fans. The right-
hand compartment contains the ink system (2). Mounted on the upper
surface is an electronics board upon which the display panel (1) is located.

Figure 6-2. Cabinet internals

Rev AA Cabinet 6-5

Willett 460, 460Mi and 460Pi Service Manual

Printhead
2

15 1 2 3
16 3

6 4 13

14
8
13
17
12
11

10 18

(1) Ground potential deflector electrode

(2) Phase detector 9
(3) Charge electrode
(4) Nozzle assembly
(5) Cover switch
(6) Knurled screw
(7) Rear cover (13) LED
(8) Head manifold (14) High voltage deflector electrode
(9) Umbilical (15) Gutter
(10) Gutter detect (16) Front cover
(11) Ceramic transducer (17) Feed valve
(12) Nozzle jet orifice (18) Bleed valve

Figure 6-3. 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 feed 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.
The bleed valve when energized removes air from the feed and return
pipework and the nozzle when being purged.
A vacuum is also applied through the bleed valve to the nozzle during
a nozzle flush.

6-6 Printhead Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

The ceramic transducer (11) is fed with a modulation signal. The

transducer causes the nozzle assembly to vibrate along its length so
that the ink stream from the nozzle jet orifice is formed into individual
droplets.
The nozzle jet orifice (12) has a diameter of 60 microns on the standard
460 Si and 460 Pi nozzles. On the standard 460 Mi nozzle, the orifice is
43 microns.
• The Light Emitting Diode (LED) (13) is located behind the charge
electrode (3). The LED is strobed at the modulation frequency so that
the position of individual droplets can be observed with a magnifying
glass (x10 minimum). The charge electrode applies an electrical charge
to each individual ink droplet. The charge applied to the droplet is
variable and affects the position of the droplet on the substrate.
• The phase detector (2) senses the strength of the electrical charge
applied to the ink droplets and adjusts the charge pulse timing
accordingly.
• The ground potential deflector electrode (1) and the high voltage
deflector electrode (14) are parallel rectangular plates. The deflector
electrodes generate a constant electrostatic field through which the
electrically charged ink droplets pass. The charged ink droplets are
deflected by the electrodes, the amount of deflection is dependent on
the charge applied to the ink droplet.
• The gutter (15) is the return path for ink droplets which are not used
for printing. The gutter delivers the ink back to the ink system.
• The front cover (16) is secured to the printhead by a knurled screw (6).
The front cover protects the printhead components. Removal of the
cover is sensed by the printer via the cover switch (5). When the cover
is removed the voltage to the deflector electrodes is turned off.
• The rear cover (7) protects the printhead internal electrical wiring and
ink system tubing.
• The umbilical (9) contains the electrical wiring and ink system tubing
from the printer.
• The head heater (8) maintains the temperature of the ink; it consists of
a heating element and a temperature sensor.
• The feed valve (17) is mounted on the heater module block. The valve
is open whilst printing and closed during the flushing cycle.
• The gutter detect (10) senses when ink is present in the gutter. It’s ink
feed tubes are metallic and a signal is fed to one of them. A signal
return lead is connected to the other. When ink (which is conductive)
is present, the signal passes through it to the return lead. The gutter
detect signal is then fed, via the umbilical, to the I/O board in the
electronics system.

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Willett 460, 460Mi and 460Pi Service Manual

Wiring diagrams for the printhead electrical and ink systems are shown in
Figure 6-4 and Figure 6-5.

Figure 6-4. Printhead Electrics and Ink System Wiring Diagram

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 Willett 460, 460Mi and 460Pi Service Manual

Figure 6-5. Wire routing under printhead manifold block

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Willett 460, 460Mi and 460Pi Service Manual

Electronics System
The printer electronics system comprises the following:
• Control panel.
• Connector panel.
• Control electronics.
• Electronics modules.

Control Panel

(1) Function keys (4) Status LEDs

(2) Liquid Crystal Display (LCD) (5) Keypad
(3) Arrow keys

Figure 6-6. Control Panel

The control panel consists of the following:

• A 70 key industrial grade membrane keypad (5). The keypad is self-
adhesive for ease of mounting and is fixed directly to the cabinet door.
• A 240 x 128 pixel backlit Liquid Crystal Display (LCD) (2). The display
has a viewing area of 120 mm x 64 mm. The display is located on the
door board PCB.

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 Willett 460, 460Mi and 460Pi Service Manual

• Basic printer control is provided by four function keys (1) to the left of
the LCD screen:

f1 Clean start or stop the ink jet.

f2 Select a message for printing.

f3 Access the menu screen.

f4 Display key status and character set(s) selected for the keypad.

• The arrow keys (3) to the right of the display allow you to navigate
through the software menu system.
• The light emitting diodes (4) on the top right of the display indicate
the system status as follows;

LAMP(S) ILLUMINATED SYSTEM STATUS

RED Any condition that prevents printing, e.g. jet

not running, EHT trip.

AMBER and GREEN The printer requires user intervention to pre-

vent a system fault occurring, e.g. ink or top-
up low.

GREEN The printer is able to print correctly.

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Willett 460, 460Mi and 460Pi Service Manual

Connector Panel

Figure 6-7. Connector panel

The connector panel is a series of nine connectors mounted on the lower

left-hand side of the cabinet. When fully populated , the connector panel
comprises the items below:
1 Print Trigger 2: a 3-way DIN connector.
2 Status O/P: a 6-way DIN connector for a set of status traffic lights
(optional).
3 RID: an 8-way DIN connector for a Remote Input Device (RID) — Not
available.
4 COMM 1: a 5-way DIN connector for an RS-232 serial
communications link. RS-232 can only be used over relatively short
distances (15 meters maximum).
5 COMM2: an 8-way DIN connector for a modem.
6 Shaft Encoder: a 4 way DIN connector.
7 I/O B: an 8-way DIN connector for the use of four uncommitted opto-
coupled outputs to be configured as required by the customer. I/O A
and I/O B can also be configured for the selection of messages stored
in the printer memory (which requires the use of both connectors).
8 I/O A: an 8-way DIN connector.
9 Print Trigger 1: a 3 way DIN connector.

Note: Only items (4),(6) and (9) are fitted as standard.

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 Willett 460, 460Mi and 460Pi Service Manual

Print Trigger 1 Connector

The printer provides a 12V 200mA 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 (Item 9 in Figure 6-7) is
as follows:

Pin Function

DIN Pin 1 +12V DC isolated supply to sensor.

DIN Pin 2 Sensor output.

DIN Pin 3 0V DC common.

Shaft Encoder Connector

The printer provides a 12 V (200 mA DC total) output for use by a shaft
encoder with a maximum frequency of 100 kHz. The pin allocation of the
shaft encoder connector (Item 6 in Figure 6-7) is as follows:

Pin Function

DIN Pin 1 +12 V DC isolated supply to shaft encoder.

DIN Pin 2 Shaft encoder output “A."

DIN Pin 3 Shaft encoder output "B."

Din Pin 4 0V DC common.

Note: The shaft encoder output must of the PUSH/PULL type.

COMM 1 Connector
The printer has an RS-232 communication port linked to the COMM1
connector (Item 4 in Figure 6-7). Its pin allocation is as follows:

Pin Function

DIN Pin 1 0VDC common.

DIN Pin 2 Transmit data out from the printer.

DIN Pin 3 Received data into the printer.

Din Pin 4 DTR output from the printer.

Din Pin 5 DCD input to the printer.

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Willett 460, 460Mi and 460Pi Service Manual

Status O/P Connector

The printer provides an output for a set of status traffic lights via the
STATUS O/P connector. The pin allocation of the connector (Item 2 in
Figure 6-7) is as follows:

Pin Function

Din Pin 1 Red lamp negative supply.

Din Pin 2 Amber lamp negative supply.

DIN Pin 3 Green lamp negative supply.

Din Pin 4 +24V DC supply to the strobe/siren.

Din Pin 5 Strobe/siren negative supply.

DIN Pin 6 +24V DC common to the traffic lights.

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 Willett 460, 460Mi and 460Pi Service Manual

Control Electronics

General

(1) Levels board

(2) CPU board
(3) I/O board
(4) Ink pump motor driver
board
(5) Door board
(6) Expansion board
(7) PSU

Figure 6-8. Control Electronics

The control electronics in 460, 460Mi and 460Pi printers are based on a
common Central Processing Unit (CPU) board (2), and an INPUT/
OUTPUT (I/O) board (3).
The other components of the control electronics are the modular power
supply (PSU) (7), the Liquid Crystal Display (LCD) and the integral
keypad. The LCD, keypad and LCD backlight inverter connect directly to
the door board (5), which in turn connects to the levels board (1). The PSU
connects directly to the I/O board.
The printer can be interrogated over a serial link in order to assess
performance. This serial link can be a direct RS-232 connection to a local
personal computer or via a MODEM and the telephone network.

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Willett 460, 460Mi and 460Pi Service Manual

CPU Board
The CPU Board circuit diagram is included Appendix A in this manual.

(1) CPU board (5) IC U19

(2) IC U31 (6) IC U9
(3) IC U40 and U41 (7) IC U21
(4) IC U38 and U39 (8) Ni-MH battery

Figure 6-9. CPU Board Major Components

Major Components
The CPU board (Item 1 in Figure 6-9) contains the hardware and software
for system control. It comprises the following major components:
• The CPU board (1) is a multi-layered motherboard that monitors and
controls all of the major printer functions. The board interfaces with

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 Willett 460, 460Mi and 460Pi Service Manual

the I/O board, PSU module, expansion board (if fitted) and external
devices (if connected) to provide an integrated product coding
system.
• 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
printer default setup
Note: These chips are the only difference between a 460 Mk III CPU board
and a Mk III CPU board from another 400-series machine or a 43s.

• IC U38 and IC U39 (4) are two integrated circuit Random Access
Memory (RAM) devices that contain the printer configuration,
calibration and message storage memory. To avoid loss of data when
the printer is switched off, they are backed up by a Nickel Metal
Hydride (Ni-MH) battery.
• IC U19 (5) is the microprocessor that monitors incoming data from the
I/O ports and translates software commands into machine statements
that control the electronic system and ink system to produce a printed
message.
• IC U21 (7) is a Real Time Clock (RTC) which contains a clock/
calendar. It has a battery backup so that the current time and date do
not have to be manually set each time the printer is switched on.
• The Ni-MH battery (8) supplies the voltage necessary to retain Real
Time Clock (RTC) and RAM data when the printer is switched OFF.
The battery is automatically charged when the printer is switched ON.
• IC U9 (6) is a Dual Universal Asynchronous Receive Transmit
(DUART) which can be configured to interface with different devices
to transmit and receive data.

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Willett 460, 460Mi and 460Pi Service Manual

Connectors
The CPU board connectors shown in Figure 6-10. Pinout details are given
in the tables that follow.

(1) CON_K (Keypad connector) (5) CON_P (Interboard connector)

(2) CON_232 (6) CON_D (Interboard connector)
(3) CON_B (Interboard connector) (7) CON_L (LCD connector)
(4) CON_S (8) CON_LAN

Figure 6-10. CPU Board Connectors

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 Willett 460, 460Mi and 460Pi Service Manual

CON_K (Item 1 in Figure 6-10) is connected to the keypad

Pin Signal Function Pin Signal Function

1 GND EMC earth 12 SL1 Scan line 1

connection

2 ALT ALT key 13 SL2 Scan line 2

3 CTL Control key 14 SL3 Scan line 3

4 SFT Shift key 15 SL4 Scan line 4

5 0V Scan line 7 16 SL5 Scan line 5

6 SL7 Return line 0 17 SL6 Scan line 6

7 RL0 18 RL4 Return line 4

8 RL1 Return line 1 19 RL5 Return line 5

9 RL2 Return line 2 20 RL6 Return line 6

10 RL3 Return line 3 21 RL7 Return line 7

11 SL0 Scan line 0 22 GND EMC earth

connection

Table 6-1: CON CPU CON_K Keypad Connector

CON_232 (2) is a RS232 serial communications port (COM1) and can be con-
nected to any other device which supports RS232.

Pin Signal Function Pin Signal Function

1 TXDA Transmit data 4 DCD Data carrier detect

2 DTR Data terminal 5 COM Common

ready

3 RXDA Receive data 6 - +8V

Table 6-2: CPU CON_232 RS232 Serial Interface

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Willett 460, 460Mi and 460Pi Service Manual

CON_B (3) is an interboard connector which connects the CPU board to the I/O board.

Pin Signal Function Pin Signal Function

1 0V Common 11 opto I/O Expansion board enable

2 Sel2 Not used 12 adc A/D converter output

enable

3 ex1 Photocell 1 input 13-20 cb0 to cb7 Control bus bits 0 to 7

4 ex2 Phase detector 21-28 db0 to db7 Data bus bits 0 to 7

5 ex3 A-D end of conversion 29 qddc D/A converter output

enable

6 ex4 Phase detector 30 levels Optical level sensors

select

7 ex5 Photocell 2/shaft encoder 31 I/O PPI enable

quadrature input

8 sel3 Print/phase 32 sft-enc Shaft encoder input

9 strobe LED strobe 33 extra1 Traffic light enable

10 PWM Pump control (pulse 34 contrast LCD contrast voltage

width modulation)

Table 6-3: Table 5 CPU CON_B I/O Board Interface

CON_S (4) is a high speed synchronous port

Pin Signal Function Pin Signal Function

1 TXD Asynchronous transmit output 5 SDATA Synchronous data

2 RXD Asynchronous receive input 6 SDEN0 Synchronous enable 0

3 0V Asynchronous data common 7 SDEN1 Synchronous enable 1

4 SCLK Synchronous clock 8 0V Synchronous common

Table 6-4: CPU CON_S RID Synchronous Port

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CON_P (5) is an interboard connector which connects the CPU board to the I/O
board.

Pin Signal Function Pin No. Signal Function

1 to 4 0V Common in out 11 and 12 - 15 V - 15 V input

from PSU from PSU
(via I/O) (via I/O)

5 to 8 +5 V +5 V input from 13 and 14 GND via I/O

PSU (via I/O)

9 and +15 V +15 V input from

10 PSU (via I/O)

Table 6-5: CPU CON_P Power Input Connector

CON_D (6) is an interboard connector which connects the CPU board to the I/
O board.

Pin Signal Function

1 to 8 00 - 07 Droplet charge data

9 and 10 0V Common

11 to 20 - Not used at present

Table 6-6: CPU CON_D Charge Data To I/O

CON_L (7) is connected to the LCD.

Pin Signal Function Pin Signal Function

1 GND Ground 8 Ia1 Control bus bit 7

2 0V 9 - Not connected

3 VCC +5 V 10 RESET LCD controller

reset

4 CONTRAST LCD contrast 11 to ad0 to Data lines

18 ad7

5 WR Write 19 0V Font Select

6 RD Read 20 sel5 Select inverse

video

7 lcd ce LCD chip

enable

Table 6-7: CPU CON_L LCD Interface

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Willett 460, 460Mi and 460Pi Service Manual

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 Signal Function Pin Signal Function

1 +15 V +15 VDC power 5 DTR Data terminal ready

2 VCC +5 VDC power 6 0V Common

3 RXDB Receive data 7 RXDB Receive data (via

inverter)

4 TXDB Transmit data 8 TXDB Transmit data (via

inverter)

Notes: Pins 7 and 8 of the CPU CON_LAN serial port are for use with a modem.
Link W3 (8) must be fitted if COM2 is to be used with the optional expansion card
and internal modem.
Link W3 must be removed if COM2 is to be used with the expansion card 20 mA
current loop or RS485 interface.

Table 6-8: CPU CON_LAN Serial Port

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I/O Board
The I/O board (Item 1 in Figure 6-11) 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 in Appendix A of this manual.

Note:This manual describes only the issue 3 I/O board.

Major Components

(1) I/O board

(2) IC U20
(3) Ink Pump motor driver board
(4) IC U1
(5) VR1
(6) 285 V DC power supply
(7) IC U15
(8) IC U16

Figure 6-11. I/O Board Major Components

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Willett 460, 460Mi and 460Pi Service Manual

• 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. IC U1 (4) acts as the
ink pump motor controller. A circuit diagram of the board is supplied
in Appendix A in this manual.
• The 300 VDC power supply (6) provides the voltage supply to the
charge amplifier which is used to charge the ink droplets.
• IC U15 (7) is a Programmable Peripheral Interface (PPI) which is used
to read the states of various sensors and control functions and to
switch control valves and some supervisory lines.
• IC U16 (8) is an Analogue to Digital Converter (ADC) which is used to
convert analogue inputs from the ink system into an 8 bit value for ink
system control.

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Connectors

(1) PEC1 (9) PIGS (17) POWER

(2) PEC2 (10) VALVES (18) CON_P0
(3) SENC (11) CON_BM2 (19) CH/MOD
(4) LEDS (12) PUMP (20) EHT/FAN
(5) T/LIGHT (13) P/TRANS (21) FAN_FAIL
(6) LEVELS (14) HEAD_2 (22) CON_D
(7) CON_B1 (15) CON_BM1 (23) JB1
(8) CON_EX (16) HEAD_1 (24) B/LIGHT

Figure 6-12. I/O Board Connectors

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Willett 460, 460Mi and 460Pi Service Manual

PEC1 (1) - Product sensor 1 via the connector panel.

Pin No. Signal Function

1 +V0 Positive DC supply to sensor

2 EXT PEC 1/2 Input from sensor

3 0V Common

Table 6-9: I/O Connector PEC1

PEC2 (2) - Product sensor 2 via the connector panel.

Pin No. Signal Function

1 +V0 Positive DC supply to sensor

2 EXT PEC 1/2 Input from sensor

3 0V Common

Table 6-10: I/O Connector PEC2

SENC (3) - Shaft encoder via the connector panel.

Pin No. Signal Function

1 +V0 Positive DC supply to shaft encoder

2 SHAFT ENCODER A Input A from shaft encoder

3 SHAFT ENCODER B Input B from shaft encoder

4 0V Common

Table 6-11: I/O Connector SENC

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LEDS (4) - LEDs are fitted on the front panel to mimic traffic lights.

Pin Signal Function Pin Signal Function

1 Red + Red LED 5 Red - Red LED

anode (+) cathode (-)

2 Yellow + Yellow LED 6 Yellow - Yellow LED

anode (+) cathode (-)

3 Green + Green LED 7 Green - Green LED

anode (+) cathode (-)

4 Strobe + Strobe LED 8 Strobe - Strobe LED

anode (+) cathode (-)

Table 6-12: I/O Connector LEDS

Caution
EQUIPMENT DAMAGE. The I/O Board LEDS connector must not
be used to drive anything other than LEDs as specified otherwise
damage may occur.

T/LIGHT (5) - Status traffic lights via the connector panel.

Pin Signal Function Pin Signal Function

1 +24 V +24 V DC to all lights 4 0 V GREEN Negative supply for green

lamp

2 0 V RED Negative supply for 5 +24 V +24 V DC to strobe/siren

red lamp

3 0 V AMBER Negative supply for 6 0 V STROBE Negative supply for

amber lamp strobe

Table 6-13: I/O Connector T/LIGHT

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Willett 460, 460Mi and 460Pi Service Manual

LEVELS (6) - Ink system level sensors.

Pin Signal Function Pin Signal Function

1 +5 V +5 V, Mixer low sensor LED 18 +5 V +5 V, VMS high sensor photo

anode transistor collector

2 +5 V +5 V, Mixer low sensor photo 19 0V 0 V, VMS high sensor LED

transistor collector cathode

3 0V 0 V, Mixer low sensor LED 20 lev5 VMS high sensor output

cathode

4 lev1 Mixer low sensor output 21 +5 V +5 V, Ink res. low sensor LED
anode

5 +5 V +5 V, Mixer OK sensor LED 22 +5 V +5 V Ink res. low sensor

anode photo transistor collector

6 +5 V +5 V, Mixer OK sensor photo 23 0V 0 V, Ink res. low sensor LED

transistor collector cathode

7 0V 0 V, Mixer OK sensor LED 24 lev6 Ink res. low sensor output

cathode

8 lev 2 Mixer OK sensor output 25 +5 V +5 V, Solvent res. low sensor

LED anode

9 +5 V +5 V, Mixer high sensor LED 26 +5 V +5 V, solvent res. low sensor

anode photo transistor collector

10 +5 V +5 V, Mixer high sensor photo 27 0V 0 V, Solvent res. low sensor

transistor collector LED cathode

11 0V 0 V, Mixer high sensor LED 28 lev7 Solvent res. low sensor out-
cathode put

12 lev3 Mixer high sensor output 29 +15 V

13 +5 V +5 V, VMS low sensor LED 30 0V

anode

14 +5 V +5 V, VMS low sensor photo 31 - 15 V

transistor collector

15 0V 0 V, VMS low sensor LED 32 0V

cathode

16 lev4 VMS low sensor output 33 GND

17 +5 V +5 V, VMS high sensor LED 34 GND

anode

Table 6-14: I/O Connector LEVELS

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CON_B1 (7) - Interboard connector to I/O board to the CPU board.

Pin Signal Function Pin Signal Function

1 0V 11 opto I/O E

2 - Not used 12 adc A/D converter output

enable

3 pec1 Photocell 1 output 13 to 20 cb0 to cb7 Control bus bits 0 to 7

4 phase Phase detector 21 to 28 db0 to db7 Data bus bits 0 to 7

det

5 ADEO A-D end of conversion 29 qddc D/A converter output

C enable

6 phase Phase detector 30 levels Optical level sensors

det enable

7 pec2 Photocell 2/shaft encoder 31 pcs3 PPI enable

quadrature output

8 print/ Print/phase 32 shaft enc Shaft encoder output

phase

9 strobe LED strobe 33 extra 1 Traffic light enable

10 pwm Pump control (pulse 34 contrast LCD contrast

width modulation)

Table 6-15: Table 17 I/O Connector CON_B1

CON_EX (8) - Interboard connector to I/O board to the optional expansion board.

Pin Signal Function Pin Signal Function

1 VCC +5 V DC 15 TACHO For use with external

DC tacho

2 to 9 db0 to db7 Data bus bits 0 to 7 16 0V

10 External message select 17 0V

11 Opto-isolated output select 18 +24 V

12 cb6 Control bus bit 6 (not used) 19 - 24 V

13 cb7 Control bus bit 7 (not used) 20 GND

14 cb0 Control bus bit 0 (not used)

Table 6-16: I/O Connector CON_EX

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Willett 460, 460Mi and 460Pi Service Manual

PIGS (9) - Will be used in future models for an ink heater/cooler system.

Pin Signal Function Pin Signal Function

1 +24 V 4 0V

2 BULK HEAT 5 HEATER Heater/cooler on/off

3 +24 V 6 0V

Table 6-17: I/O Connector PIGS

VALVES (10) - Ink system solenoid valves.

Pin Signal Function Pin Signal Function

1 +24 V +24 V DC to solvent top up 9 +24 V +24 V DC to feed valve V6

valve V1

2 - ve Solvent top up valve control 10 - ve Ink feed valve control signal

signal

3 +24 V +24 V DC to Ink top up 11 +24 V +24 V DC to gutter valve V8

valve V2

4 - ve Ink top up valve control 12 - ve Gutter valve control signal

signal

5 +24 V +24 V DC to VMS diverter 13 +24 V +24 V DC auto power off

valve V3

6 - ve VMS diverter valve control 14 - ve Auto power off control signal

signal

7 +24 V +24 V DC to solvent flush 15 +24 V +24 V DC to purge valve V10

valve V4

8 - ve Solvent flush valve control 16 - ve Purge valve control signal

signal

Table 6-18: I/O Connector VALVES

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CON_BM2 (11) - Ink pump motor driver board.

Pin Signal Function Pin Signal Function

1 B OUT Stator drive B (green) 5 HC Position signal from Hall effect

sensor C (green)

2 A OUT Stator drive A (black) 6 0V Hall effect sensor -ve supply

3 C OUT Stator drive C (white) 7 HB Position signal from Hall effect

sensor B (white)

4 +6 V Hall effect sensor +ve 8 HA Position signal from Hall effect

supply sensor A (blue)

Table 6-19: I/O Connector CON_BM2

PUMP (12) - Ink system pump.

Pin Signal Function Pin Signal Function

1 B OUT Stator drive B 5 HC Position signal from Hall effect sensor C

2 A OUT Stator drive A 6 0V Hall effect sensor -ve supply

3 C OUT Stator drive C 7 HB Position signal from Hall effect sensor B

4 +6 V Hall effect sen- 8 HA Position signal from Hall effect sensor A

sor +ve supply

Table 6-20: I/O Connector PUMP

P/TRANS (13) - Ink system temperature sensor and the pressure transducer.

Pin Signal Function Pin Signal Function

1 +10 V +10 V DC supply volt- 5 BULK INK TEM- Output from mixer tank
age to transducer PERATURE temperature sensor

2 +ve +ve output from 6 0V 0 V to temperature sen-

transducer sor

3 - ve - ve output from 7 +5 V +5 V DC to temperature

transducer sensor

4 0V 0 V to transducer 8 GND

Table 6-21: I/O Connector P/TRANS

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Willett 460, 460Mi and 460Pi Service Manual

HEAD_2 (14) - Printhead connector 2 via the umbilical

Pin Signal Function Pin Signal Function

1 VCC +5 V DC 7 0V

2 Not used 8 +5 V +5 V DC to temp sensor

3 Not used 9 HE temp Head temp sensor output

4 0V 10 0V 0 V to temp sensor

5 VCC +5 V DC 11 Head heater return

6 Fire sensor Fire sensor 12 +24 V +24 V to head heater

(not used at present)

Table 6-22: I/O Connector HEAD_2

CON_BM1 (15) - Ink pump motor driver board.

Pin Signal Function Pin Signal Function

1 +24 V Supplies to motor 5 ENABLE Enable ink pump motor

control board
2 0V 6 PRESS TRANS I/P Pressure transducer input

3 +15 V 7 REQ PRESS I/P Requested pressure input

4 - 15 V 8 GND

Table 6-23: I/O Connector CON_BM1

HEAD_1 (16) - Printhead connector 1 via the umbilical.

Pin Signal Function Pin Signal Function

1 +12 V +12 V DC to phase 6 0V 0 V connection to LED

detector amplifier cathodes

2 - 12 V - 12 V DC to phase 7 STROBE Strobe signal to LED anode

detector amplifier LED

3 0V 0 V connection to phase 8 Signal from phase detector

detector amplifier amp

4 GUTTER Oscillator signal to gutter 9 LID +ve to lid switch

DETECT detect SWITCH

5 0V 0 V connection to gutter 10 0V 0 V connection to lid switch

detect

Table 6-24: I/O Connector HEAD_1

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CON_P0 (17) - Interboard connector from I/O board to CPU board. It carries the DC voltages from
the PSU.
Pin Signal Function Pin Signal Function

1 to 4 0V 0V 11 and 12 - 15 V - 15 V DC to CPU

5 to 8 +5 V +5 V DC to CPU 13 and 14 GND

9 and 10 +15 V +15 V DC to CPU

Table 6-25: I/O Connector CON_P0

POWER (18) - PSU.

Pin Signal Function Pin Signal Function

1 15 V 15 V DC from PSU 5 +5 V +5 V DC from PSU

2 0V 0 V from PSU 6 +24 V +24 V DC from PSU

3 +5 V +5 V DC from PSU 7 0V 0 V from PSU

4 - 15 V - 15 V DC from PSU 8 - 24 V - 24 V DC from I/O board

Table 6-26: I/O Connector POWER

CH/MOD (19) - Printhead via the umbilical.

Pin Signal Function Pin Signal Function

1 CHARGE Charge amplifier output 3 mod 1a Modulation 0 V

2 0 V CHARGE Charge amplifier 0 V 4 mod 1b Modulation signal output

Table 6-27: I/O Connector CH/MOD

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EHT/FAN (20) - Cooling fan and EHT module.

Pin Signal Function Pin Signal Function

1 0V 0V 6 EHT + +ve supply to EHT module

2 +24 V SW +24 V DC (switched) 7 EHT - - ve supply to EHT module

3 PUMP +24 V DC 8 VCC +5 V DC

4 +24 V SW + 24 V DC (switched) 9 Lev 8 Spare digital input

fan

5 FAN - ve fan supply 10 0V 0V

Table 6-28: I/O Connector EHT/FAN

FAN_FAIL (21) - Fan failure sensor PCB.

Pin Signal Function Pin Signal Function

1 +ve in Fan fail +ve input (on the 460, 4

this pin is shunted to pin 6)

2 +5 V +5 V DC supply (on the 460, 5 0V 0 V supply

this may be used to power a
positive air pump)

3 6 - ve in Fan fail -ve input

Table 6-29: I/O Connector FAN_FAIL

CON_D (22) - Interboard connector from I/O board to CPU board.

Pin Signal Function Pin Signal Function

1 to 8 dd0 to dd7 Droplet charge data 10 0V Common

9 - Not used 11-20 - Not used

Table 6-30: I/O Connector CON_D

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 Willett 460, 460Mi and 460Pi Service Manual

B/LIGHT (24) - Backlight of the Liquid Crystal Display (LCD)

Pin Signal Function

1 +24 V +24 V DC to backlight inverter

2 - ve BKLT Backlight -ve supply

3 GND

Table 6-31: I/O Connector B/LIGHT

JB1 (23) Used to configure the photocell inputs PEC1 and PEC2.
PEC1 is connected to product error 1 via the connector panel.
PEC2 is connected to product error 2 via the connector panel.

Table 6-32: I/O Board Jumper

Test point Signal LED Color Function

TP1 (14) 0 V. LED1 (11) green Customer 10 V isolated

supply present.

TP2 (8) +285 V DC charge amplifier LED2 (9) red Charge amplifier supply.
supply.

TP3 (12) Ink temperature at viscom- LED3 (6) yellow -24 V.

eter delivery line.

TP4 (7) Charge voltage to print- LED4 (5) red -15 V charge amplifier.
head.

TP5 (13) Ink system pressure (1 V — LED5 (10) green +24 V valve/fan/heater
1 bar). supply.

TP6 (4) Modulation drive voltage to

printhead.

TP7 (2) Phase detector output prior

to hedgehog clipping.

TP8 (3) 0 V.

TP9 (1) +5 V (can be used with

logic probe).

Table 6-33: I/O Board Test Points and LEDs

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Willett 460, 460Mi and 460Pi Service Manual

(1) TP9
(2) TP7
(3) TP8
(4) TP6
(5) LED4
(6) LED3
(7) TP4
(8) TP2
(9) LED2
(10) LED5
(11) LED1
(12) TP3
(13) TP5
(14) TP1

Figure 6-13. I/O Board Test Points and LEDs

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 Willett 460, 460Mi and 460Pi Service Manual

Levels Board
1
27

21

20
2
19

18 26
4

17
5
16
24

25 7

8
15

23 13
14 12 11 10 9
22

(1) Connector JP1 (11) Connector JP8 (21) Connector JP13

(2) IC U2 (12) Connector JP6 (22) Connector JP102
(3) IC U3 (13) Connector JP7 (23) Connector JP103
(4) IC U4 (14) Connector JP5 (24) Transistor Q103
(5) Fuses (15) Connector JP4 (25) IC U101, IC U102
(6) Connector JP9 (16) Resistor barrier (26) Connector JP101
(7) Connector JP11 (17) Zener diodes (27) Connector JP15
(8) Connector JP2 (18) Connector JP14 (28) Connector JP104
(9) Connector JP10 (19) Connector JP12
(10) Connector JP3 (10) Connector JP16

Figure 6-14. Levels board components and connections

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Willett 460, 460Mi and 460Pi Service Manual

The Levels interface board is designed to interface the I/O board with the
level sensors. The level sensors use conductivity probes to detect the levels
of the fluids. Logic signals are produced, which are passed to the I/O
board. Additionally signals are passed to and from the I/O board, door
board and CPU.
There are six channels for the level sensors:
• Mixer low
• Mixer OK
• Mixer high
• VMS low
• VMS high
• Ink low

Level sensor circuitry

The level detection sensors use the conductivity of the ink to determine
when the level has been reached. Two probes are inserted into the
appropriate tank. One probe is fed with an AC signal and the other probe
is connected to ground. The signal level across the probes is monitored, if
it falls below a fixed threshold due to the ink bridging the probes, the
output logic signal changes state. AC is used as opposed to DC to prevent
any electrolytic action occurring.
An oscillator formed by U1B generates the AC signal. This produces a
square wave at its output (pin 7) of approximately 90 Hz at 16 volts peak
to peak. This is passed via RC network to “soften” the edges of the square
wave, to the input of a buffer amplifier U1A, providing a 16 volt peak to
peak signal. The signal’s DC content is removed by a capacitor and fed to
a potential divider formed by two resistors (100 k and 470 k). At this
junction of these resistors the signal is fed via the Zener barrier to the
probe, forming a parallel resistance across the 470 k resistor.
The anode of a signal diode is connected to the junction of the resistors,
forming a half wave rectifier circuit which charges a capacitor. This
capacitor holds a DC voltage of approximately 3.0 volts with the probes
uncovered. This voltage is compared with a reference voltage of 2.5 volts
(generated by REF1) at the inputs of the comparator (U3/U4). The
comparator outputs logic 1 when the probe is uncovered. When the probe
is covered with ink the AC voltage across the probe falls (junction of 470 k
ohm resistor) due to the conductivity of the ink. The DC voltage across the
charge capacitor also falls below the reference voltage and the output of
the comparator changes to logic 0.

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Zener barrier
The Zener barrier is designed to limit the amount of energy available at
the probes in the event of a fault in the printer electronics. The Zener
barrier limits the energy to a value less than would cause ignition of the
solvent. All probe connections have a combination of a wire wound
resistor, Zener diode and fuse between the probe connector and the
monitoring circuit. Each signal line to the probes has two parallel path of
series connected Zener diodes to the chassis connection. The series diodes
are connected anode to anode, giving a limited voltage across the signal
line of ±15.7 volts and with the parallel combination a limited fail safe
mode if a diode fails. The 0 volt connection has only one parallel set of
Zener diodes to the chassis connection.

Fuses
The fuse in each circuit is rated at 50 mA (fast blow) and protects the
circuits as follows:
• Fuse F1: mixer low circuit.
• Fuse F2: mixer OK circuit.
• Fuse F3: mixer high circuit.
• Fuse F4: VMS low circuit.
• Fuse F5: VMS high circuit.
• Fuse F6: ink tank sensor circuit.

Supplies
A 5 V supply is for the ICs is provided by a +5 V shunt regulator IC
(REG1). The input of the regulator is connected to the +15 V voltage rail.
C1 and C2 provide decoupling for the regulator.

LED drivers
A seven stage Darlington drive IC provides two channels (ink low and top
up low), via two 470 Ohm resistors, to drive the ink low and top up low
LEDs.

Peltier circuit
The Peltier cooling device (condenser) is switched on and off using a
mosfet transistor Q103. This transistor is controlled by the PIGS output on
the I/O board. This output is controlled by software and it switches on
when the cabinet temperature reaches a set value above ambient
temperature.
Software also disables the condenser if the viscosity value is 2 points too
thin compared to the set value.

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Willett 460, 460Mi and 460Pi Service Manual

The cabinet temperature is measured by temperature sensor U21 on the I/

O board.
The switch on the Peltier draws approximately 2 A from the +5 V supply
rail but this then drops to approximately 1 A after about 5 minutes. A 2.5
A anti-surge fuse F102 protects the Peltier and transistor circuit.

Stirrer motor controller (460 Pi only)

The mixer and reservoir tanks of the pigmented machines require their
contents to be stirred to prevent the ink pigment separating from the
solvent. A magnetic follower stirrer bar is used inside the two tanks with a
stirrer motor and rotating magnet outside the tank. There are
circumstances which cause the stirrer to stall. The motor controller is
designed to detect this situation and take corrective action. The controllers
for both stirrers are identical.
The stirrer motor is a 24 V brushless fan with a circular magnet attached to
its rotor. Adjusting the supply voltage controls the speed.
The controller monitors the motor current and amplifies the current pulses
caused by the motors internal switching circuit. These pulses are applied
to a tachometer circuit (U101 and U102) which acts as a frequency to
voltage converter. As the motor speed increases the pulse frequency
increases and the tachometer output voltage increases. This is added to an
offset voltage and inverted by op amp U103. The output voltage from this
op amp thus decreases as the motor speed increases and is used to drive
the stirrer motor via an emitter follower.
At start up the motor speed is zero and the op amp output is
approximately 14 V due to the offset, giving the motor the maximum
starting power to overcome any start up resistance. As the motor speed
increases the op amp output voltage, the motor drive voltage reduces,
until a stable running voltage is reached. This is normally around 5.5 V
with the motor running unloaded. If the load on the motor is increased, it
slows down and causes the drive voltage to increase. This process
continues until a stable running voltage is achieved. If the motor stalls, the
drive voltage increases to approximately 14 V, thus applying maximum
power to the motor, which causes the motor to start rotating within 2-3
seconds.

Optical level sensor circuit

The signals that are required to drive the optical level sensor probe in the
top-up solvent tank are taken directly from the I/O board and are routed
via connectors JP1 and JP10 to the optical level sensor. There is no active
circuitry on the Levels board to control this sensor.

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Gutter pump control circuit (460 Pi only)

A +24V supply is present at JP9 pin 4 and is routed via a 250mA anti-surge
fuse to JP104 pin 1. This fuse is used to protect the gutter pump driver
mosfet Q104. The open collector output from the ULN2803 (I/O board
U19) is located on JP9 pin 5 and is pulled up to +5V using R130. Mosfet
Q105 inverts this signal and provides the gate drive for the gutter pump
driver Mosfet Q104. Diode D38 protects Q104 against back EMF when the
gutter pump switches off.

Levels-out (1) - Interconnection signals between I/O board and Levels board

Pin Signal Function Pin Signal Function

1 to 3 - - 24 INK LOW Logic Signal. To

I/O board.

4 MIXER Logic signal. 25 +5V Optical sensor

LOW To I/O board. LED anode

5 to 7 - - 26 +5V Optical sensor

phototransistor
collector

8 MIXER Logic signal. 27 0V Optical sensor

OK To I/O board. LED cathode

9 to 11 - - 28 Solvent Optical sensor

top-up low phototransistor
emitter

12 MIXER Logic signal. 29 +15V Supply in

HIGH To I/O board.

13 to 15 - - 30 0V Supply in

16 VMS Logic signal. 31 -15V Supply in

LOW To I/O board.

17 to 19 - - 32 0V Supply in

20 VMS Logic signal. 33 Chassis

HIGH To I/O board. ground

21 to 23 - - 34 Chassis
ground

Table 6-34: Levels out connector JP1

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Willett 460, 460Mi and 460Pi Service Manual

Door switch (8) - Door switch connections

Pin Signal Function

1 0V Door switch return

2 DOOR SWITCH Door switch signal

3 - -

Table 6-35: Door switch connector JP2

Res-levels (15) - Ink top-up tank probe connections

Pin Wire Signal Function Pin Wire Signal Function

Color Color

1 Brown CHASSIS Ink reservoir low 5 CHASSIS 0V

GROUND common probe GROUND

2 Red INK LOW Ink reservoir low 6 CHASSIS 0V

PROBE signal probe GROUND

3 0V Top-up reservoir low 7 CHASSIS 0V

common probe GROUND

4 CHASSIS 0V 8 CHASSIS 0V
GROUND GROUND

Table 6-36: Reservoir connector JP4

FMS-levels (14) - FMS ink system probe connections

Pin Wire Signal Function Pin Wire Signal Function

Color Color

1 Black CHASSIS Mixer low 6 White MIXER HIGH Mixer high

GROUND common probe PROBE probe

2 Red MIXER LOW Mixer low 7 CHASSIS VMS low

PROBE signal probe GROUND common probe

3 CHASSIS Mixer OK 8 Pink VMS LOW VMS low probe

GROUND common probe PROBE

4 Yellow MIXER OK Mixer OK probe 9 CHASSIS VMS high

PROBE GROUND common probe

5 CHASSIS Mixer high 10 Blue VMS HIGH VMS high

GROUND common probe PROBE probe

Table 6-37: Ink system connector JP5

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 Willett 460, 460Mi and 460Pi Service Manual

EHT (11) - Connections for EHT module

Pin Signal Function

1 EHT + +ve supply to EHT module

2 EHT - -ve supply to EHT module

3 - -

Table 6-38: EHT Connector JP8

IO-fan-EHT (6) - Supply rails & control signals between I/O and Levels boards

Pin Signal Function Pin Signal Function

1 0V Power ground 6 EHT+ +ve supply to

EHT module

2 +24V DC Fan power 7 EHT- -ve supply to

(switched) (switched) EHT module

3 0V Power ground 8 +5V +5V supply to

Peltier

4 - - 9 DOOR Door closed

SWITCH detection

5 AUTO OFF Active low signal 10 0V Power ground

SOURCE from I/O board

Table 6-39: FAN/EHT connector JP9

Res/LEDs (9) - Connection details for optical level sensor ink low LED and top-
up low LED

Pin Signal Function Pin Signal Function

1 +5V Optical sensor LED 6 Ink low Ink low LED

anode LED sink drive

2 +5V Optical sensor pho- 7 +15V Supply to ink

totransistor collector low LED

3 0V Optical sensor LED 8 Top-up low Top-up LED

cathode LED sink drive

4 Top-up Optical sensor pho- 9 +15V Supply to

low totransistor emitter top-up LED

Table 6-40: Res/LEDs JP10

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Willett 460, 460Mi and 460Pi Service Manual

Fans (7)

Pin Signal Function Pin Signal Function

1 +24V DC Fan power 4 0V Fan return

(switched)

2 0V Fan return 5 - -

3 +24V DC Fan power

(switched)

Table 6-41: Fans Connector JP11

IO-LCD (19)

Pin Signal Function Pin Signal Function

1 GND Chassis ground 11 AD0 Data line bit 0

2 0V Power ground 12 AD1 Data line bit 1

3 VCC +5V 13 AD2 Data line bit 2

4 CONTRAST LCD contrast 14 AD3 Data line bit 3

5 WR Write 15 AD4 Data line bit 4

6 RD Read 16 AD5 Data line bit 5

7 LCD CE LCD chip enable 17 AD6 Data line bit 6

8 LA1 Control bus bit 7 18 AD7 Data line bit 7

9 - - 19 0V Font select

10 RESET LCD controller 20 SEL5 Select inverse

reset video

Table 6-42: I/0 LCD connector JP12

IO-LEDS (21)

Pin Signal Function Pin Signal Function

1 Red LED source Switched positive feed 5 Red LED return 0V return

2 Yellow LED source Switched positive feed 6 Yellow LED return 0V return

3 Green LED source Switched positive feed 7 Green LED return 0V return

4 - - 8 - -

Table 6-43: LED connector JP13

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 Willett 460, 460Mi and 460Pi Service Manual

IO-BLIGHT (18)

Pin Signal Function Pin Signal Function

1 24V Backlight supply 3 - -

2 BACKLIGHT SINK Switched 0V return

Table 6-44: Backlight connector JP14

IO-KBRD (27)

Pin Signal Function Pin Signal Function

1 CHASSIS EMC earth 12 SL1 Scan line 1

GROUND connection

2 ALT Alternate key 13 SL2 Scan line 2

3 CTL Control key 14 SL3 Scan line 3

4 SFT Shift key 15 SL4 Scan line 4

5 0V Power ground 16 SL5 Scan line 5

6 SL7 Scan line 7 17 SL6 Scan line 6

7 RL0 Return line 0 18 RL4 Return line 4

8 RL1 Return line 1 19 RL5 Return line 5

9 RL2 Return line 2 20 RL6 Return line 6

10 RL3 Return line 3 21 RL7 Return line 7

11 SL0 Scan line 0 22 CHASSIS EMC earth

GROUND connection

Table 6-45: I/0 keyboard connector JP15

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Willett 460, 460Mi and 460Pi Service Manual

DOOR-PCB (20)
Pi Signal Function Pin Signal Function
n
1 24V Backlight supply 26 0V Font select
2 BACK- Switched 0V 27 AD7 Data line bit 7
LIGHT SINK return
3 CHASSIS EMC earth 14 AD6 Data line bit 6
GROUND connection
4 ALT Alternate key 29 AD5 Data line bit 5
5 CTL Control key 30 AD4 Data line bit 4
6 SFT Shift key 31 AD3 Data line bit 3
7 0V Power ground 32 AD2 Data line bit 2
8 SL7 Scan line 7 33 AD1 Data line bit 1
9 RL0 Return line 0 34 AD0 Data line bit 0
10 RL1 Return line 1 35 RESET LCD controller
reset
11 RL2 Return line 2 36 - -
12 RL3 Return line 3 37 LA1 Control bus bit 7
13 SL0 Scan line 0 38 LCD CE LCD chip
enabled
14 SL1 Scan line 1 39 RD Read
15 SL2 Scan line 2 40 WR Write
16 SL3 Scan line 3 41 CONTRAST LCD contrast
17 SL4 Scan line 4 42 VCC +5V
18 SL5 Scan line 5 43 0 VOLTS Power ground
19 SL6 Scan line 6 44 GND Chassis ground
20 RL4 Return line 4 45 GREEN LED Switched
SOURCE positive feed
21 RL5 Return line 5 46 GREEN LED 0V return
RETURN
22 RL6 Return line 6 47 YELLOW LED Switched
SOURCE positive feed
23 RL7 Return line 7 48 YELLOW LED 0V return
RETURN
24 CHASSIS EMC earth 49 RED LED Switched
GROUND connection SOURCE positive feed
25 SEL5 Select inverse 50 RED LED 0V return
video RETURN

Table 6-46: Door PCB connector JP16

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 Willett 460, 460Mi and 460Pi Service Manual

Consenser control (28) - Condenser control

Pin Signal Function Pin Signal Function

1 +24V +24V supply 4 - -

2 Pigs out Condenser on/off control 5 - -

3 - - 6 - -

Table 6-47: Condenser control connector JP101

Peltier (28) - Peltier output control

Pin Signal Function Pin Signal Function

1 +5V +5V supply to Peltier 4 0V 0V

2 +5V +5V supply 5 - -

3 Peltier sink Peltier drive voltage

Table 6-48: Peltier control connector JP102

Stirrers (23) - Connection details for ink stirrers 1 and 2

Pin Signal Function Pin Signal Function

1 - - 4 Stirrer 2 +V supply to
supply stirrer 2

2 Stirrer 1 +V supply to 5 Stirrer 2 Stirrer 2 return to

supply stirrer 1 return control circuit

3 Stirrer 1 Stirrer 1 return to

return control circuit

Table 6-49: Stirrers connector JP103

Gutter pump (28) - Connection details for the gutter pump

Pin Signal Function

1 +V supply to pump +24V supply to gutter pump

2 - -

3 Gutter pump sink Gutter pump drive output

Table 6-50: Gutter pump connector JP104

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Willett 460, 460Mi and 460Pi Service Manual

Liquid Crystal Display Door Board

The LCD door board provides a mounting plate for the LCD module,
backlight inverter and the connection interface from these devices to the
Levels board. The front panel keyboard connecting route through this
board has no active circuitry. The three LED drivelines are protected from
external voltage spikes by the inclusion of a varistor surge suppressor
across each LED device.

Figure 6-15. LCD Door Board

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 Willett 460, 460Mi and 460Pi Service Manual

Expansion Board
The expansion board is optional to the 460, 460Mi and 460Pi printers. The
expansion board connects to the I/O board and offers the external
message selection and time of flight compensation options.

5 7 9

8
23

10
4

22

3
11
21

12

20 15

13
19

14

18

17 16

(1) Jumper W1 (7) PEC2_IN (13) MSG_A (19) MODEM

(2) Jumper W2 (8) PEC2_OUT (14) MSG_B (20) RS-232
(3) Jumper W3 (9) SENC_IN (15) POWER1 (21) CON_LAN
(4) Jumper W4 (10) SENC_OUT (16) CON_EX (22) RS1
(5) PEC1_IN (11) RELAYS1 (17) POWER2 (23) 20mA
(6) PEC1_OUT (12) OPTO_OUT (18) S1

Figure 6-16. Expansion board connectors and jumpers

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Willett 460, 460Mi and 460Pi Service Manual

External Message Select

The External Message Select input is an 8 bit wide input from two BCD
switches. Each of the input lines comprises a 3 kW current limiting
resistor, which is part of DIL1 and an opto isolator LED, which is part of
U4 (LSD) and U8 (MSD).
The LED is illuminated when the input is low.
The supply to the input switches is selected by links W1 and W2 and can
be either the internal 24 V supply or an external supply of between 10 V
and 30 V.
The opto isolator outputs are inverted by U1 and U5 and fed to the octal
latch/buffer U3, which is connected to the processors data bus enabling
the software to read the message select input. Up to 99 messages can be
selected. All connections to the external connectors are made through
EMC filters.

Relay and Opto-isolated Outputs

There are two change over relay outputs and four opto isolated outputs
available for control of external equipment. These outputs are driven from
an octal latch U7 connected to the processors data bus.
• Outputs Q0 to Q6 of the octal latch drive a Darlington driver U21,
which drives the relays RL1, RL2 and the opto isolators U9.
• Outputs Q0 to Q3 drive the opto isolators.
• Outputs Q4 and Q5 drive the relays.
• Output Q6 drives the Time of Flight Correction edge select opto
isolator and an LED indicator.
• Output Q7 and its associated Darlington driver are currently spare.
The relay and opto isolator outputs are fed through filters to improve the
EMC performance.
Each opto isolator is capable of switching up to 10 mA at 24 V and each
relay contact is capable of switching 5 A at 24 V.

Warning
LETHAL VOLTAGES. Under no circumstances must mains voltages
be switched directly from these contacts. If mains voltage is required
to be switched by these relays an intermediate relay must be used.

Note: Although the relay contacts are rated for mains voltage operation the filters
and the connectors are not and would not comply with the Low Voltage Directive.

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Additional Serial Comms Port

The second Comms port, COM2, from the CPU can be configured as
RS232, RS485 or 20 mA loop interface. When configured as RS232, an
internal modem can be driven or a second RS232 port can be used. Only
one interface configuration can be set up at a time. The RS485 output can
be terminated if required with link W4.
A MAX232, U13, is used as the RS232 driver with a MAX485, U14 used as
the RS485 driver and an HCPL4100 and HCPL4200 are used as the 20 mA
loop driver. The 20 mA transmitter and receiver connections are available
separately.
The logic level TX data line from the DUART on the CPU is connected to
all three drivers. The logic level DUART receive input is connected to one
of the interfaces via a link, W3, which selects which of the interfaces is
used.
The transmit handshake line is converted to RS232 levels and is available
on the MODEM and RS232 connectors. It is also used to control the
transmit/receive switching of the RS485 interface.
The RS 232 interface has two connectors, a 25 W D type (MODEM) and a 6
W HE14 (RS232). The two connectors cannot be used together and are
arranged so that if a modem is fitted, the RS232 connector cannot be fitted
and vice versa. The RS232 lead is the same lead used to connect the
standard RS232 DIN connector to the RS232 port on the CPU board.

Note: When the additional Comms Port is being used, it is important that link
W3 on a Mk2 CPU board is removed as this interferes with the received data.

The modem can be powered from either the internal 12 V supply or an

external 12 V supply dependant on the settings of S1.
LED2 is illuminated when modem power is available. LED D1 indicates
the DCD output from the modem.

Time Of Flight Correction

The Time Of Flight Compensation is used to compensate for the positional
error of the print in applications where the product line speed varies. The
circuit doubles the number of shaft encoder pulses for a pre-set period
triggered by the photocell 1 input. The pre-set period is dependent on the
print head to product distance and is controlled by RV1.
The sequence of events is as follows:
• The Photocell input 1 PEC1_IN1 is triggered by the product, which
causes a negative going edge at monostable U18A pin 11.

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• The output of the monostable, pin 10, is a logic 1 for the duration of
the compensation period. This is used to enable a second monostable
U18B. The compensation period is adjustable by means of RV1.
• This second monostable is triggered by the delayed negative edge of
the shaft encoder pulse. The delay is approximately 3.8 us.
• The monostable output is a positive pulse of approximately 2.8 us.
This is added to the shaft encoder pulse by the exclusive OR gate
U16C.
Thus when the photocell is triggered an extra pulse is added to each shaft
encoder output pulse for the duration of the compensation period.
The photocell type for PEC1 and PEC2 (PNP/NPN), can be selected by
links on JB1. The setting of this is identical to the photocell type selection
on the I/O board.
The trigger pulse from PEC1 is passed through an exclusive OR gate to
select which edge triggers the compensation circuit. This is controlled by
the Q6 output from the opto isolator driver. The default configuration is
for the circuit to trigger on the positive edge of the photocell pulse. This is
usually the leading edge of the product. When the yellow LED D3 is
illuminated the circuit triggers on the negative photocell edge.
A mathematical description of the operation of the Time Of Flight
Compensation circuit is available as a separate document.
Filters are used on the photocell and shaft encoder inputs to improve the
EMC performance.

Port Address Locations

The serial comms port is controlled as PORT B of the DUART (U9) on the
CPU board.
The Time of Flight Compensation circuit does not have an address since it
is dedicated hardware only.
The MESSAGE SELECT PORTS are READ at location #280 with
MESSAGE A as the Least Significant nibble of the data bus and MESSAGE
B as the Most Significant nibble.
The OPTO OUTPUT PORT and the RELAYS PORT are WRITTEN to at
location #280. The significance of each bit is as follows:
• bit 0OPTO OUTPUT CHANNEL 1
• bit 1OPTO OUTPUT CHANNEL 2
• bit 2OPTO OUTPUT CHANNEL 3
• bit 3OPTO OUTPUT CHANNEL 4
• bit 4OUTPUT CHANGEOVER RELAY 1

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• bit 5OUTPUT CHANGEOVER RELAY 2

• bit 6TIME OF FLIGHT COMPENSATION TRIGGER EDGE (0 = +ve, 1
= -ve)
• bit 7not used
The TACHO INPUT/AUTOMATIC TEST RIG FEEDBACK SIGNAL is
routed through this board to the seventh channel of the A to D converter
on the I/O board at location #2A0.

W1 and W2 Message Select Power

1-2 Internal

2-3 External, 10V - 30V

W3 Serial Comms

1-2 RS-232 or Modem

2-3 RS-485

4-5 20mA loop

W4 RS-485 Termination

1-2 270R termination

2-3 Not terminated

JB1 Links Photocell Polarity

A-B and C-D PEC1 NPN

B-C and D-E PEC1 PNP

F-G and H-I PEC2 NPN

G-H and I-J PEC2 PNP

S1 Modem Power

1 and 4 ON Internal 12V supply

2 and 3 OFF

1 and 4 OFF External 12V supply

2 and 3 ON

1 and 4 ON Internal 12V supply and 12V available

2 and 3 ON for powering external equipment

Table 6-51: Expansion board link and switch settings

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Willett 460, 460Mi and 460Pi Service Manual

PEC1_IN (2) - connected to the product sensor via the connector panel

Pin Signal Function Pin Signal Function

1 VDD Positive DC supply 3 VSS 0V common

to sensor

2 - Output from PEC1

Table 6-52: Expansion board connector PEC1_IN

PEC1_OUT (3) - connected to the PEC1 connector located on the I/O board

Pin Signal Function Pin Signal Function

1 VDD Positive DC supply 3 VSS 0V common

to sensor

2 - Output from PEC1

Table 6-53: Expansion board connector PEC1_OUT

SENC_IN (4) - connected to a shaft encoder via the connector panel

Pin Signal Function Pin Signal Function

1 VDD Positive DC supply 3 - Output B from shaft

to shaft encoder encoder

2 - Output A from shaft 4 VSS 0V common

encoder

Table 6-54: Expansion board connector SENC_IN

SENC_OUT (5) - connected to the SENC connector located on the I/O board

Pin Signal Function Pin Signal Function

1 VDD Positive DC supply 3 - Output B from shaft

to shaft encoder encoder

2 - Output A from shaft 4 VSS 0V common

encoder

Table 6-55: Expansion board connector SENC_OUT

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 Willett 460, 460Mi and 460Pi Service Manual

20mA (6) - for connection to a 20mA current loop communications link (COM 2)
via the connector panel

Pin Signal Function Pin Signal Function

1 TX+ Transmit loop +ve 5 TX- Transmit loop -ve

2 - Linked to pin 6 6 - Linked to pin 2

3 RX+ Receive loop +ve 7 RX- Receive loop -ve

4 - Linked to pin 8 8 - Linked to pin 4

Table 6-56: Expansion board connector 20mA

MSG_A (8) and MSG_B (7) are the connectors for 8 opto coupled inputs for
BCD message select

Pin Signal Function Pin Signal Function

1 db0 Data bit 0 5 db2 Data bit 2

2 0V 6 0V

3 db1 Data bit 1 7 db3 Data bit 3

4 0V 8 0V

Table 6-57: Expansion board connector MSG_A

MSG_A (8) and MSG_B (7) are the connectors for 8 opto coupled inputs for
BCD message select

Pin Signal Function Pin Signal Function

1 db4 Data bit 4 5 db6 Data bit 6

2 0V 6 0V

3 db5 Data bit 5 7 db7 Data bit 7

4 0V 8 0V

Table 6-58: Expansion board connector MSG_B

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CON_232 (9) - serial communications port which is configured for the RS-232
protocol and is connected to the CPU board

Pin Signal Function Pin Signal Function

1 TXD Transmit data 4 DCD Data carrier detect

2 DTR Data terminal ready 5 Common Common

3 RXD Receive data 6 - Not used

Table 6-59: Expansion board connector CON_232

CON_EX (10) - interboard connector that connects the expansion board to the
I/O board

Pin Signal Function Pin Signal Function

1 VCC +5V DC 16 0V

2-9 db0 to Data bus bits 0 to 7 17 0V

db7

10 - External message select 18 +24V

11 - Opto-isolated output select 19 - Not used

12-14 - Not used 20 GND

15 TACH0

Table 6-60: Expansion board connector CON_EX

MODEM (13) - for connection of the optional modem, which fits directly onto
the connector

Pi Signal Function Pin Signal Function

n

1 Not used 9 Positive supply

2 TXD Transmit data 10-14 Not used

3 RXD Receive data 15 Positive supply

4-6 Not used 16-19 Not used

7 Ground 20 DTR Data terminal

ready

8 DCD Data carrier 21-25 Not used

detect

Table 6-61: Expansion board connector MODEM

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OPTO_OUT (14) - the connector for four uncommitted opto-coupled outputs

via the connector panel

Pin Signal Function Pin Signal Function

1 01+ Opto output 1 +ve 5 03+ Opto output 3 +ve

2 01- Opto output 1 -ve 6 03- Opto output 3 -ve

3 02+ Opto output 2 +ve 7 04+ Opto output 4 +ve

4 02- Opto output 2 -ve 8 04- Opto output 4 -ve

Table 6-62: Expansion board connector OPTO_OUT

RELAYS (15) - the connector for the change over relays output via the connector panel

Pin Signal Function Pin Signal Function

1 - RL1 normally open contact 4 - RL2 normally open contact

2 - RL1 normally closed contact 5 - RL2 normally closed contact

3 - RL1 changeover contact 6 - RL2 changeover contact

Table 6-63: Expansion board connector RELAYS

CON_LAN (17) - for connection to the CPU board

Pin Signal Function Pin Signal Function

1 Not used 5 DTR Data terminal ready

2 VCC +5V DC 6 0V Common

3 RXDB Receive data 7 Not used

4 TXDB Transmit data 8 Not used

Table 6-64: Expansion board connector CON_LAN

RS485 (18) - for connection to an RS-485 communications link (COM2 via the
connector panel

Pin Signal Function Pin Signal Function

1 -ve Data A 3 Common

2 +ve Data B 6

Table 6-65: Expansion board connector RS485

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Ink Pump Motor Driver Board

Figure 6-17. 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. It contains the controller logic
and drive circuits to control the three phase brushless motor with Hall
effect position sensors, which are used to drive the pump.
The speed of the motor is determined by the Pulse Width Modulation
(PWM) input from the I/O board and feedback from the pressure
transducer. The PWM level is buffered by U4A and the pressure signal is
inverted by U4B. These signals are combined in the error amplifier U4C
with an offset generated by R24 and the -12 V supply. U4C and U4D form
an integrator with a time constant of 100 ms defined by C6 and R18. The
output of the integrator is coupled to the motor controller via diode D1
preventing the input to the controller becoming negative. The effect of the
pressure feedback and the integrator reduces the motor speed as the
pressure reaches the level set by the PWM input. The motor speed is
regulated by the controllers internal PWM circuit.
The motor controller IC receives position signals from the hall effect
sensors on the motor. The internal logic determines which of the output
drivers are active. The output drivers drive six power FETs which switch
power to the motor coils. Only two FETs, one P channel top FET and one
N channel bottom FET are on at any time. The sources of the bottom FETs
are fed through a sensing resistor, which feeds a voltage proportional to
the motor current into the controller. If the voltage exceeds 100 mV,
equivalent to a 2 A motor current, the controller uses its internal PWM
system to reduce the motor drive current.

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The amplifier/integrator U4 power supply is ± 12 V derived from the ± 15

V supplies from the I/O board. And the motor supply is taken from the
+24 V supply via an adjustable 3 A regulator set to a nominal 22.5 V. The
Hall effect sensors are supplied from the 6.25 V reference supply from the
controller IC.
The motor controller PCB has two links fitted to enable the sensors to be
either 60 degree or 120 degree types controlling the direction of the motor.
The normal configuration of the board has no links fitted.
The controller is also capable of driving a brushed motor by setting the
sensor inputs to a fixed configuration and using only two of the motor
driver outputs. This can be most easily achieved by wiring the motor
connector to the required configuration. It is then possible to use the same
motor controller and I/O boards in machines using both brushed and
brushless motors without changing the board set up.
Also included on this board is a circuit to oscillate the gutter valve on and
off at a pre-selectable frequency of 5 Hz or 7 Hz. Selectable by J4, which
can also disable the circuit. The effect of this circuit is to reduce the solvent
consumption caused by sucking back excess air. This valve oscillation
only occurs when the machine is printing, or is ready to print. i.e. EHT is
on, therefore it is inhibited when the EHT is off via J5 and J3 pin 1 going
low. When the EHT is on ISO1 shorts out R44 therefore pulling the
reference on U7 pin 13 up and enabling a square wave output from the
comparator U7d.

Note: The circuit described above is permanently disabled on the 460Pi printer.

The Quad Op-Amp U7 forms an astable oscillator which creates a

triangular wave output on pin 8 which is fed into the comparator to
generate the square wave output required to switch Q7 on and off. R 40 is
used to adjust the mark/space ratio of the signal.
There is also a small circuit designed to prevent the feed valve from
overheating if left on for long periods.
The valve requires an electrical signal of 24 V for it to switch on, although
once it is switched on it only requires approximately 12 V to remain
energized. A hit and drop circuit is used which switches R47 in series with
the feed valve 250 ms after retracting, reducing the voltage flowing across
it. This is achieved by Q8 becoming turned on when the feed valve is
switched on by J2 pin 10 going low. 250 ms later C13 charges up allowing
the gate voltage to drop and for Q8 to turn off.
D5 protects the I/O board from damage due to C11 discharging during
power down. D2 & D6 are flywheel diodes which reduce the back EMF
generated by the gutter valve, and the feed valve, respectively.

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Motor control board connector. Ref: VALVES

Pin Wire color Valve destination Pin Wire color Valve destination

1 Gray or red/white V1 9 White V6

2 Clear or blue/white V1 10 Black V6

3 Pink V2 11 Brown V8

4 Violet V2 12 Red V8

5 Green V3 13 Violet V11 feed valve

6 Blue V3 14 Pink V11 feed valve

7 Orange V7 15 Green V12 bleed valve

8 Yellow V7 16 Blue V12 bleed valve

Table 6-66: Motor control board valve connectors

Motor control board connector. Ref: I/O VALVES

Pin Wire color Valve destination Pin Wire color Valve destination

1 Black PIN 1 9 Blue PIN 9

2 Brown PIN 2 10 Violet PIN 10

3 - 11 -

4 Red PIN 4 12 Gray PIN 12

5 Orange PIN 5 13 -

6 Yellow PIN 6 14 White PIN 14

7 - 15 Turquoise PIN 15

8 Green PIN 8 16 Pink PIN 16

Table 6-67: Motor control board I/O valve connectors

The 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. This is achieved with the circuit shown in Figure 6-18.

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24V SUPPLY

TP34 D9
GF1B

1
TO VALVE

1
C14

2
4
100n
R54
280R

R53
360k

3
CONTROL

D11 Q10
GF1B BSP17

Figure 6-18. Pico Valve Control Circuit

The valve is connected between TO VALVE line and the 24 V SUPPLY

line.
When the valve is switched on the IO PCB driver pulls the “CONTROL”
line low, which pulls the source of the FET low. The gate is held high by
C14, and the FET is turned on, and the drain remains close to the
CONTROL rail, thus the valve has 24 V across it.
As R53 charges C14, after approximately 50 ms the gate/source voltage
drops to a point where the FET turns off, effectively leaving the valve in
series with R54. As this is 280 ohms and the valve is 280 ohms, there is a
potential of 12 V across the valve.
When the software turns the valve off, the CONTROL line is made open
circuit by the IO PCB driver.
The valves resistance and R54 in series pull the CONTROL line up to 24 V,
which discharges C14 via D11.
D9 ensures that the back EMF from the valves inductance does not exceed
the FET’s maximum voltage rating.

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PSU Board

General Specification
The PSU (Item 1 in Figure 6-8) 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.

Operating temperature 0 to 50 ºC.

Storage temperature -20 to 85 ºC.

Cooling Free air convection.

Efficiency 80% typical.

Holdup time 20 ms.

Overvoltage type crowbar, trip point 5.9 V to 7 V.

Overload protection Foldback.

Switching frequency >30 Kilohertz (kHz).

Designed to comply UL478, 1012, CSA22.2, VDE0806.

with

EMI Meets FCC class “B”.

Table 6-68: PSU Board General Specification

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 Willett 460, 460Mi and 460Pi Service Manual

Output Specification

Output Voltage Load A Tolerance Ripple Noise Line Reg Load Reg
(V) (+/- %) (mV) (%) (%)
Min Rated Max

+5 0.5 4 8 1 50 1 1

+15 0 0.5 1 10 100 2 8

-15 0 0.5 1 10 100 2 8

+24 V 0.1 2 2.5 5 150 1 5

Table 6-69: PSU Board Output Specifications

Notes:Each output can provide up to a maximum load, but total load cannot
exceed 85 W continuously.
+5 V output is adjusted to +/- 1% at 60% rated load at factory.
Tolerance is measured with all outputs at 60% rated load.
Line regulation is measured from low line to high line at rated load.
Load regulation is measured by +/- 40% load change from 60% rated load, and all
other outputs is kept at 60% rated load.
Ripple and noise is measured by using a 12" twisted wire terminated with a 47µF
capacitor.
Efficiency is measured at rated load.
All parameters except line regulation are specified at 115/230 VAC input, rated
load, 25º C ambient.

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Electronics Modules
(1) Ink system pump
(2) Electronics compartment
cooling fans
(3) EHT module

Figure 6-19. Printer Electronics Modules

Ink System Pump

The ink system pump (Item 1 in Figure 6-19) provides the flow of ink to
drive the ink system. The motor is a brushless DC type. The pump head is
a geared type producing ink flow from two rotating meshed gears.

Note: The 460Pi uses a more heavy duty pump than the 460Si and the 460Mi in
order to handle more abrasive pigmented inks.

Electronics Compartment Cooling Fans

Three cooling fans (Item 2) are provided to cool the electronic equipment.
The lower door fan extracts air from the inner compartment and circulates
it around the door area to provide additional surface area to aid cooling.
The air is then re-circulated back into the electronics compartment via the
upper door fan. The fan on the left side of the cabinet blows external air
onto the electronics.

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EHT Module
The EHT module (Item 3) generates the extra high tension voltage
required by the high voltage deflector electrode.

Mains Input Circuit

The AC mains supply (Figure 6-20) is supplied, via three core cable to the
mains filter. 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. The output from the On/Off switch is fed to
connector TB1 on the PSU via fuses 1 and 2. Fuse ratings are 1.35 A for a
220/240 V supply and 5 A for a 110 V supply.

PSU

F1 TB1
N
N
F2 L
L
E

Figure 6-20. Mains Input Circuit

The live and neutral lines are protected by separate fuses.

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Willett 460, 460Mi and 460Pi Service 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. Figure 6-21 shows the ink system
components.

1 2 3

W
3
O
L

7
F

(1) Ink reservoir (8) Ink system pump

(2) Condenser (9) Flush pump
(3) Solenoid valves (10) Gutter pump
(4) Top-up reservoir (11) Pressure damper (hidden)
(5) Pre-pump filter (12) Ink reservoir stirrer
(6) Fluid management system (FMS) (13) Mixer tank stirrer
(7) Main filter

Figure 6-21. Ink System Components

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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 are all of the same
design. The valves are single-acting, operated by an electrical actuator
(solenoid) with spring return. The flow is from the common port, “C”
(Item 3 in Figure 6-22) to the normally open port “R” (1) when the valve is
not energized (off). When energized (on) the flow is from the common
port to the normally closed port “P” (2). Valves V11 and V12 are miniature
shut-off valves and are mounted on the heater block within the printhead.

(1) Normally open port (R)

(2) Normally closed port (P)
(3) Common port (C)

Figure 6-22. Solenoid Valve

2-port valves have a blanking plug welded over the “R” port. 3-port
valves have a barb fitted at the “R” port.

V1 Solvent Top-up Valve (located at the solvent top-up reservoir)

When V1 is energized, solvent top-up is drawn through the valve under
vacuum from the venturi.
V1 is pulsed for periods of up to 5 seconds when the VMS system detects
that the ink viscosity is at least 1 second too thick.
V1 is a 2-port valve.

V2 Ink Top-up Valve (located at the ink reservoir)

When V2 is energized, replenishment ink is drawn through the valve
under vacuum from the venturi.
V2 is energized when the level of the ink in the FMS mixer tank falls below
the “Mixer tank OK” ink level detector.
V2 is a 2-port valve.

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V3 VMS Diverter Valve (located on the FMS ink system)

The VMS diverter valve controls the flow of ink into the VMS chamber via
restrictor (R1), which controls the ink viscosity.
V3 is energized when the VMS system becomes operational under
software control or when the ink level falls below the VMS “low level
detect” probe.
V3 is de-energized after a short time delay once ink is detected by the VMS
“high level” detect probe.
The time taken for ink to flow out of the VMS chamber through a restrictor
orifice between the high and low level detect probes determines the ink
viscosity.
When V3 is de-energized, the flow of ink is directed into FMS mixer tank.
V3 is a 3-port valve.

V6 Feed Valve (located on the FMS ink system)

The feed valve is used to control the flow of ink to the printhead.
When V6 is energized, ink is allowed to flow to V11 in the printhead and
out through the nozzle.
On 460 Si and 460 Mi printers, V6 is a 2-port valve, identical to V1 and V2.
On 460 Pi printers, a unique valve is used for V6. This stem of this version
of the feed valve has a metal A1 barb containing a small restrictor hole.
When the jet is not running but the pump is, this hole periodically allows a
small flow of ink to pass through V6 to the gutter valve (V8). This helps
ensure that ink does not build up and eventually block the valve.

V7 Flush Valve (located on the FMS ink system)

The flush valve provides either vacuum (which is derived from the
suction side of the main system pump) or pressure to the flush solvent
which controls the flush pump to direct flushing solvent to the nozzle
during “clean jet start” and “shutdown.”
The flush pump is primed by vacuum being applied to the flush pump
diaphragm when V7 is de-energized.
System ink pressure is applied to the flush pump diaphragm to direct
pressurized solvent to the nozzle when V7 is energized.
V7 is a 3-port valve.

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V8 Gutter Valve (located on the FMS ink system)

The gutter valve directs the vacuum generated by the gutter pump.
When V8 is energized, vacuum is applied to the printhead gutter, which
returns unused ink (non-printed drops) to the FMS mixer tank for
recirculation.
During the umbilical purge function, V8 is de-energized. Vacuum is
applied to the return tube of the nozzle for umbilical purging. During idle
mode on a 460 Pi, vacuum is applied to R3, preventing ink pigment from
settling in the valve and its associated tubing.
V8 is a 3-port valve that can be easily identified by its black base (the other
valves have a white base).

V11 Jet Valve (located in the printhead)

V11 when energized allows the flow of ink to the nozzle during printing.

V12 Bleed Valve (located in the printhead)

V12 when energized allows ink to flow through the nozzle return pipe.
V12 is energized during printhead/umbilical purging and momentarily
during “jet start up,” “shutdown” and during nozzle flush.

Top Up and Ink Reservoirs

The ink and top up reservoirs (Items 1 and 4 in Figure 6-21) are of similar
design and each have a capacity of 1.2 liters. Located on the top of each
reservoir is a manifold which consist of the mounting points for the
solenoid valves (valve 1 is on the ink manifold, valve 2 is on the top up
manifold) and the filler tube for top up or ink. Each reservoir houses an
internal low level sensor.

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Ink System Filters

The ink system has six filters:

Main System Filter (located inside the filter compartment)

The primary purpose of the main system filter is to provide filtered ink to
the nozzle for printing and to the VMS.
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.
Pigmented inks utilize the lower filtration rating, typically 20 microns due
to the pigment used to color the ink having a relatively large particulate
size.
Machines using non-pigmented inks generally have a smaller filtration
rating, typically 5 microns.

Pre Pump Filter (located inside the filter compartment)

The Pre-pump filter filters all the ink prior to entering the main system
pump.
The filter medium is stainless steel with a filtration rating of 30 microns.

Pre Head Filter (located below the FMS printhead manifold)

The pre head filter is a secondary filter to the main system filter.
When the main system filter is exchanged for a new item during routine
servicing, contaminants may accidentally be introduced into the system
tubing. The pre head filter is fitted to trap these particulates.
The filter medium is stainless steel with a filtration rating of 8 microns.

Last Chance Filter (located behind the nozzle in the printhead)

The last chance filter which is fitted to the “clean” nozzle assembly during
manufacture is designed to prevent ingress of particulates into the nozzle
whilst being assembled at the factory or fitted as a spare part during
servicing.
The filter medium is stainless steel with a filtration rating of 18 microns.

Note: This filter is not present in the 460 Pi.

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Flush Filter (located near flush pump)

The flush filter is designed to remove any particulates from the flushing
solvent prior to being delivered to the nozzle during “clean jet start” and
“stop” routines.
The filter is fitted in the pipeline after the flush pump rather than in-line
before the flush pump eliminating the possibility of introducing
contaminants into the flush line in the event of the flush pump being
exchanged for a new item.
The filter medium is stainless steel with a filtration rating of 8 microns.

VMS Filter (located inside FMS top box)

The VMS filter is a “last chance” filter designed to catch contaminants,
which may be introduced during the replacement of the main system filter
and thereby obstruct the inlet restrictor orifice (R1) of the VMS system.
The filter medium is stainless steel with a filtration rating of 75 microns.

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Fluid Management System (FMS)

(1) VMS chamber

(2) VMS high level probe
(3) VMS low level prove
(4) Mixer tank
(5) Mixer tank level high probe
(6) Mixer tank level OK probe
(7) Temperature probe
(8) Mixer tank level low probe

Figure 6-23. FMS Components

The FMS (Item 17 in Figure 6-21) has solenoid valves V3, V6, V8 and V7
externally mounted on it. It houses the following components:
• Mixer tank (Item 4 in Figure 6-23).
• Mixer tank level high probe (5).
• Mixer tank level OK probe (6).
• Mixer tank level low probe (8).
• Mixer tank ink temperature probe (7).
• Viscosity Monitoring System (VMS) (1).

Viscosity Monitoring System (VMS) Chamber

Located inside the FMS top box, the VMS constantly monitors the
viscosity of the ink in the system. This is done by filling the VMS chamber
with ink and then timing how long it takes for the ink to drain from the
chamber. High and low levels sensors in the chamber detect when it is full
and when it is empty.

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The top of the VMS chamber is covered by an injection moulded cover,

which is secured with a gasket and four screws.
The VMS top cover incorporates a pre formed stainless steel pipe, which is
connected to V3 via a PTFE tube. The pipe allows ink into the VMS
chamber during the filling period.
The VMS chamber has two ink level probes, “High” and “Low”. These
probes are of the metal rod conductivity type.
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)” on page 6-68.

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

The Venturi jet pump provides a partial vacuum (typically, 0.6 bar), which
is used for purging the nozzle and umbilical tubes and also for
backflushing the nozzle.
The vacuum derived from the Venturi jet pump is created by the flow of
high-pressure ink through a small diameter tube (inlet tube) into a slightly
larger diameter tube (outlet tube).
The jet of ink is directed out of the inlet tube and into the outlet tube. The
inlet and outlet tubes are directly in line with each other and a suction port
or third tube is located at the point between the inlet and outlet tubes. The
gutter return tube is connected to this suction port.
The high velocity of the jet of ink as it enters the outlet tube causes air to be
drawn from the suction port and into the jet. The higher the jet velocity the
higher the flow rate generated at the suction port.

Pressure Transducer (located on the FMS system manifold)

The pressure transducer (Item 10 in Figure 6-21) monitors the ink system
pressure, providing continuous electrical feedback to the system
electronics and pump control system to maintain (within limits) a constant
printing pressure.

Ink System Pump (located on the ceiling of the ink system compartment)
The ink system pump (Item 3 in Figure 6-21) is a positive displacement
gear pump driven by a 24 V dc brushless motor.
The pump provides stable ink pressure to the nozzle during printing and
also provides a flow of ink to the VMS and Venturi jet pump for drawing
unused ink from the printhead and returning it to the FMS ink system for
recirculation.

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Flush Pump (located close to the FMS)

The flush pump (Item 8 in Figure 6-21) is a simple diaphragm type pump
consisting of two injection moulded pump housings, a flexible diaphragm,
two check valves and housings.
A flange of the diaphragm (the diaphragm is located in a cavity in one the
two housings) acts as a sealing gasket when the two housings are bolted
together. The housing containing the diaphragm cavity also has an ink
connection which allows either ink under pressure or vacuum to move the
diaphragm backwards and forwards.
The other housing contains the two check valves:
• The input check valve only allows flow into the pump and is
connected to a pipe, which draws flushing solvent from the top-up
reservoir.
• The output check valve only allows flow out of the pump and is
connected to a pipe that feeds the flush solvent to the manifold in the
printhead.
During operation, the diaphragm is controlled by V7.
When vacuum (generated by the suction of the main system pump) is
applied to the diaphragm, flush solvent is drawn from the top-up
reservoir and into the pump cavity to prime the pump.
During “clean start” and “stop” cycles, pressure is applied to the
diaphragm through the switching of V7. The input check valve seals close,
forcing flushing solvent through the output check valve to the printhead
and through V11.

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Condenser
To reduce the amount of solvent used, the printer incorporates the solvent
recovery condenser. This consists of a condenser (2) to which is attached a
heatsink (1). Solvent vapor from the FMS unit is fed to the condenser via
input pipe (3). The solvent vapor is condensed and the condensate is
returned to the FMS unit via tube (5). The exhaust gas is then fed to
atmosphere via tube (4) which terminates at the bottom of the cabinet.

1 2
3 4

(1) Heatsink (located in electronics compartment)

(2) Condenser assembly
(3) Input
(4) O/P to atmosphere
(5) O/P to mixer tank

Figure 6-24. Top-up condenser

Gutter Pump (460Pi only)

Most pigmented inks use surfactants to improve the wetting/coating of
the pigments. These surfactants cause the ink to foam and retain high
levels of oxygen. Foamed ink causes many problems for CIJ printers,
including incorrect viscosity measurement and printhead buildup. The
460Pi uses a separate diaphragm pump to provide additional suction at
the gutter. The pump is operated from a 24 VDC signal supplied by the I/
O board. This signal is controlled by the printer firmware.

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Pressure Damper
To reduce ink buildup within the printhead, it is important to maintain a
very stable breakup, which can be improved by stabilizing the system
pressure. The pressure damper is designed to absorb pressure
fluctuations. On 460 Si and 460 Mi printers, the damper is located on the
front of the FMS tray under the main filter. On 460 Pi printers, the damper
is located on the right of the FMS tray, behind the gutter pump.

Stirrers (460 Pi only)

The contents of the mixer tank and ink reservoir tank must be stirred in
order to prevent the ink pigment separating from the solvent. A stirrer
motor and rotating magnet are used outside the tanks. Inside the tanks,
there are magnetic follower bars. These rotate when the motors rotate.
Since pigmented inks are very abrasive, the collar of the follower bars will
wear away over a two to three month period. As they are degraded, drag
on the follower bars increases and eventually they will stop rotating.
Because of this, the followers should be checked and replaced on a regular
maintenance scheme.

Figure 6-25. Follower bar wear

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 Willett 460, 460Mi and 460Pi Service Manual

Printhead Operation

Ink Jet Information

An electrically conductive ink is supplied under pressure by the ink
system to the nozzle assembly (Item 2 in Figure 6-26) 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. The transducer crystals (4 and 5) causes
the nozzle assembly to vibrate longitudinally, breaking up the ink stream
into droplets, a small distance away (the break up point) from the nozzle
jet orifice. The frequency of modulation for the 60 micron nozzle is usually
set to 76.8 kHz. On a 460 Pi, however, the frequency can be set to either 64
KHz or 76.8 kHz, depending on the nozzle fitted. The nozzle has a
damping mass (6 and 7) attached to the rear of the transducer to
mechanically “tune” the nozzle assembly to the modulation frequency.
The ink droplets are produced at the same rate as the modulation
frequency, are uniform in size and separated by equal distances.

(1) Nozzle jet orifice

(2) Nozzle assembly
(3) Ink feed pipe
(4) Crystal transducer
(5) Crystal transducer
3
(6) Damping mass
(7) Damping mass

7
6
1 4 5

Figure 6-26. Ink Jet Formation

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Willett 460, 460Mi and 460Pi Service Manual

Droplet Charging
The charge electrode (Item 1 in Figure 6-27) is positioned at the break up
point of the ink stream and extends for several drops either side of it. This
allows a tolerance for break up position and shields the ink stream from
the influence of the other electrostatic fields. The distance between the
nozzle assembly (2) and the charge electrode is 2 mm.

1 Charge electrode
2 Nozzle assembly

Figure 6-27. Charge Electrode

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. When a
drop of ink then breaks from the jet it will have trapped on it a charge
directly proportional to that on the charge electrode. If the positive voltage
is then removed from the charge electrode, the negative charge on the jet
will discharge through the ink jet and nozzle assembly to ground.
However, the drop of ink which has become detached from the jet cannot
discharge as it no longer has a conductive path to ground.

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 Willett 460, 460Mi and 460Pi Service Manual

Droplet Deflection
After passing through the charge electrode the droplet stream passes
through an electrostatic field maintained by the deflector electrodes which
are connected to a high tension supply (typically 6 kV). The negatively
charged droplets are deflected by the field towards the high voltage
deflector electrode (Item 5 in Figure 6-28). The distance a drop is deflected
is proportional to the charge carried, which is in turn proportional to the
voltage applied to the charge electrode when the drop became detached
from the ink jet.

(1) Gutter
(2) Droplet path to gutter
(3) Ground potential deflector electrode
(4) EHT block
(5) High voltage deflector electrode
(6) Deflected droplet path
3
(7) Substrate
2
1

7 6

Figure 6-28. Droplet Deflection

The charged droplets once deflected (6) leave the printhead to form
characters in a dot matrix format on the substrate (7). Droplets which are
not required for printing are not charged and are therefore not deflected

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Willett 460, 460Mi and 460Pi Service 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.
• Ensure that the ink is kept at a viscosity value corresponding to the
ink temperature and the type of ink in use.
• Generate a vacuum for gutter suction.

Operation
The pump draws ink from the mixer tank and circulates it round a system
divided into several paths. After circulation the unused ink is returned to
the mixer tank.
Circulation ensures that the ink remains thoroughly mixed and any
addition of ink or solvent will be rapidly mixed in.
Filtered ink is fed from the pump to three sub-systems:
• The VMS.
• The printhead nozzle.
• The venturi, which applies a vacuum to the nozzle or the gutter to
perform the following operations:
a. To remove debris from the nozzle during flushing.
b. To draw solvent through the umbilical tubes (thus cleaning them)
during shut down.
c. To collect non-deflected ink droplets, via the gutter, when printing.
The returned ink or solvent is fed back to the mixer tank via a baffle to
reduce frothing.

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Figure 6-29 and Figure 6-30 show the overall operation of the ink system.

Figure 6-29. 460 Si and Mi ink system

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Willett 460, 460Mi and 460Pi Service Manual

Figure 6-30. 460 Pi ink system

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Valves and restrictors in Figure 6-29 are represented as follows:

V1 Solvent Top Up Valve V11 Jet Valve

V2 Ink Top Up Valve V12 Bleed Valve

V3 VMS Diverter Valve R1 Restrictor 1

V6 Feed Valve R2 Restrictor 2

V7 Flush Valve VT Venturi

V8 Gutter Valve

Viscosity Monitoring System Sequence

The viscosity of the ink is checked by the Viscosity Monitoring System
(VMS) whenever the jet is running.
This procedure is as follows:
1 Solenoid valve V3 opens directing ink into the VMS chamber, which is
an integral part of the FMS
2 Ink flows into the VMS chamber via V3 and restrictor R1 until the
high level sensor is covered. At this point V3 closes, stopping the flow
of ink into the chamber.
3 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 energizes and
the chamber starts to fill again.
4 The time taken for the ink to run out of the chamber is dependent on
its viscosity; the thicker the ink, the longer it will take to drain. The
viscosity of the ink is affected by solvent loss during normal machine
operation as well as by its temperature, which is monitored by a
sensor in the mixer tank.
5 The CPU compares the time taken for the ink to drain against a value
calculated by the software. The software takes into account the type of
ink (entered during system calibration) and its temperature.
6 If the ink is too thick (i.e. the time to drain is longer than the calculated
value) solenoid valve V1 opens. The pump draws solvent from the top
up reservoir, adding it in small doses to the mixer tank every 2nd
VMS cycle until the viscosity is correct (see “Top Up Addition to
Mixer Tank” on page 6-65).
7 The viscosity monitoring sequence is repeated each time that the low
level sensor in the VMS chamber is uncovered.

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Note: Ink is only added to the mixer tank when the tank level is below the OK
level sensor.

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Clean Start
This method starts on flush (pure solvent) in order to dissolve any ink
residues in the jet orifice. It then bleeds on flush to remove air from the
nozzle before switching to ink, eliminating ink splash and spray during
start-up.
The Clean Start Jet Sequence is as follows:
The solvent from the filter is forced through the umbilical connection to
the printhead. At the printhead, the solvent enters the heater manifold and
passes into the main fluid path between the jet valve and the nozzle. The
solvent continues along the main fluid path to the ("last chance") filter,
removing ink residues along the way before the solvent enters the nozzle.
The jet starts when the nozzle becomes pressurized by the solvent flow. If
the previous stop was a clean stop, the jet will consist of almost pure
solvent. The flow of solvent quickly removes any ink residues in the jet
orifice. Fluid in the jet is caught by the gutter and directed to the mixer
tank.
Once the solvent is flowing through the jet, the jet valve opens, merging
ink with the solvent. The bleed valve then opens to increase the fluid flow
through the nozzle, removing any trapped air bubbles from the nozzle
body. Once the bleed valve opens, the flush pump valve (V7) switches off,
preventing further solvent from being pumped into the nozzle. The flush
pump returns to its priming stroke and the non-return valves in the pump
prevent fluid from the printhead returning to the umbilical connection.
Approximately ten seconds after the flush pump switches off, the bleed
valve closes and ink continues to flow through the jet at 4 bar. Modulation
is switched on and the ink pressure changes to give the correct jet velocity.
Heater manifold temperature is allowed to reach the correct value before
enabling the phasing checks on the jet.

Mnemonica Function in Sequence

P0 Turn Phasing off to ensure jet is not charged at start-up

PH Hide bad phasing (due to phasing being disabled)

PUC Place pump into closed loop control mode

G1 Grace period on

VG1 Enable gutter valve (V8) to prevent ink being sucked out of the
bleed tube resulting in a jet kick when the bleed solenoid opens

W2000 Wait for 2 seconds

PU40 Set the pump pressure to 4 bar

W15000 Wait for 15 seconds before starting to allow the flush pump to
charge, in case the flush pump has been previously emptied

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Willett 460, 460Mi and 460Pi Service Manual

Mnemonica Function in Sequence

G0 Grace period off

L Log occurrence of current sequence

VL1 Enable flush pump valve (V7) to pressures flush pump

W4000 Wait for 4 seconds

VP1 Enable bleed valve (V12)

W100 Wait for 0.1 second

VF1 Enable jet valve (V11)

W500 Wait for 0.5 second

VR1 Enable ink feed valve (V6) to merge ink with solvent steam

W1500 Wait for 1.5 seconds

VP0 Disable bleed valve (V12)

W5000 Wait for 5 seconds

VL0 Disable flush pump valve (V7) to re-charge the flush pump

W1000 Wait for 1 second

VP1 Enable bleed valve (V12) to remove air from the nozzle body

W10000 Wait for 10 seconds

VP0 Disable bleed valve (V12)

W2000 Wait for 2 seconds

PUD Place pump into default loop control mode

M1 Enable modulation

PUC Place pump into closed loop control mode

WH Wait for head temperature

P1 Enable phasing

WC Wait for pre-run checks

PS Show bad phasing

E1 Enable EHT

Ready to Print

a. These mnemonics can be used when you select any one of the following from
the System menu: Set jet start sequence, Set jet stop sequence, Set jet flush se-
quence, Set jet clean start sequence, Set system flush purge sequence or Set jet
clean stop sequence.

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 Willett 460, 460Mi and 460Pi Service Manual

Quick Start
This method starts without a flushing sequence, and uses the ink supply
to bleed air from the nozzle.

Mnemonic Function in Sequence

P0 Turn Phasing off to ensure jet is not charged at start-up

PH Hide bad phasing (due to phasing being disabled)

PUC Place pump into closed loop control mode

G1 Grace period on

VG1 Enable gutter valve (V8) to prevent ink being sucked out of the
bleed tube resulting in a jet kick when the bleed solenoid opens

W2000 Wait for 2 seconds

PU40 Set the pump pressure to 4 bar

G0 Grace period off

L Log occurrence of current sequence

W3000 Wait for 3 seconds

VR1 Enable ink feed valve (V6)

W2000 Wait for 2 seconds

VP1 Enable bleed valve (V12)

W100 Wait for 0.1second

VF1 Enable jet valve (V11) to merge ink with solvent steam

W10000 Wait for 10 seconds

VP0 Disable bleed valve (V12)

PUD Place pump into default loop control mode

M1 Enable modulation

PUC Place pump into closed loop control mode

WH Wait for head temperature

P1 Enable phasing

WC Wait for pre-run checks

PS Show bad phasing

E1 Enable EHT

Ready to print

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Clean Stop
This method switches from ink to flush in order to purge the nozzle. This
method allows time for the manifold, nozzle and jet orifice to be purged of
ink before stopping the jet.
The Clean Stop Jet Sequence is as follows:
Deflector plate voltages are switched off before beginning this sequence.
The ink pressure is set to 4 bar and the modulation voltage switches off. To
increase the ink flow through the nozzle body, the bleed valve switches
on.
The flush pump valve switches on applying solvent pressure to the
printhead. Pure solvent is forced through the filter to the printhead mixing
solvent into the ink stream in the heater manifold.
Approximately one second after the solvent starts to mix with the ink, the
feed valve (V6) in the cabinet switches off, removing ink pressure from the
printhead. Ink ceases to flow into the heater manifold and the solvent
flushes ink from the nozzle body. Five seconds later the bleed valve
switches off and then switches on again, introducing solvent into the jet
valve, which inhibits ink residues forming whilst the machine is switched
off. The jet valve (on the heater manifold) switches off, ensuring that no
ink diffuses into the solvent. At this point, no ink should be present in the
nozzle body.
The gutter valve switches off, increasing the suction on the bleed system.
After a short pause, the bleed valve switches off. After another short
pause, the gutter valve switches on to clear any fluid from the gutter. Once
the gutter valve switches off, the main ink pump also switches off.

Mnemonic Function in Sequence

G1 Enable grace period

E0 Disable EHT

W1000 Wait for 1 second

PU40 Set the pump pressure to 4 bar

W5000 Wait for 5 seconds

G0 Disable grace period

L Log occurrence of current sequence

P0 Disable phasing

M0 Disable modulation

VP1 Enable bleed valve (V12)

W10000 Wait for 10 seconds

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 Willett 460, 460Mi and 460Pi Service Manual

Mnemonic Function in Sequence

VL1 Enable flush pump valve (V7) to pressures flush pump

W1500 Wait for 1.5 seconds

VR0 Disable ink feed valve (V6)

W1500 Wait for 1.5 seconds

VF0 Disable jet valve (V11)

VP0 Disable bleed valve (V12)

VL0 Disable flush pump valve (V7) to recharge flush pump

W30000 Wait for 30 seconds to clear the gutter line

W30000 Wait for 30 seconds to clear the gutter line

W30000 Wait for 30 seconds to clear the gutter line

W30000 Wait for 30 seconds to clear the gutter line

PUD Place pump into default loop control mode

PU00 Disable pump (set pressure to 0 bar)

W1000 Wait for 1 second

VG0 Disable gutter valve

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Willett 460, 460Mi and 460Pi Service Manual

Quick Stop

Note: This sequence is used to manually stop the jet for a short period, or to
automatically stop the jet during an EHT trip, charge error, etc.

This method switches off the ink without flushing the nozzle or manifold.
Hence the manifold and the nozzle are full of ink when the jet stops. The
machine must not be left in this state for long periods, as drying ink in the
jet orifice may make restarting difficult. This procedure is primarily
intended for situations where the machine may be stopped and restarted
several times in quick succession. Under these conditions, the use of
solvent may become excessive and cause dilution of the ink.

Mnemonic Function in sequence

L Log occurrence of current sequence

E0 Disable EHT

W1000 Wait for 1second

P0 Disable phasing

VP1 Enable bleed valve (V12)

W100 Wait for 0.1second

VF0 Disable jet valve (V11)

VP0 Disable bleed valve (V12)

W30000 Wait for 30 seconds to clear gutter

W30000 Wait for 30 seconds to clear gutter

VR0 Disable ink feed valve (V6)

M0 Disable modulation

PU00 Disable pump (set pressure to 0 bar)

W1000 Wait for 1 second

VG0 Disable gutter valve (V8)

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Nozzle Flush
When Nozzle flush is selected, the vacuum from the venturi is applied to
the return side of the nozzle, creating suction at the nozzle orifice. Solvent
is applied to the nozzle orifice to clear any blockage.
Nozzle flush will automatically time out after 2 minutes but can be
stopped at any time before that by pressing

f1 Abort Flush.

A nozzle flush can be started with the jet running or stopped. If the jet is
running, selecting Nozzle flush will first of all de-energize feed valve V6
to stop the flow of ink to the nozzle.

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 energized. Ink from the reservoir flows round
the system into the mixer tank until the level OK sensor is covered. V2 is
then de-energized.

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. If the
actual time to empty is greater than the reference value, the viscosity of
the ink is too high. Solvent top up valve V1 is energized for up to 5
seconds every 2nd VMS sequence until the viscosity is corrected.

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System Software
7
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:

1 Press or until the menu is highlighted.

2 Press enter .

To select an item from a menu:

1 Press or until the option is highlighted.

2 Press enter .

Note: If there are too many items on the menu to display on screen, the label
“More” appears adjacent to the top and/or bottom of the menu to indicate more
menu entries above or below those currently displayed. Scroll through the items
by repeatedly pressing or .

Using the Keypad

To select a menu or item press the combination of the Alt key and the letter
highlighted in the menu or item name.

For example, press alt +M to select the Messages menu. alt +E is

useful to access the Editor menu while editing a message.

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Entering Text, Numbers and Toggle Values

To enter text into a field, simply type the required text or special character
using the keypad.

Numerical values can be entered using keys 0 to 9, or by pressing to

increase the value or to decrease the value.

ctrl plus or increases or decreases a numerical value by +10

and -10 respectively.

Toggle values (e.g. on/off) can be changed by pressing or . These

keys are also used in some menu options to set and unset attributes.

Esc Key
If at any time you want to exit a menu without changing any settings,
press .
esc

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 Willett 460, 460Mi and 460Pi Service Manual

Messages Menu
Messages Menu Menu Option Function

Select Print Opens the Select Message menu. Select a

Message message to be printed or edited.

Message Opens the Parameters For: menu for the

Parameters selected message. All parameters can be
changed.

Default parameters Opens the Default Parameters menu. The

default parameters, used for new messages,
can all be changed.

Edit Message Opens the Select Message to Edit menu. The

selected message is opened in an edit screen.
To save the edited message, go to the Editor
menu

New Message Opens the New Message dialogue. The user is

prompted to enter the new message name. The
new message can then be typed in the edit
screen. To save the new message, go to the
Editor menu. The parameters for a new mes-
sage are set to the default values.

Delete Message Opens the Select Message to Delete menu.

The selected message is deleted.

Copy Message Opens the Copy Message dialogue. Enter a

message name to copy From: and a message
name to copy To:. If the message name to
copy to is an existing message, an Already
exists. Overwrite it? dialogue is opened
(answer with Y or N). Otherwise a new mes-
sage is created.

Message Select Opens the Message Select Source dialogue,

Source with options Internal or External.

Edit External Opens the External Message Select menu.

Select Table Enter the names of the messages you want to
be available to the external source. The exter-
nal message names can be added, edited and
deleted. Press F2 to select message names
from a list of those available.

Delete All Deletes all internal messages.

Messages

Show Free Displays the Memory Space screen, showing

Message Space message space free, work space free and the
largest block of message RAM.

Quit Returns to the quick screen.

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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 are copied into the message at print time e.g.
expiry date, shift code.

Modify Attributes Opens the Set Attributes menu. One or more attributes
can be set. Set attributes are shown as highlighted.
The set attributes are applied to the selected text in the
message. (Attributes are properties which can be
applied to individual characters).

In-line Attributes Opens the Select Attribute menu. One selected

attribute is applied to text about to be typed in the mes-
sage.

Copy Text Copies the selected text to the clipboard.

Paste Text Pastes the text from the clipboard at the cursor posi-
tion.

Set Keyboard Opens the Select Keyboard Type menu. Select the
Type keyboard type to be used for the edit session. Charac-
ters from more than one language alphabet can be
included in a message.

Save Message Saves the message being edited and continues edit-
ing.

Save and Exit Saves the message being edited and exits the editor
(SHIFT-F1) screen.

Clear Message Deletes the entire content of the message being

edited.

Abandon Exits the editor screen without saving any changes to

the message.

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User Fields Menu

User Fields Menu Menu Option Function

Edit user field Opens the Select user field to edit menu. Options are all
the existing user fields. Selecting a text field opens an
individual dialogue for the new user field with Text and
Attribute options. Selecting a counter field opens a menu
with options for the counter parameters. Selecting a logo
field opens the Edit Logo screen.

New user field Adds a new user field to the selected message. Opens
the New User Field dialogue with Name and Description
fields. Selecting a Text description opens the New Field
dialogue with Text and Attribute fields. Selecting a
Counter description opens the New Counter dialogue
with fields for the counter parameters. Selecting a Logo
description opens the Edit Logo screen.

Delete user field Opens the Select user field to delete menu with options
of all existing user fields.

Reset Counter Opens the Select counter to reset menu with options of
all existing counters.

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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.

photocell or internal timer. Use manual print to print one
copy of the selected message when the print command is
given. This feature can be used to check the printer oper-
ation whilst off-line. The photocell must be uncovered to
use manual print.

Continuous Print The message is printed repeatedly without an external

trigger. Opens the Continuous print dialogue. Continuous
mode can be toggled between Off, SE Mode and Time
Mode. SE mode delay and Time mode delay can be indi-
vidually adjusted between 1 and 10000 pulses.

SE Mode uses external shaft encoder pulses to set the

gap between the start of each print.

Time Mode uses internally generated pulses to set the

gap between the start of each print.

Distance defines the resolution of the shaft encoder and

the number of pulses per meter. Enter the interval in mm
to set the distance between the start of each point.

Print Ack Control Sends a signal to an external control system, normally via
COMM1. Same as Print acknowledge on the Print Control
menu. The Print acknowledge option can be set to Off,
After Comp, After Print or After both. The Print ACK code
option can be set between 1 and 255.

DIN Print DIN printing automatically inverts and reverses alternate

prints. This is used to enable the message to be read
from either side of the cable or hose. DIN print can be
adjusted in the Message Parameters menu.

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 Willett 460, 460Mi and 460Pi Service Manual

Password Menu
Password Menu Menu Option Function

Enter Password Opens the Enter Password dialogue,

together with the Current password level.
The user is prompted to enter a password
to change to a different password level.

Clear Password The password is cleared for the current

access level and access is returned to
password level 0.

Set Password for level 1 Opens the New Password dialogue. The
user is prompted to enter a new password
for level 1.

Set Password for level 2 Opens the New Password dialogue. The
user is prompted to enter a new password
for level 2.

Set Password Levels Opens the Change Password Level menu.

This has options for the Quick Screen and
each of the menus. When an option is
selected, a further dialogue appears with
options to change the password level for
each option available in the menu. The
password levels can be set in the range 0
to 3, where level 0 has no password protec-
tion.

This option is for use by trained service

personnel only.

Automatic Logout Enabling the automatic logout feature

instructs the printer to automatically log
users out (revert to access level 0) after
several minutes of inactivity (no keyboard
input).

This feature is designed to protect the

printer from access by unauthorized users.

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System Menu
System Menu Menu Option Function

Status Displays the fault list, containing the possible

faults with current faults highlighted.

Clean The ink jet is started and Starting the jet is dis-
Start Jet played. A flush and bleed sequence is performed
to eliminate ink splashing and spray before ink is
fed to the nozzle.

Quick The ink jet is started and Starting the jet is dis-
Start Jet played. Use Quick Start if the machine has been
off for less than half an hour.

Clean The ink jet is stopped, the nozzle and related ink
Stop Jet system pipes are cleaned

Quick The ink jet is stopped. The nozzle and manifold

Stop Jet remain full of ink. Use Quick Stop if the machine
will be off for less than half an hour.

Nozzle The nozzle orifice is cleansed by the application

Flush of solvent and a suction action. The flush contin-
ues for two minutes unless F1 is pressed to abort
it.

System The machine is started and the flush pump oper-

Flush Purge ated. This function purges air from the flush sys-
tem during commissioning or when air has been
introduced to the flush system during a fault, etc.
Press Enter and a dialog opens: Are you sure
YES-NO.

Umbilical When using Umbilical Purge the umbilical feed

Purge and return tubes must be disconnected from the
nozzle feed and return tubes. Loop the umbilical
feed and return tubes together and cap the noz-
zle feed and return tubes - see Umbilical Purge
maintenance procedure. Opens the Umbilical
Purge dialogue. Select Enable to start and Dis-
able to stop the umbilical purge.

Fill Mixer Tank Used during commissioning only, to prime the

mixer tank to the correct level.

Charge Error Opens the Machine Control dialogue. Charge

Shutdown error can be toggled between Enable and Dis-
able.

Gutter Fault Opens the Machine Control dialogue. Gutter fault

Shutdown can be toggled between Enable and Disable.

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 Willett 460, 460Mi and 460Pi Service Manual

System Menu Menu Option Function

Rolling Phase Opens the Phasing dialogue. Rolling Phase can

Disable be toggled between Enable and Disable. Rolling
phase must always be enabled during normal
printer operations to ensure best print quality. It
does this by automatically checking and adjust-
ing the small changes in the timing of the signal
pulse applied to the charge electrode. Rolling
phase must be disabled to view the position of
the ink jet break-off, as the strobe LED which
monitors the timing of the pulse applied to the
charge electrode appears to make the ink drops
move. Therefore when checking the break up of
the jet it is important to disable rolling phase.

Idle Mode Opens the Machine Control dialogue. Idle Mode

(appears on can be toggled between Enable and Disable.
460Pi only)

Debug Monitors the electronic system to detect possible

Monitor hardware or software faults. This facility should
only be used by experienced Willett-trained engi-
neers.

Set Jet Start Allows setting of the timing and sequence of the
Sequence valves in the ink system for the jet start process.
Opens the Jet startup sequence dialogue with a
warning. This facility should only be used by
experienced Willett-trained engineers.

Set Jet Stop Allows setting of the timing and sequence of the
Sequence valves in the ink system for the jet stop process.
Opens the Jet shutdown sequence dialogue with
a warning. This facility should only be used by
experienced Willett-trained engineers.

Set Jet Flush Allows setting of the timing and sequence of the
Sequence valves in the ink system for the jet flush process.
Opens the Jet flush sequence dialogue with a
warning. This facility should only be used by
experienced Willett-trained engineers.

Set Jet Allows setting of the timing and sequence of the

Clean Start valves in the ink system for the jet clean start
Sequence process. Opens the Jet clean start sequence dia-
logue with a warning. This facility should only be
used by experienced Willett-trained engineers.

Set System Allows setting of the timing and sequence of the

Flush Purge valves in the ink system for the flush purge pro-
Sequence cess. Opens the System flush purge sequence
with a dialog and warning. This facility should
only be used by experienced Willett-trained engi-
neers.

Rev AA System Menu 7-9

Willett 460, 460Mi and 460Pi Service Manual

System Menu Menu Option Function

Set Jet Allows setting of the timing and sequence of the

Clean Stop valves in the ink system for the jet purge process.
Sequence Opens the Jet clean stop sequence dialogue with
a warning. This facility should only be used by
experienced Willett-trained engineers.

Set Idle Mode Allows setting of the timing and sequence of the
Sequence valves in the ink system for the idle mode pro-
(appears on cess. This facility should only be used by experi-
460Pi only) enced Willett-trained engineers.

7-10 System Menu Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

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.

Set Language Allows the language used for the display to be set.
Opens the Select prompt language menu with the
language options available (available languages
depend on the model type of the machine). Select-
ing a language automatically sets the appropriate
keyboard type for that language.

Photocell Source Selects the photocell source to be used. Opens the

Print Control menu. Photocell source can be tog-
gled between External 1 and External 2. (NB Exter-
nal 2 requires special software).

Photocell Levels Selects the active level for the photocells. Opens
the Photocell levels dialogue. Photocell 1 and Pho-
tocell 2 can be toggled individually between Active
high and Active low.

Shaft Encoder An external shaft encoder should be used where

Source there may be variations in the speed at which the
product passes the printhead. Opens the Print
Control menu. SE source can be toggled between
External (when an external shaft encoder is used)
and Internal (when an internal timer is used).

Remote An RS-232 serial port can be selected for commu-

nication with other devices. Opens the Select Port
for Remote dialogue. Options are Off, COM1 and
COM2.

Serial Port Baud Allows the baud rates for the serial ports to be set.
Rates Opens the Configure serial ports menu. The baud
rate can be set to 75, 110, 150, 300, 600, 1200,
2400, 4800, 9600 or 19200 baud.

Set Shifts Opens the Set shifts menu. The shift start time, the
length of the shift and the shift identification char-
acter can be set (see Figure 2-10. on page 2-24.)

Barcode Setup Opens the Barcode Bar/Space Ratios menu. Up to

four bar widths and four space widths can be set.

LCD Contrast Opens the LCD Contrast menu. LCD Contrast can
be set to a value from 0 to 255. Also, Back Light
Saver can be set to Enable or Disable and Key pad
buzzer can be set to Enable or Disable.

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Willett 460, 460Mi and 460Pi Service Manual

Configure Menu Menu Option Function

Backup System Parameters set during the calibration process are

Settings saved to memory, overwriting any previously saved
parameters.

Restore System Previously saved parameters and settings are read

Settings from memory, undoing any recent changes.

Full System Reset Opens the System Restart dialogue. This gives
three options:

Initialize, restarts the printer. No settings are

changed.

Reset - keep messages, restores all parameters to

their factory values. No messages are deleted.
Note that if you have saved your system settings,
you may recall the printer configuration using the
Restore System Settings option.

Reset - all messages deleted, same as Reset -

keep messages except that all user-configured
messages are deleted (TEST MESSAGE is not
deleted).

Select Alternative Opens the Select alternative zero dialogue. Alter-

Zero native zero symbol can be set to one of several
available zero characters.

7-12 Configure Menu Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Calibrate Menu
Note:The FIN is a 12 digit code. The following example shows the ink
performance information that is contained within the 12 digits.

110/110/47/ 32/ 35

(viscosity curve) (pressure) x 1/10 bar (Printhead temperature)

Calibrate Menu Menu Option Function

Diagnostics Opens the Diagnostics screen. This displays infor-

Screen mation on the ink system status, which can be use-
ful when diagnosing printer faults.

This screen can also be directly accessed at any

time by pressing the key on the keypad.

Set Ink Type Opens the Select Ink Type dialogue. This prompts
the user to enter the Fluid Identification Number
(FIN), the ink number and the top-up number. After
all three numbers are entered, the display asks for
the FIN to be retyped to confirm the accuracy of the
initial entry.

Heater Set Point Opens the Ink System dialogue. Running Pressure
and Ink temperature can be adjusted. The Heater
Set Point is automatically set when the FIN is
entered (units are 10x Temp °C).

Set Running Opens the Ink System dialogue. Running Pressure

Pressure and Ink temperature can be adjusted. The Running
Pressure is automatically set when the FIN is
entered (units are 10x press bar).

Pressure The Pressure Zero Offset option allows the ink sys-
Zero Offset tem pressure to be set to zero relative to local
atmospheric pressure; this operation should be
carried out with no ink in the system and the pump
not running.

Opens the Pressure Zero Offset dialogue, contain-

ing “Are You Sure?” which must be confirmed with
Y or cancelled with N.

VMS Chamber This function calibrates the Viscosity Monitoring

Calibration System for the ink currently selected. When cali-
brating the VMS, ensure that the ink in the mixer
tank has been added from a new bottle; if not, drain
the tank and replenish with fresh ink.

Rev AA Calibrate Menu 7-13

Willett 460, 460Mi and 460Pi Service Manual

Calibrate Menu Menu Option Function

Modulation Set The modulation voltage can be set manually to

Level achieve optimum jet breakup. Opens the Machine
Control dialogue. The Modulation set value can be
adjusted between 1 and 99.

Auto Modulate This option automatically sets the modulation volt-

age to achieve optimum jet breakup. Ensure that
Rolling Phase is enabled when performing an Auto
Modulate.

Phase Charge Set Opens the Phasing menu. The Phase Charge
value can be adjusted between 0 and 255. This
value should normally be set to 8 ±1 and is the
value of Phase Profile shown in the Diagnostics
screen. The distance the phase detector is from the
jet can affect the value required for good phasing;
the distance should be approximately 1 mm.

Phase Offset Set Opens the Phasing menu. The Phase Offset value
can be adjusted between 0 and 15. On 460 Si and
460 Mi printers, this should normally be set to 9. On
460 Pi printers, this should normally be set to 12.

Manual Phase Opens the Phasing menu. The Manual Phase

Angle value can be adjusted between 0 and 15.
This option can be used to set the phase angle to
the last one used and stop the phasing changes.
This effectively freezes the droplets when viewed
against the printhead LED.

Charge Value This option is used to adjust the amount of charge

applied to the ink droplets in order to achieve opti-
mum print quality. Opens the Phasing menu. The
Charge Value can be adjusted between 0 and 255.

EHT Range Set This option sets the upper and lower limits of the
EHT field so that good quality print is achieved at
all character height settings. Opens the Set EHT
Ranges dialogue. EHT Value 1 through to EHT
Value 10 can be adjusted to between 0 and 255. If
F2 is pressed while the Set EHT Ranges dialogue
is displayed then all values are automatically cali-
brated.

EHT Trip Level Set This option calibrates the trip level for the EHT cir-
cuit.

Set S.E. Rate Configures the rate (in pulses per minute) of an
external shaft encoder.

7-14 Calibrate Menu Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Data Logging Menu

Data Logging Menu Menu Option Function

Software Part No. Displays the software version installed.

Compilation Date/ Displays the date the software was compiled

Author and the name of the author.

Product Counter Opens the Product counter dialogue with

“Reset Counter and Display it?” fields. Select
Yes or No for each field.

View Run Hours Displays the pump run hours and machine run
hours.

Reset Run Hours Opens a dialogue with the following options:

Set pump alarm hours, range 0-65535

Reset pump run hours, Yes or No
Set machine alarm hours, range 0-65535
Reset machine run hours, Yes or No

The running hours should be reset only under

exceptional circumstances by trained service
personnel.

Serial Port Opens the Configure data logging dialogue

Functionality with fields for the parameters required for data
logging via a serial port.

Log onto remote Connects to a remote device.

Log off remote Disconnects from a remote device.

Enter Service Opens the Enter Service Information dialogue.

Information The printer location, modem telephone num-
ber, customer name and address can be
entered.

Rev AA Data Logging Menu 7-15

Willett 460, 460Mi and 460Pi Service Manual

7-16 Data Logging Menu Rev AA

Assembly / Disassembly
8
Introduction
This section contains complete instructions for the removal and
installation of the components and sub-assemblies listed below:

Component Page Component Page

Pump Motor Control Board 8-3 Flush Pump 8-24

I/O Board 8-3 Solenoid Valves 8-26

CPU Board 8-6 Cooling Fans 8-28

Levels Board 8-7 EHT Module 8-29

Power Supply Unit 8-8 Head Manifold 8-30

PSU Fuses 8-9 Phase Detector 8-32

LCD Board 8-11 EHT Block 8-34

Keypad 8-12 Nozzle Assembly 8-36

Top Up Reservoir Sensor 8-13 Umbilical 8-38

Mains Cable Gland 8-15 Gutter Pump (460 Pi) 8-42

Fluid Management System 8-17 Pressure Damper 8-44

Ink System Pump 8-20 Stirrers (460 Pi) 8-46

Main Filter 8-22

Warning
LETHAL VOLTAGES. Lethal voltages are present within this
equipment when it is connected to the mains electrical supply. Only
trained and authorized 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.

Rev AA Introduction 8-1

Willett 460, 460Mi and 460Pi Service 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.

Electronic Board Layout

(1) Motor control board

(2) Expansion board
(3) I/O board
(4) CPU board
(5) Levels board
(6) 18mm standoffs

Figure 8-1. Motor Control Board, I/O Board and CPU Board

8-2 Electronic Board Layout Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Pump Motor Control Board

Removal
1 Disconnect the printer from the mains electrical supply.
2 Remove all connections to the motor control board noting their
position and orientation.
3 Disconnect and withdraw the motor control board taking care not to
damage any of its components.

Installation
1 Connect the motor control board to the I/O board ensuring the
interboard connections mate correctly.
2 Refit the connectors.

I/O Board

Removal
1 Disconnect the printer from the mains electrical supply.
2 Remove all connectors from the I/O board noting their position and
orientation for Installation.
3 Remove and retain the six securing nuts and washers. Pull the I/O
board away from the CPU board (4) taking care not to damage the
interboard connectors.

Installation

Note: The 460 uses an issue 3 I/O board. This board may be used on older 450/
460/470 machines. Boards previous to issue 2, however, must not be used on the
460.

1 Position the I/O board (Item 3 in Figure 8-1) on the 18 mm stand-offs

(6) with the component side facing out and the LEVELS connector at
the top right hand corner.
2 Push the I/O board on to the CPU board (4), ensuring that the
interboard connectors mate correctly.

Rev AA Pump Motor Control Board 8-3

Willett 460, 460Mi and 460Pi Service Manual

3 Secure the I/O board using the six nuts and washers retained step 3 of
the removal process.
4 Reconnect the connectors.

Calibration
When a new Mk 3 I/O board is fitted, calibrate the 285 V rail limit as
described below:
1 Reconnect power to the printer and switch on the printer.
2 Set a digital voltmeter to a range suitable for measuring 285 V DC.
3 Connect the positive probe to TP2 (Item 2 in Figure 8-2) and the
negative probe to TP1 (4).
4 Adjust VR1 (1) to give a reading of 285 V ±1 V.
5 When the adjustment is complete, seal VR1 with a suitable sealing
compound.

Note: The jet must be running and the EHT ON to perform the calibration.
In this state, LED 2 (2) will illuminate brightly. If the 285 V is not switched
on, LED 2 will be illuminated dimly and only 15 V will be measured at the
test point.

8-4 I/O Board Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

6 Re-calibrate the system (see “Restore Calibration Parameters” on

page 5-34) and calibrate the modulation value (see “Modulation
Calibration (Manual)” on page 5-23.)

(1) VR1
(2) TP2
(3) LED 2
(4) TP1

Figure 8-2. I/O Board Calibration

Rev AA I/O Board 8-5

Willett 460, 460Mi and 460Pi Service Manual

CPU Board

Removal
1 If possible, make note of all the printer’s current configuration
settings.
2 Disconnect the printer from the mains electrical supply.
3 Remove the I/O board (Item 2 in Figure 8-1).
4 Remove all connectors from the CPU board (3), noting their position
and orientation for Installation.
5 Remove and retain the six 18 mm stand-offs (5) and remove the CPU
board.
6 Note the position of all links on the old CPU board.

Installation

Note: If the flash EPROMs on the new CPU board have not been pre-loaded with
the 460 Boot Monitor Program, transfer the flash EPROMs from the old CPU
board to the new CPU board.

1 Set the links on the new CPU board as noted above.

2 Position the CPU board on the six 18 mm stand-offs (5) with the
component side facing outwards and CON_K at the top left hand
corner.
3 Secure the CPU board with the six 18 mm stand-offs retained in step 3
of the removal procedure.
4 Refit the connectors.
5 Refit the I/O board and download the correct software for the
machine type.

Caution
TYPING ERROR. It is not possible to re-configure the CPU/FLASH
if the wrong configuration byte is typed.

6 Input any of the calibration settings you managed to record in step 1

of the removal procedure.
7 Perform any additional calibration necessary to return the printer to
normal operation.

8-6 CPU Board Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Levels Board

Removal

Note: It is possible to remove the entire electronics board assembly as a unit to

gain access to the Levels board.

1 Disconnect the printer from the mains electrical supply.

2 Remove the I/O board (see “I/O Board” on page 8-3).
3 Remove the CPU board (see “CPU Board” on page 8-6).
4 Remove all connectors from the Levels board (Item 4 in Figure 8-1).
5 Remove and retain the eight 18 mm stand offs and the earth strap
from the board.
6 Remove the Levels board.

Installation
1 Position the Levels board and earth strap and secure with the eight 18
mm stand offs.
2 Refit all connectors.
3 Refit the CPU board (see “CPU Board” on page 8-6).
4 Refit the I/O board (see“I/O Board” on page 8-3).

Rev AA Levels Board 8-7

Willett 460, 460Mi and 460Pi Service Manual

Power Supply Unit

W
O
L
F

1
(1) PSU (2) Quarter turn fasteners (x2)

Figure 8-3. Power supply unit

Removal
1 Disconnect the printer from the mains electrical supply.
2 Open the outer and inner doors.
3 Disconnect the mains live, neutral and earth push-on connectors from
the input side of the mains filter unit.
4 Remove the EHT plug from the EHT module.
5 Undo the two quarter-turn fasteners (Item 2 in Figure 8-3) securing
the unit.
6 Lift the PSU (1) forward and up to allow access to the electrical
connectors.
7 Disconnect the two electrical connectors and earth strap.
8 Remove the unit from the cabinet.

8-8 Power Supply Unit Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

9 Remove the two screws securing the EHT module to the PSU.

Installation
1 Fit the EHT module to the PSU assembly and secure with the two
screws obtained in step 9 of the removal process.
2 Connect the two electrical connectors and earth strap.
3 Correctly position the unit and secure with the two quarter-turn
fasteners.
4 Connect the mains live, neutral and earth push-on connectors to the
input side of the mains filter unit.
5 Insert the EHT plug into the EHT module.
6 Connect the printer to the mains electrical supply.

PSU Module Fuse Replacement

To replace PSU module internal fuse, proceed as follows:
1 Remove the PSU module as described above.
2 Remove and retain the four retaining screws shown in Figure 8-4 and
lift off the cover.

Figure 8-4. PSU Cover Retaining Screws

Rev AA Power Supply Unit 8-9

Willett 460, 460Mi and 460Pi Service Manual

3 Remove the fuse F1 from its holder (at the upper right-hand corner of
the PCB).

Figure 8-5. Location of PSU Fuse F1

4 Replace the fuse with one of identical value and voltage rating (T3A
250V). F1 is a fast acting glass tube fuse, 5.5 mm diameter, 21 mm
long.
5 Refit the PSU cover and secure it with the screws removed in step 2.
6 Refit the PSU as described above.

8-10 Power Supply Unit Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

LCD Board
(1) Bezel
(2) Keypad
(3) Standoffs
(4) Viewing window
(5) LCD board
(6) Securing nuts and washers
(7) Cabinet door

Figure 8-6. Keypad and LCD panel

Removal
1 Open the printer door (Item 7 in Figure 8-6).
2 Identify the LCD board (5) and remove the two ribbon connectors.
3 Remove and retain the four nuts and corresponding washers (6)
securing the LCD board to the stand-offs.
4 Remove the LCD board.
5 Carefully withdraw the assembly far enough to gain access to the
third ribbon connector.
6 Remove the ribbon connector and withdraw the assembly.

Rev AA LCD Board 8-11

Willett 460, 460Mi and 460Pi Service Manual

Installation
1 Connect the ribbon connector to the LCD board.
2 Position the board on the four stand-offs.
3 Secure the board using the four nuts and corresponding washers (6).
4 Connect the two ribbon connectors.
5 Close the printer door.

Keypad

Removal
1 Remove the LCD board from the printer (see “LCD Board” on page 8-
11).
2 Carefully remove the silicone sealant from the keypad (Item 2 in
Figure 8-6) connector tails.
3 Remove the black bezel (1) from the keypad.
4 Peel the keypad complete with overlay from the printer cabinet.

Installation
1 Clean the top surface of the printer cabinet including the viewing
window (4) to remove any adhesive left by the old keypad.
2 Remove the backing from the new keypad and fix in position on the
printer cabinet.
3 Apply silicone sealant around the edges of the LCD board.
4 Fit the LCD board (see “LCD Board” on page 8-11).
5 Position overlay on keypad and fix in position.
6 Apply silicone sealant around keypad connector tails.

8-12 Keypad Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Top Up Reservoir Sensor

Removal
1 Immediately above the sensor is a connector that joins the two leads
coming out of the sensor to a cable that originates in the electronics
compartment. Unclip this connector to separate the lead wires from
the cable.
2 Unscrew the sensor from the threaded receptacle on top of the
reservoir and lift it out.

Installation
1 Screw the level detector into the receptacle in the tank.
2 Join the connector at the end of the reservoir sensor lead wires to the
end of the cable disconnected in step 1 of the removal process.

Exchanging the Sensor and LED

(1) Level Detect Retainer
(2) Sensor Holder
(3) Sensor and LED
(4) Spacer Tube
(5) Spring
(6) Lens Retainer and Glans
(7) Sensor and LED wires

Figure 8-7. Level Detector

1 Remove the sensor from the tank as described above.

2 Unscrew the lens retainer (Item 6 in Figure 8-7) and thread it over the
trailing leads of the sensor and LED.

Rev AA Top Up Reservoir Sensor 8-13

Willett 460, 460Mi and 460Pi Service Manual

3 Slide the sensor holder (2), sensor and LED (3), spacer tube (4), spring
(5), lens retainer, glans (6) and wires (7) out of the level detect retainer
(1).
4 Remove the sensor and LED from the sensor holder.
5 Slide the sensor, LED and wires out of the spacer tube, spring, lens
retainer and glans. Discard the sensor and LED.
6 Slide the new sensor and LED into the glans, lens retainer, spring and
spacer tube.
7 Place the new sensor and LED in the sensor holder.
8 Re-insert the sensor holder, sensor, LED, spacer tube, spring, lens
retainer, glans and wires into the level detect retainer.
9 Screw the lens retainer and glans into the level detect retainer. Do not
over-tighten.
10 Install the assembled level detector as described above.

8-14 Top Up Reservoir Sensor Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Mains Cable Gland

(1) Mains cable gland

(2) Mains switch

1
Figure 8-8. Location of mains cable gland and mains switch

4 (1) Side panel

(2) Mains switch
(3) Mains cable gland
1 (4) Nut
(5) Washer

Figure 8-9. Removal and installation of mains switch

Removal
1 Disconnect the cables from the terminals at the rear of the mains
switch (Item 2 in Figure 8-9) noting their position for Installation.
2 Remove the cover (3) from the mains switch.
3 Push the switch out of its mounting hole, noting the orientation for
installation.

Rev AA Mains Cable Gland 8-15

Willett 460, 460Mi and 460Pi Service Manual

Installation
1 Push the mains switch (Item 2 in Figure 8-9) into its mounting hole
after checking for correct orientation.
2 Fit the cover (3) to the switch.
3 Reconnect the cables removed in step 1 of the removal procedure to
the terminals at the rear of the switch.

8-16 Mains Cable Gland Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

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. It is also
advisable to wear safety glasses when carrying out maintenance.
Apply barrier hand cream before handling ink.
If ink or top-up contaminates the skin, wash immediately with soapy
water. DO NOT use washdown or solvent to clean ink stains from
the skin.

Removal
1 Disconnect the top-pipe from the pre-pump filter.
2 Perform a nozzle flush and wait for the pump to start.
3 When the pipes are de-primed (10-16 seconds after the pump starts
racing), turn the mains on/off switch to OFF.
4 If you are working on a 460Pi, disconnect the tubes leading to the
gutter pump and the pressure damper.
5 Disconnect the mains electrical supply.
6 Reconnect the top-pipe to the pre pump filter.
7 Disconnect the condenser return pipe from the top of the FMS (Item 1
in Figure 8-10).
8 Disconnect the condenser input pipe from the condenser (see Item 3 in
Figure 6-24 on page 6-75).
9 Disconnect the four electrical connectors from the valve coils.
10 Undo the two quarter-turn fasteners and pull the FMS forward until it
is possible to unplug the temperature sensor connector.
11 Disconnect the seven level sense wires, noting their position for
Installation.
12 Disconnect the Venturi feed pipe (Item 2 in Figure 8-10) from the T-
piece.

Rev AA Fluid Management System (FMS) 8-17

Willett 460, 460Mi and 460Pi Service Manual

(1) Condenser return pipe

(2) Venturi feedpipe
(3) Valve electrical connections
(4) Main filter
(5) Quarter-turn fasteners x2
(6) FMS tray
(7) FMS securing screws
(8) FMS (mixer tank)
(9) Ink system manifold

Figure 8-10. FMS removal

13 Unscrew the three socket head screws securing the ink system
manifold (9).
14 Withdraw the ink system manifold whilst pulling the Venturi feed
pipe through the manifold until the pipe is clear.
15 Remove the main filter (4). See “Main Filter” on page 8-22 for removal
instructions.

8-18 Fluid Management System (FMS) Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

16 Remove the FMS from the machine.

Installation
1 Align the FMS with the locating lugs, which are mounted on top of the
leak detectors.
2 Install the main filter (4). See “Main Filter” on page 8-22 for
installation instructions.
3 Install the ink system manifold ensuring that the Venturi feed pipe is
correctly located.
4 Secure the manifold using the three socket head screws.
5 Connect the condenser return pipe to the FMS (1).
6 Connect the input pipe into the condenser.
7 Connect the Venturi feed pipe to the T-piece.
8 Connect the seven level sense wires (near item 7).
9 Connect the temperature sensor connector.
10 Push the FMS unit until it is correctly seated on the locating lugs and
secure with the two quarter-turn fasteners (5).
11 Connect the gutter pump tubes and the pressure damper tubes.
12 Check that all fluid connections are secure and that the bottom of the
cabinet is clean and dry.
13 Connect the valve coil connections to the correct valves.
14 Connect the electrical supply.
15 Commission the ink system as described in “Commissioning” on
page 2-2.
16 Recalibrate the VMS (see “Manually Priming the Flush Pump” on
page 5-17).

Rev AA Fluid Management System (FMS) 8-19

Willett 460, 460Mi and 460Pi Service Manual

Ink System Pump

(1) Ink system pump

Figure 8-11. Ink System Pump Removal

Removal
1 De-prime the ink system (see “Fluid Management System (FMS)” on
page 8-17).
2 Disconnect the PUMP connector from the I/O board.
3 Remove and retain the two captive screws securing the pump to the
printer cabinet.
4 Using a 12 mm spanner, undo the two Festo fittings connected to the
pump and pull off the tubing.
5 Use the arrow on the pump head to note orientation.
6 Remove the pump from the bulkhead taking care not to spill ink into
the exposed cabinet. Place a wad of tissue or absorbent cloth
underneath the pump to catch any ink spillage.

8-20 Ink System Pump Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Installation
1 Ensure that the pump is the correct type for the machine.
2 Remove one of the fluid connectors.
3 Inspect ink pump seal and exchange for a new item if necessary.
4 Refit fluid connector ensuring the O-ring is in the correct position.
5 Position the pump in the cabinet ensuring the arrow on the pump
head points downward.
6 Using a 12 mm spanner, tighten the two Festo fittings to the pump
and connect the tubing.
7 Secure the pump to the cabinet using the two captive screws.
8 Connect the PUMP connector to the I/O board.
9 Remove the tissue or cloth (placed to catch ink spillage) from beneath
the pump.

Rev AA Ink System Pump 8-21

Willett 460, 460Mi and 460Pi Service Manual

Main Filter

2
3
W
O
L

1 F

(1) Bleed cap

(2) Ink system main filter
(3) Spring holder

Figure 8-12. Main Filter

Removal
1 Turn off the printer and disconnect the mains electricity supply.
2 Open the cabinet door.
3 Grasp the filter body (Item 2 in Figure 8-12) and pull it out of the
spring holder (3). Pull the filter forward, clear of the printer cabinet.
4 Place a suitable container under the main filter to collect any ink
spillage.
5 Unscrew and retain the nuts from the filter elbows and release the
pipes from the filter.
6 Remove the filter.

Installation
1 Obtain a new filter and check that the bleed cap (1) is finger tight.
2 Fit the new filter, making sure the filter is oriented so that the bleed
cap is on the bottom.
3 Insert the pipes into the elbow connectors and tighten the nuts.

8-22 Main Filter Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

4 Push the filter body back into the spring holder. Check that the ink
pipes are not kinked.
5 Switch on the mains electricity supply and restart the printer. Check
for leaks.
6 Close and lock the cabinet door.
7 Dispose of waste ink in accordance with local instructions.

Rev AA Main Filter 8-23

Willett 460, 460Mi and 460Pi Service Manual

Flush Pump
(1) Quarter turn fasteners
(2, 5) Plastic fixing nuts (3 total)
(3) FMS tray
(4) Flush pump mounting
screws (2 total)

Figure 8-13. Flush Pump Removal

Removal
1 Remove and retain the two quarter turn fasteners (Item 1 in Figure 8-
13).
2 Lift the FMS tray (3) forwards out of the ink compartment.
3 The flush pump is secured by two mounting screws (4) accessed from
underneath the FMS tray. Remove and retain the two screws.
4 Remove and retain the plastic fixing nut (2, 5) on each of the hose
connectors and withdraw the hoses. Note that a third plastic fixing

8-24 Flush Pump Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

nut (green) is not pictured because it would appear behind the flush
pump in this figure. This nut and hose should also be removed.

Installation
Installation is the reverse of removal.

Rev AA Flush Pump 8-25

Willett 460, 460Mi and 460Pi Service Manual

Solenoid Valves
(1) Electrical connector
(2) Circlip
(3) Barb (V3, V7, V8 only)
(4) Tube
(5) Solenoid windings
(6) Valve block
(7) Retaining screws
(8) Dual O-ring assembly
(9) Captive retaining screw

Figure 8-14. Solenoid Valve Components

Removal
1 Turn off the printer and disconnect it from mains power.
2 Loosen the captive retaining screw and remove the electrical
connector (Item 1 in Figure 8-16) from the body of the valve.
3 Remove the tube (4) from the barb (3) if present (valves V3, V7 and
V8).
4 Remove the circlip (2) and slide the solenoid windings (5) off the valve
block (6) (note the orientation of the solenoid).
5 Remove and retain the two screws (7) securing the valve block to the
manifold.
6 Remove the valve block, complete with O-ring assembly. Retain the
O-ring assembly (8).

Installation
1 Fit the O-ring assembly (8) retained in step 6 of the Removal
procedure to the valve block (6).
2 Fit the valve block to the manifold and secure it with the two screws
(7) retained in step 4 of the removal process.
3 Slide the solenoid windings (5) on to the valve block and secure with
the circlip.

8-26 Solenoid Valves Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

4 Refit the electrical connector. See Table 8-1 for the correct connections.

Valve Wire colors

V3 Green/blue

V6 Black/white

V7 Orange/yellow

V8 Red/brown

Table 8-1: Valve wire connections

5 Refit the tube (4) on to the barb on the valve (if present).

Rev AA Solenoid Valves 8-27

Willett 460, 460Mi and 460Pi Service Manual

Cooling Fans

Removal
1 Disconnect the mains electrical supply.
2 Open the outer and inner cabinet door.
3 Identify the fan connector (JP11) on the Levels board and sever the fan
cable at the joint in the fan harness.
4 Remove fan finger guards.
5 Remove the four nuts and corresponding washers securing the fan to
the door.
6 Remove the fan.

Installation
1 Mount the fan on the door using the four nuts and corresponding
washers.
2 Reconnect the fan cable by soldering. Slide a new length of heatshrink
on to one side of each of the electrical connections. Solder the
connections and slide the heatshrink over each soldered joint.
3 Fit the fan finger guard.
4 Connect fan lead to JP11 on the Levels board.

8-28 Cooling Fans Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

EHT Module

W
O
L
F

(1) EHT plug

3 (2) Blanking plug
(3) Mounting bracket
(4) EHT module
1 2 4
Figure 8-15. EHT Module Removal

Removal
1 Disconnect the EHT plug (1) from the EHT module (4).
2 Disconnect JP8 from the Levels board.
3 Remove and retain the two screws securing the EHT module (4) to the
mounting bracket (3).
4 If the module has a spare EHT output, remove the blanking plug (2)
from that output.

Installation
1 If the EHT module to be installed has two EHT output sockets,
connect the blanking plug to the spare EHT output.
2 Using the two screws, secure the EHT module to the mounting
bracket.
3 Connect the electrical connector to JP8 on the Levels board.

Rev AA EHT Module 8-29

Willett 460, 460Mi and 460Pi Service Manual

4 Connect the EHT plug from the EHT module.

Head Manifold
The head manifold incorporates the gutter detect module and the head
heater.
$
 (1) Knurled screw
(2) Rear cover securing screws
(3) Ink barb
(4) Electrical connections
(5) Rear cover
(6) Front cover
(7) Feed Valve
(8) Return valve
! %
!

#
&

"

Figure 8-16. Head Manifold

Removal
1 Slacken the knurled screw (Item 1 in Figure 8-16) and slide the front
cover (6) off the printhead.
2 Remove and retain the two rear cover securing screws (2).
3 Slide the rear cover (5) back over the umbilical until it is clear of the
printhead.
4 Remove the heat shrink from the five electrical connections (4) at the
rear of the head heater. Make a note of how the wires are connected
and then unsolder the connections.
5 Disconnect the electrical connections to the feed valve (7) and return
valve (8).
6 Remove the tubes from the barbs (3) from the front and rear of the
head manifold.

8-30 Head Manifold Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

7 Remove the two screws under the print head tray that secure the head
heater/manifold in place.
8 The head heater can now be removed from the printhead.

Installation
1 Place the head heater in position on the printhead, with the electrical
connections to the rear.
2 Replace the screws securing the head heater/manifold in place on the
print head tray.
3 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 heat shrink over each soldered joint.
4 Reconnect the electrical connections to the feed valve and return
valve.
5 Push the ink tubes (3) on to the connectors at each end of the head
manifold.
6 Slide the rear cover (5) into position on the printhead and secure it
with the two screws (2) Removal step 2.
7 Slide the front cover on to the printhead and secure it with the
knurled screw (1).

Rev AA Head Manifold 8-31

Willett 460, 460Mi and 460Pi Service Manual

Phase Detector
4 (1) Printhead front cover
(2) Top deflector plate
1
(3) Phase detector
(4) Knurled screw
2 (5) Rear cover securing screw
3 (6) Rear cover
(7) Phase detector cable
(8) Phase detector clamping screw
(9) Cable clamp screw (x2)
(10) Lateral adjustment screw

5
8

10 7 9

Figure 8-17. Phase Detector Removal and Installation

Removal
1 Slacken the knurled screw (Item 4 in Figure 8-17) and slide the front
cover off the printhead.
2 Remove and retain the two rear cover securing screws (5) and slide
the rear cover (6) back until it is clear of the printhead.
3 Remove the heat shrink from the connections between the phase
detector and the cable loom. Make a note of how the wires are
connected and desolder the connections.
4 Slacken the phase detector clamping screw (8) and slide out the
detector. If necessary, slacken the lateral adjustment screw (10).
5 Slacken the rear cable clamp screws (9) to release the phase detector
cable.
6 Remove the phase detector from the printhead.

8-32 Phase Detector Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Installation
1 Route the phase detector cable (7), through the cable clamps (9) to the
rear of the printhead. Tighten the rear cable clamp screws (9), making
sure that the clamp does not crush the cables.
2 Slide the phase detector into its mounting hole and position it so that
the top of the detector is 1mm below the printhead nozzle orifice.
Tighten the clamping screw (8) to hold the detector in position.
3 Slide lengths of heat shrink on to one side of each of the phase
detector connections. Resolder the connections (as noted in step 3 of
the removal procedure) and slide the heat shrink over each soldered
joint.
4 Start the jet and ensure that the phase profile is correct (see “Phase
Profile Adjustment” on page 5-18).
5 Slide the rear cover (6) back into position and secure it with the two
screws (5) retained in step 2 of the removal procedure.
6 Slide the front cover (1) into position and secure it using the knurled
screw (4).

Rev AA Phase Detector 8-33

Willett 460, 460Mi and 460Pi Service Manual

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

8
4
7 5

12 11 10

Figure 8-18. EHT Block Removal and Installation

Removal
1 Slacken the knurled screw (Item 3 in Figure 8-18) and slide the front
cover (1) from the printhead.
2 Remove and retain the two rear cover securing screws (4).
3 Slide the rear cover back until it is clear of the printhead.
4 Cut the wires to the EHT housing.
5 Remove the two cable clamps (10 and 11).
6 Disconnect the strobe LED wires – colored blue and violet.
7 Loosen the phase detector clamping screw (8). Slide the phase detector
out of the EHT block, through the bottom of the printhead.
8 Loosen the charge electrode clamping screw (7) and pull the charge
electrode cable (6) from the EHT block.
9 Remove and retain the 0 V detector plate fixing screw (2) and deflector
plate. Pull the 0 V connecting cable away from the EHT block.

8-34 EHT Block Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

10 Remove and retain the two EHT block securing screws (12) which are
situated below the block.
11 Remove the EHT block, disconnecting the gutter return pipe as the
block is removed.

Installation
1 Place the EHT block in position, connecting the gutter return pipe at
the same time. Secure the block with the two screws retained in step 9
of the removal process (12).
2 Refit the 0 V deflector plate and 0 V connecting cable removed at
Removal step 7. Secure them with the fixing screw retained at
Removal step 8.
3 Fit the charge electrode cable (6) to the EHT block and tighten the
clamping screw (7).
4 Slide the phase detector back into the EHT block from the bottom of
the printhead. Position the top of the phase detector 1mm below the
nozzle orifice. Tighten the clamping screw (8).
5 Refit the front and rear cable clamps (10 and 11) taking care that the
cables are routed correctly through the channels in the clamps and not
crushed when the clamps are tightened.
6 Exchange the EHT housing and 22 MΩ resistor for new items, and
solder the resistor into the housing.
7 Using the supplied potting compound, fill the EHT housing up to the
top and cover with the supplied lid.
8 Carry out a full alignment procedure on the printhead (see “Printhead
Alignment” on page 11-7).
9 Slide the rear printhead cover (5) into position and secure it using the
two screws (4) Removal step 2.
10 Slide the front cover (1) into position and secure it using the knurled
screw.

Rev AA EHT Block 8-35

Willett 460, 460Mi and 460Pi Service Manual

Nozzle Assembly
(1) Nozzle assembly
2 (2) Knurled screw
(3) Rear cover securing screws
(4) Rear cover
(5) Heater manifold
(6) Cable/nozzle clamp screw
(7) Nozzle adjusting screw
1

7 6
Figure 8-19. Printhead Nozzle Removal and Replacement

Removal
1 Slacken the knurled screw (Item 2 in Figure 8-19) and slide the front
cover off the printhead.
2 Remove and retain the two rear cover securing screws (3) and slide
the rear cover (4) off the printhead.
3 Identify the leads from the nozzle to the wiring loom. Remove the
heat shrink and desolder the connections.
4 Disconnect the ink feed and return tubes from the heater manifold (5).

Note: If necessary, use a precision knife to cut the tubes away from the barb
fittings. Be very careful, however, not to damage the fittings themselves.

5 Remove and retain the cable/nozzle clamp screw (6) and the nozzle
adjusting screw (7).

8-36 Nozzle Assembly Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

6 Slide out the nozzle assembly (complete with last chance filter).

Note: Ensure that the new nozzle is the correct type prior to Installation:

Installation
1 Slide the nozzle assembly into position and secure it using the cable/
nozzle clamp screw (6) and the nozzle adjusting screw (7).
2 Tighten the lateral clamping screws (5).
3 Reconnect the ink feed and return tubes to the heater manifold (5).

Note: A short blast of hot air from a heat gun may improve the seal between
the barb fitting and the nozzle tube.

4 Slide a length of heat shrink over the nozzle electrical leads, resolder
the connections to the wiring loom and cover the soldered joints with
the heat shrink.
5 Select Nozzle Flush from the software menu option and irrigate the
nozzle orifice with washdown.
6 Slide the rear cover back into position and secure it with the two
screws (3) retained at Removal step 2.
7 Align the printhead (see “Printhead Alignment” on page 11-7).
8 Refit the front cover and secure it with the knurled screw (2).
9 Calibrate the modulation value (see “Modulation Calibration
(Manual)” on page 5-16).

Rev AA Nozzle Assembly 8-37

Willett 460, 460Mi and 460Pi Service Manual

Umbilical
The umbilical is attached to the printer by a lock nut.

Figure 8-20. Umbilical connection

Removal
1 Ensure the electrical supply is disconnected from the printer.
2 Disconnect the red-striped tube (Item 6 in Figure 8-21) from the flush
pump output filter.
3 Disconnect the black-striped tube (5) from the pre-head filter.
4 Disconnect the green-striped tube (2) and the clear tube (1) from
printhead manifold on the FMS.
5 Follow these four tubes to the bulkhead that divides the ink
compartment from the electronics compartment. Slacken the
bulkhead tube gland nuts and withdraw the tubes through the
bulkhead.

8-38 Umbilical Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

6 Disconnect the yellow-striped tube from the positive air pump (if
fitted).

(1) Clear tube

(2) Green-striped-tube
(3,4) Filters
(5) Black-striped tube
(6) Red-striped tube

Figure 8-21. Umbilical tube connections

7 Disconnect the modulation cable from the I/O board connector

labeled CH/MOD.
8 Disconnect the multi-core cable from the connectors Head_1 and
Head _2 on the I/O board.
9 Disconnect the four-way cable from the I/O board connector labelled
VALVES. Disconnect by removing the individual crimp connections
from the housing, noting their color and position.
10 Disconnect the EHT plug from the EHT module.

Rev AA Umbilical 8-39

Willett 460, 460Mi and 460Pi Service Manual

11 Remove the power supply unit to gain access to the cables to be

removed (see “Power Supply Unit” on page 8-8).
12 Disconnect the umbilical earth wire from the earth stud at the side of
the compartment.
13 Remove and retain the cable screen clamp screw (located near the
umbilical entry to the cabinet).
14 Undo and remove the umbilical lock nut.
15 Withdraw the umbilical, cables and tubes through the umbilical hole.

Installation
1 Fit the new umbilical, cables and tubes through the umbilical hole.
2 Fit and tighten the umbilical lock nut.
3 Strip the insulation to reveal the screen of the 15-way and 4-way
modulation cable to allow the cable clamp to make a sound electrical
contact with the outer screen of the cable.
4 Fit and tighten the cable screen clamp screw.
5 Connect the umbilical earth wire to the earth stud at the side of the
cabinet.
6 Refit the power supply unit (see “Power Supply Unit” on page 8-8).
7 Connect the EHT plug into the EHT module.
8 Connect the four-way cable to the I/O board connector labeled
VALVES.
9 Connect the multi-core cable to the connectors (Head_1 and Head _2)
on the I/O board.
10 Connect the modulation cable to the I/O board connector. (CH/
MOD)
11 Connect the yellow striped tube to the air pump (if fitted).
12 Pass the remaining tubes through the bulkhead tube glands and
tighten the nuts.
13 Connect the green-striped tube and the clear tube to the printhead
manifold located on the FMS. The green-striped cable goes on the left
of the three outlets. The clear tube goes on the middle one.
14 Connect the red-striped tube and the black-striped tube to the filters
in the ink system from which they were disconnected.
15 Perform an umbilical purge (see “Umbilical Purge” on page 11-5) and
flush purge.

8-40 Umbilical Rev AA

 PIN WIRE
PIN WIRE 1 BROWN

8-41
Willett 460, 460Mi and 460Pi Service Manual

1 2 RED
2 3 ORANGE
16 Ensure no leaks are present from the fluid connections during the

3 4 YELLOW

Umbilical
4 5 GREEN
57, 61 43, 61
30mm
5 60, 61 15 CORE CABLE 6 BLUE
15 CORE CABLE
6 7 VIOLET
WIRE LINK
7 8 CLEAR
8 YELLOW/WHITE
9 WHITE 29,50
35mm
9 BLUE/WHITE
10 BLACK
10 RED/WHITE
11 GREEN/WHITE 4 3
SOCKET PIN
12 GREY 665mm
2 1 LAYOUT
LOCKNUT AND SEAL SHOWN IN POSITION PIN WIRE
FOR REFERENCE ONLY KEEP THESE PARTS 450mm 1 CHARGE SIGNAL
IN THE MINIGRIP BAG SUPPLIED WITH 665mm 56,55 2 CHARGE SCREEN
THE UMBILICAL ASSEMBLY. 63
BLEED ALSO PLACE ITEMS 20, 26, 31, 39,40, EHT WIRE 25mm 3 MODULATION BLACK
MANIFOLD VALVE
(BLACK STRIPE) AND 58 INTO THE MINIGRIP BAG 4 MODULATION RED
CABLE.
EARTH WIRE SUPPLIED WITH THE
49

Figure 8-22. Umbilical Connection Details

30 UMBILICAL ASSEMBLY. CHARGE
59
FLUSH
(RED STRIPE)
605mm
47,29
30mm 30mm
25mm
25m 13 MODULATION

DATUM
30mm m
DATUM
DATUM

40
51
40m m
m
m 440mm
FEED EARTH WIRE
140m
m
(CLEAR)
40mm
40
57 m
VIOLET
225m PINK
CHARGE GREEN
above procedure.

BLUE
m
m

’D’ SPEC
40

GUTTER
750mm
(YELLOW STRIPE)
(BLUE STRIPE)
mm
55
59
48
m
40m

30mm
4x340mm
24 MANIFOLD VALVE
mm

EHT WIRE
49 330mm
CABLE.
150
HEATSHRINK TUBING
m MODULATION
80m
YELLOW STRIPE
’D’ SPEC TUBE
24

Rev AA
Willett 460, 460Mi and 460Pi Service Manual

Gutter Pump (460 Pi only)

(1) Gutter pump tubes
(2) Securing screws
(3) FMS tray
(4) Gutter pump cable
(5) Gutter pump screws
(6) Gutter pump

Figure 8-23. Gutter pump removal

Removal
1 Switch the mains power off and disconnect the printer from mains
power.
2 Remove the two securing screws (2) and carefully lift the FMS tray (3)
outwards until the gutter pump locating screws (5) are accessible.
3 Disconnect the two tubes (1) emerging from the gutter pump (6),
noting their positions.
4 Disconnect the gutter pump electrical connector from the levels board
(item 28 in Figure 6-14 on page 6-37).

8-42 Gutter Pump (460 Pi only) Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

5 Remove the grommet located between the two cabinet compartments

and withdraw the gutter pump cable (4).
6 Remove the two gutter pump screws (5), located underneath the FMS
tray and remove the gutter pump (6).

Installation
1 Attach the gutter pump (6) to the FMS tray (3) using the two gutter
pump screws (5).
2 Insert the gutter pump cable in the hole between the two
compartments and attach the grommet.
3 Connect the gutter pump tubes (1) to the gutter pump (6).
4 Slide the FMS tray into position and tighten the two fastening screws
(2).
5 Connect the gutter pump electrical connector to the levels board.

Rev AA Gutter Pump (460 Pi only) 8-43

Willett 460, 460Mi and 460Pi Service Manual

460 Pi Pressure Damper

(1) Pressure damper tubes
(2) Securing screws
(3) FMS tray
(4) Pressure damper
(5) Pressure damper screws

Figure 8-24. Pressure damper removal

Removal
1 Switch the mains power off and disconnect the printer from mains
power.
2 Disconnect the two tubes (1) from the pressure damper (4), noting
their positions.
3 Remove the two securing screws (2) and carefully lift the FMS tray (3)
outwards until the pressure damper locating screws (5) are accessible.
4 Remove the two pressure damper locating screws (5).
5 Retrieve the pressure damper.

8-44 460 Pi Pressure Damper Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Installation
1 Attach the pressure damper (4) to the FMS tray (3) using the two
pressure damper screws (5).
2 Connect the pressure damper tubes (1) to the pressure damper (4).
3 Slide the FMS tray into position and tighten the two securing screws
(2).

Rev AA 460 Pi Pressure Damper 8-45

Willett 460, 460Mi and 460Pi Service Manual

FMS and Ink Tank Stirrers (460 Pi only)

(1) Ink tank stirrer

(2) FMS stirrer
(3) Securing screws
(4) FMS tray

Figure 8-25. Stirrers removal

FMS Stirrer Removal

1 Switch the mains power off and disconnect the printer from mains
power.
2 Remove the two securing screws (3) and carefully lift the FMS tray (4)
outwards until the stirrers (1 and 2) are accessible.
3 Remove the stirrers electrical connection from the levels board ( item
23 in Figure 6-14 on page 6-37).
4 Remove the wires from the electrical connector and draw the cable
through the cable gland in the bulkhead.
5 Remove the two screws that secure the stirrer to the FMS tray (the are
located on the bottom of the tray).
6 Remove the stirrer.

8-46 FMS and Ink Tank Stirrers (460 Pi only) Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Ink Tank Stirrer Removal

1 Follow steps 1 through 4 of the FMS stirrer removal procedure.
2 Unscrew the ink housing nut while the ink tank is raised to release the
stirrer.

Installation
Installation is the reverse of removal for both the FMS stirrer and the ink
tank stirrer.

Ink Reservoir Magnetic Follower Replacement

The magnetic follower bar in the ink reservoir should inspected (and
perhaps replaced) roughly once every six months.
1 Use a syringe and tubing to remove all ink from the ink reservoir.
2 Remove the electrical connections to the valve and the two level
sensor probes.
3 Unscrew the ink housing nut to allow the ink reservoir to be removed.
4 Remove the ink reservoir manifold.
5 Turn the ink tank upside down into a suitable ink catcher to retrieve
the magnetic follower and metal plate from inside the reservoir.
6 Check the magnetic follower for signs of wear to the collar rib in the
middle of the bar. If the collar is worn, replace the follower bar with a
new one.

7 Clean the metal plate.

8 Place the follower in the ink reservoir and switch the printer on and
check that the magnetic follower rotates correctly.
9 Reattach the ink reservoir manifold.
10 Hold the ink reservoir in position and replace the ink housing nut.
11 Reattach the valve electrical connector and the level sense electrical
connections.
12 Refill the ink reservoir.

Rev AA FMS and Ink Tank Stirrers (460 Pi only) 8-47

Willett 460, 460Mi and 460Pi Service Manual

Mixer Tank Magnetic Follower Replacement

The magnetic follower bar in the mixer tank should be inspected (and
perhaps replaced) roughly once every six months.
1 Gain access to the top of the FMS by removing the FMS tray.
2 Free the lid of the FMS by removing the following:
• the two level probes from the VMS sensors
• the condenser output vent pipe (Item 1 in Figure 8-26)
• the blue festo fitting on top of the venturi (2)
• the four allen screws which hold the lid on (3)

Figure 8-26. Removing the FMS lid

3 Remove the lid (4).

8-48 FMS and Ink Tank Stirrers (460 Pi only) Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

4 Remove the three screws (Item 1 in Figure 8-27)which fasten the mixer
tank to the top of the FMS.

Figure 8-27. Removing the top portion of the FMS

5 Left the top of the FMS away (2) from the mixer tank (3).
6 Remove the magnetic follower bar and check it for wear. Replace if
necessary.
7 Remove any ink sediment from the metal plate located in the bottom
of the mixer tank.
8 Place the magnetic follower bar back in the mixer tank make sure that
it rests on the magnetic plate rather than near the tubes on the other
side chamber.
9 Switch the printer power on before reassembling the FMS. Make sure
that the follower bar rotates correctly.

Rev AA FMS and Ink Tank Stirrers (460 Pi only) 8-49

Willett 460, 460Mi and 460Pi Service Manual

10 Replace the top of the FMS and secure it with the three screws
removed in step 4.
11 Replace the FMS lid and secure it with the four allen screws removed
in step 2.
12 Replace the blue festo fitting, the condenser output vent pipe and the
two VMS sensor level probes.
13 Return the FMS tray to its proper position.

8-50 FMS and Ink Tank Stirrers (460 Pi only) Rev AA

Maintenance Schedule
9
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.

Task Daily Weekly 6 Months 1 Year 24 Months Reference

Check Printhead, clean as

required 9 page 6-6

Clean Printer Cabinet

9 page 6-4

Visual inspection of
connections and fittings 9
Clean EHT block
9 page 8-34

Replace cooling fan dust

filter* 9 page 8-28

Replace main ink filter

9 page 8-22

Replace pre-pump filter

9 page 6-70

Replace “last chance”

filter in printhead 9 page 12-17

Clean all valves

9 page 11-1

Inspect magnetic follower

bars and clean metal 9 pages 8-46
and 8-47
stirrer plates
Replace pre-head filter
and flush filter 9 page 6-70

Replace ink pump

§
9 page 8-20

Table 9-1: Preventative Maintenance Schedule

Rev AA 9-1
Willett 460, 460Mi and 460Pi Service Manual

Task Daily Weekly 6 Months 1 Year 24 Months Reference

* May be required as often as every few days or as infrequently as once a month depending on fac-
tory conditions.
§
Check and replace only if necessary

Table 9-1: Preventative Maintenance Schedule

9-2 Rev AA
Troubleshooting
10
Warning
LETHAL VOLTAGES. Lethal voltages are present within this
equipment when it is connected to the mains electrical supply. Only
trained and authorized 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.

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. It is also
advisable to wear safety glasses when carrying out maintenance.
Apply barrier hand cream before handling ink.
If ink or top-up contaminates the skin, wash immediately with soapy
water. DO NOT use washdown or solvent to clean ink stains from
the skin.

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.

Rev AA 10-1
Willett 460, 460Mi and 460Pi Service Manual

Introduction
Before carrying out the fault finding and repairs described in this section it
is advisable to move the printer from the production line to a clean
environment.
When a fault condition occurs, the first step in diagnosing the fault should
be to check the following:
• The fault and status icons displayed on the display.
• The status LEDs on the I/O board.
Table 10-2 on page 10-7 through Table 10-5 on page 10-9 list the possible
faults. The tables contain either remedial action or a reference to more
detailed fault finding information.
By using the schematics and the associated tables to check signal voltages
and waveforms, the faulty component or sub-assembly can be pinpointed.

10-2 Introduction Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Fault Finding

Printer Fails to Initialize

Possible Cause Remedial Action

No mains supply Check that mains supply is available and switched on.

Mains input cable disconnected or 1. Check that mains input cable is connected.
faulty 2. Check continuity of cable. Repair or replace if faulty.

Printer mains fuse(s) failed Check the fuses next to the mains power switch.
Replace if necessary.

Faulty mains switch Check mains power switch for continuity. Replace if
faulty.

Cable between mains switch and 1. Check cable connections. Reconnect if necessary.
PSU is disconnected or faulty 2. Check cable for continuity. Replace if faulty.

PSU faulty or PSU output not 1. Check LEDs 1, 2 (dim or bright), 3, 4 and 5 on I/O
reaching the I/O board board (see “I/O Board Status LED Location” on
page 10-4).
2. If any LED is extinguished go through steps 9 to 11 in
that order.

Cable between PSU and I/O 1. Check that cable is connected. Reconnect if neces-
board is faulty or disconnected sary.
2. Check cable for continuity, replace if faulty.

PSU fuse failed Check fuse, replace if necessary (see “PSU Module
Fuse Replacement” on page 8-9).

PSU faulty Replace PSU (see “Power Supply Unit” on page 8-8).

I/O or CPU board failed 1. Check that LEDs 1, 2 (dim or bright), 3, 4 or 5 on I/O
board are illuminated (“I/O Board Status LED Loca-
tion” on page 10-4).
2. Change I/O board (see “I/O Board” on page 8-3). If
fault remains then change CPU board (“CPU Board”
on page 8-6).

Note: LED2 on the I/O board has a clear lens that glows red when illuminated.

Rev AA Fault Finding 10-3

Willett 460, 460Mi and 460Pi Service Manual

(1) LED 1 (green); +12 V isolated supply (3) LED 3 (yellow); -24 V
(2) LED 2 (red); (4) LED 4 (red); -15 V
285 V (bright) charge amplifier supply (5) LED 5 (green); +24 V valve/ pump/heater supply
(+15 V (dim); no printhead cover fitted)

Figure 10-1. I/O Board Status LED Location

10-4 Fault Finding Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

TP1 = 1
TP2 = 2
TP3 = 3
TP4 = 4
TP5 = 5
TP6 = 6
TP7 = 7
TP8 = 8
TP9 = 9

Figure 10-2. I/O Board Test Point Locations

Test point Signal

TP1 0 V.

TP2 +285 V DC charge amplifier supply.

TP3 Ink temperature at viscometer delivery line.

TP4 Charge voltage to printhead.

TP5 Ink system pressure (1 V — 1 bar).

TP6 Modulation drive voltage to printhead.

Table 10-1: Functions of I/O board test points

Rev AA Fault Finding 10-5

Willett 460, 460Mi and 460Pi Service Manual

Test point Signal

TP7 Phase detector output prior to hedgehog clipping.

TP8 0 V.

TP9 +5 V (can be used with logic probe).

Table 10-1: Functions of I/O board test points

10-6 Fault Finding Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

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.

Possible Cause Remedial Action

Backlight shut down by screen Press any key on the keypad to restart the backlight.
saver facility

Backlight inverter faulty 1. Check for 24 V DC at 3 way input connector on

backlight converter (Pins 1 and 2 on I/O board B/
LIGHT connector).
2. Check for 1000 V AC at output leads from backlight
inverter (Pins 3 and 5).
3. If 24 V DC present but 1000 V AC missing, change
the LCD/backlight assembly (see “LCD Board” on
page 8-11).

Cable from I/O board to backlight 1. If 24 V DC is not present at backlight inverter but is
is disconnected or faulty present at Pins 1 and 3 of B/LIGHT connector on I/
O board, check that the cable is connected
between the two.
2. Check cable for continuity, replace if faulty.

Backlight faulty If 1000 V AC is present at output of backlight inverter

but backlight not illuminated, change the LCD/Back-
light assembly (see “LCD Board” on page 8-11).

I/O or CPU board faulty 1. Check for 24 V DC on pins 1 and 3 of B/LIGHT con-
nector on I/O board. If voltage not present, change
I/O board (see “I/O Board” on page 8-3).
2. If changing the I/O board does not clear the fault,
change the CPU board (see “CPU Board” on
page 8-6).

Table 10-2: Display Backlight Failure

Rev AA Display Faults 10-7

Willett 460, 460Mi and 460Pi Service 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 Check cable for continuity. Replace if faulty.
and LCD is faulty.

I/O board or CPU board faulty. Change I/O board (see “I/O Board” on page 8-3) or
CPU board (see “CPU Board” on page 8-6).

LCD faulty. Change LCD assembly

(see “LCD Board” on page 8-11).

Table 10-3: Display Failure

Keypad Faults

Possible Cause Remedial Action

Ribbon cable between CPU board 1. Check that cable is connected.

and keypad is disconnected or 2. Check cable for continuity, replace if faulty.
faulty

CPU board faulty Exchange CPU board

(see “CPU Board” on page 8-6).

Keypad faulty Exchange keypad (see “Keypad” on page 8-12).

Table 10-4: Keypad Failure

10-8 Display Faults Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Display Icons
Icon Name Possible Cause Remedial Action

Ink Level Ink top up or solvent top 1. Top up the empty reservoir with ink or
Low up reservoir empty. The solvent as necessary. Check that the
part number of the ink or icon is no longer displayed. If it is still
solvent is also displayed. displayed, proceed to Step 2.

Top Up Cable between sensor 2. Check that cable is connected to CONN

Level Low and I/O board is faulty or LEVELS on the I/O board. (see “CPU
disconnected. Board” on page 8-6 for connector loca-
tion).

Sensor faulty. 3. If sensor faulty, replace FMS (see “Fluid

Management System (FMS)” on page 8-
17).

I/O or CPU board faulty 4. Replace I/O board

(see “I/O Board” on page 8-3) or CPU board

(see “CPU Board” on page 8-6).

Mixer Tank The mixer tank level is Fill mixer tank (see “Fill Mixer Tank” on
Level Low too low. page 5-14)

Valve V2 not functioning Change valve (see “Solenoid Valves” on

correctly. page 8-26), I/O board (see “I/O Board” on
page 8-3) or CPU board (see “CPU Board”
on page 8-6).

Valve V2 stuck internally. Clean valve V2 (see “Valve Cleaning” on

page 11-1).

Replace valve (see “Solenoid Valves” on

page 8-26) if fault remains.

Sensor or cable faulty. 1. Check that cable is connected.

2. Replace FMS (see “Fluid Management
System (FMS)” on page 8-17), I/O board
(see “I/O Board” on page 8-3), CPU
board (see “CPU Board” on page 8-6) or
Levels board (see “Levels Board” on
page 8-7).

Table 10-5: Display Icons

Rev AA Display Icons 10-9

Willett 460, 460Mi and 460Pi Service Manual

Icon Name Possible Cause Remedial Action

Mixer Tank The mixer tank level is For troubleshooting instructions, see “Mixer
Level High genuinely too high (i.e. Tank Level High” on page 10-13.
the level high sensor is
covered with ink).
or
There is a fault in the
level high sensor circuit
and a fault is being indi-
cated even though the
sensor is not covered.

Viscosity Top up reservoir empty. Fill the top up reservoir with solvent and run
Error the machine to correct the viscosity.

Top up reservoir valve Change valve (see “Solenoid Valves” on

(V1) not functioning cor- page 8-26), I/O board (see “I/O Board” on
rectly. page 8-3) or CPU board (see “CPU Board”
on page 8-6).

Valve V1 stuck internally. Clean valve V1 (see “Valve Cleaning” on

page 11-1).

Replace valve (see “Solenoid Valves” on

page 8-26) if fault remains.

VMS inlet restrictor Clean inlet restrictor (see “VMS Inlet

blocked. Restrictor Cleaning” on page 11-2).

VMS outlet blocked. Clean outlet restrictor (see “VMS Outlet

Cleaning” on page 11-3).

VMS level sensor or Check that cable is connected.

cable faulty.
Replace FMS if sensor faulty (see “Fluid
Management System (FMS)” on page 8-
17), I/O board (see “I/O Board” on page 8-
3) or CPU board (see “CPU Board” on
page 8-6).

I/O board faulty. Replace I/O board (see “I/O Board” on

page 8-3).

CPU board faulty. Replace CPU board (see “CPU Board” on

page 8-6).

Service Filters require replace- 1. Exchange the filters for new items (see
ment. “Main Filter” on page 8-22).
2. Reset the pump run hours (see “Data
Logging Menu” on page 7-15).

Table 10-5: Display Icons

10-10 Display Icons Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Icon Name Possible Cause Remedial Action

Printhead Printhead cover is not fit- Re-fit the cover.

Cover ted correctly.
Open

Gutter Nozzle blocked. 1. Perform nozzle flush (see “Nozzle Flush”

Fault on page 6-91).
2. Check that the jet is going into the gutter.
Repeat nozzle flush 3 or 4 times if
required.

Nozzle misaligned. Re-align printhead (see “Printhead Align-

ment” on page 11-7).

Faulty gutter detect cir- Replace gutter detect module (see “Head
cuit. Manifold” on page 8-30), I/O board (see “I/
O Board” on page 8-3) or CPU board (see
“CPU Board” on page 8-6).

EHT Trip Dirty or wet printhead. Clean and thoroughly dry printhead (see
“Umbilical Purge” on page 11-5).

EHT trip out of calibra- Re-calibrate EHT trip (see “Set EHT Trip
tion. Level (Normal Operation)” on page 5-31).

Faulty EHT circuit. Replace faulty component/EHT Module

(see “EHT Module” on page 8-29), I/O
board (see “I/O Board” on page 8-3) or CPU
board (see “CPU Board” on page 8-6).

Cabinet Environment too hot for Measure ambient temperature. If it is

Too Hot printer. greater than 45°C, move the printer to a
cooler position or reduce ambient tempera-
ture by improving ventilation etc.

Printer air inlet or outlet Check that the printer is level and that the
blocked. inlet (grille on the bottom of the printer) and
outlet (vent on printer’s right side) are clear.

Fan failed Check for 24 V DC across pins 4 and 5 on

the EHT/FAN connector on the I/O board. If
the voltage is present, replace the fan (see
“Cooling Fans” on page 8-28).

I/O board faulty Replace I/O board (see “I/O Board” on

page 8-3).

CPU board faulty Replace CPU board (see “CPU Board” on

page 8-6).

Table 10-5: Display Icons

Rev AA Display Icons 10-11

Willett 460, 460Mi and 460Pi Service Manual

Icon Name Possible Cause Remedial Action

Charge Dirty printhead Clean printhead (see “Umbilical Purge” on

Error page 11-5).

Viscosity incorrect Refer to the viscosity error icon in this table

for possible causes and remedial action.

Modulation incorrect Adjust as required (see “Modulation Cali-

bration (Manual)” on page 5-23).

Head heater circuitry Replace head heater (see “Head Manifold”

faulty on page 8-30), I/O board (see “I/O Board”
on page 8-3) or CPU board (see “CPU
Board” on page 8-6).

Faulty nozzle assembly Replace nozzle (see “Nozzle Assembly” on

or modulation circuitry page 8-36), I/O board (see “I/O Board” on
page 8-3) or CPU board (see “CPU Board”
on page 8-6).

Charge electrode or cir- Replace EHT Block cabling (see “EHT

cuitry faulty Block” on page 8-34), I/O board (see “I/O
Board” on page 8-3) or CPU board (see
“CPU Board” on page 8-6).

Phase detector or cir- Replace phase detector cabling (see

cuitry faulty “Phase Detector” on page 8-32), I/O board
(see “I/O Board” on page 8-3) or CPU board
(see “CPU Board” on page 8-6).

Table 10-5: Display Icons

10-12 Display Icons Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Mixer Tank Level High

To determine why the Mixer Tank Level High icon is displayed, proceed
as follows:
1 Loosen the two quarter turn fasteners (Item 2 in Figure 10-3) and lift
the FMS tray (3) forwards and out of the printer.
2 Remove the filler plug (1) from the FMS (4).
3 Use a syringe and plastic tube, remove 100 ml of ink from the FMS to
uncover the level high sensor.
4 If the icon is no longer displayed, the level high sensor is working
5 If the icon remains on the display, the level high sensor circuit is
faulty.
(1) Filler plug
(2) Fasteners
(3) FMS tray
(4) FMS

Figure 10-3. Location of FMS Filler Plug

Rev AA Display Icons 10-13

Willett 460, 460Mi and 460Pi Service Manual

Note: Before carrying out the checks listed in Table 10-6, add 100 ml of ink to the
FMS to ensure that the mixer tank level OK sensor is covered.

Fault Possible Cause Remedial Action

Mixer Tank Level VMS incorrectly cali- Check ink viscosity (see “Press to enable both func-
High-Sensor brated tions.” on page 5-35). If incorrect, drain the mixer tank
Covered and refill with new ink (see “Fill Mixer Tank” on
page 5-14). Recalibrate the VMS (see “Manually
Priming the Flush Pump” on page 5-17).

Mixer OK, sensor or Go to the Diagnostic screen of the Calibrate menu

cable faulty (see “Calibrate Menu” on page 7-13). If Mixer OK is
OFF then the sensor circuit is faulty.

Check that the sensor cable is connected.

Replace FMS (see “Fluid Management System

(FMS)” on page 8-17) if level sensor is faulty.

Replace I/O board (see “I/O Board” on page 8-3) or

CPU board (see “CPU Board” on page 8-6).

Faulty valve on ink or Replace valve if faulty (see “Solenoid Valves” on

top up reservoir page 8-26).

Valve stuck internally Clean valve V2 (ink) and V1 (top up) (see “Valve
Cleaning” on page 11-1). Replace valve if fault
remains (see “Solenoid Valves” on page 8-26).

Mixer Tank Level Cable between Mixer Check that cable is connected
High-Sensor level high sensor and I/
uncovered O is faulty or discon-
nected

Mixer level high sensor If sensor faulty, replace FMS (see “Fluid Management
circuit faulty System (FMS)” on page 8-17).

Replace I/O board (see “I/O Board” on page 8-3) or

CPU board (see “CPU Board” on page 8-6).

Table 10-6: Mixer Tank Level High Possible Causes

10-14 Display Icons Rev AA

Cleaning and
Adjustment 11
Valve Cleaning
1 Remove the valve (see “Solenoid Valves” on page 8-26).
2 Remove the valve plate retaining screws (Item 1 in Figure 11-1).
Retain the screws and note the orientation of the plate.
3 Pull the valve stem (2) and the valve plate (3) away from the valve
block (4).

1
(1) Valve plate retaining screws
(2) Valve stem
(3) Valve plate
(4) Valve block
2

4 1 3

Figure 11-1. Valve Components

4 Disassemble the internal valve components (Figure 11-2) noting the

orientation of each.
5 Clean all the components in a suitable Willett solvent washdown.
6 Reassemble the internal valve components.
7 Fit the valve plate to the valve block and secure it using the two
screws removed in step 2.
8 Refit the valve in the printer.

Rev AA Valve Cleaning 11-1

Willett 460, 460Mi and 460Pi Service Manual

(1) Valve block

 (2) Valve plunger
(3) Valve plate
(4) Valve stem
(5) Valve stem O-ring
(6) Valve plunger spring

!
"

Figure 11-2. Valve Internal Components

VMS Inlet Restrictor Cleaning

1 Remove valve V3 from the FMS valve plate (see “Fluid Management
System (FMS)” on page 8-17).
2 Pull the VMS restrictor block (Item 3 in Figure 11-3) 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.
3 Wash the restrictor block with solvent. Blow through the restrictor
orifice (4) with an air line or force solvent through it.
4 Hold the restrictor block up to the light and check that the orifice is
clear.
5 Refit the restrictor block over the valve retaining screws, with the O-
rings (5) facing outwards.

Caution
If step 5 is not performed correctly, the restrictor block may be
obstructed by the valve face gasket.

11-2 VMS Inlet Restrictor Cleaning Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

6 Refit the valve (see “Solenoid Valves” on page 8-26).

(1) Valve retaining screws

(2) Valve body
(3) VMS restrictor block
(4) Restrictor orifice
(5) O-rings

Figure 11-3. VMS Restrictor Cleaning

VMS Outlet Cleaning

1 Remove all screws from the top of the FMS; retain all screws, washers
and seals.
2 Remove the top of the FMS.
3 Remove the four retaining screws (Item 1 in Figure 11-4) from the top
of the VMS chamber (3) remove the lid (2) and sealing gasket located
under the lid. Note the orientation of the gasket.
4 Carefully run a fine wire through the outlet orifice in the bottom of the
chamber.
5 Syringe a small amount of ink into the VMS chamber and check that it
runs out into the mixer tank below.
6 When the outlet is clear, refit the VMS chamber lid and gasket and
secure it using the four screws removed at step 3.
7 Refit the top of the FMS using the screws removed at step 1.

Rev AA VMS Outlet Cleaning 11-3

Willett 460, 460Mi and 460Pi Service Manual

(1) Retaining screw

(2) VMS chamber lid
1
(3) VMS chamber 2

Figure 11-4. VMS chamber

11-4 VMS Outlet Cleaning Rev AA

 Willett 460, 460Mi and 460Pi Service 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
• if a new umbilical has been fitted
• if the type of ink or the ink color is to be changed
Follow these steps:
1 Set the mains switch to off and disconnect the printer from the mains
supply.
2 Loosen the knurled screw (Item 2 in Figure 11-5) and remove the
printhead front cover (3).

(1) Ground potential deflector electrode

(2) Knurled screw
(3) Front cover
(4) Rear cover securing screws
(5) Rear cover
(6) Printhead body

Figure 11-5. Printhead Assembly

3 Remove the rear cover securing screws (4) and slide the rear cover (5)
off the printhead body (6).

Rev AA Umbilical Purge 11-5

Willett 460, 460Mi and 460Pi Service Manual

4 Remove nozzle tubes from the manifold barbs then fit a short loop of
tube between the two barbs to link then together.
5 Connect the printer to the mains supply and set the mains supply to
on.
6 Select the Umbilical Purge option from the System menu.

7 Select Enable and press or to start the umbilical purge.

8 After fifteen minutes stop the umbilical purge, by selecting Disable

from the Umbilical Purge option.

9 Disconnect the short loop of tubing then reconnect the nozzle tubes
back onto the barbs.
10 Slide the rear cover back into position on the printhead and secure it
using the two screws (4) removed at step
11 Refit the front over (3) and secure it with the knurled screw (2).

11-6 Umbilical Purge Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Printhead Alignment
1 Slacken the knurled nut and remove the front cover from the
printhead.
2 Secure the printhead vertically in a suitable stand with the nozzle
pointing downwards. Place a suitable container beneath the printhead
to catch the ink.
3 Disable Gutter Detect and Charge Check as follows:
a. Access the System menu.
b. Select Gutter Fault Shutdown Disable.
c. In the Machine Control sub-menu, select Gutter Fault and toggle to
Disable.

d. Select Charge Error and toggle to Disable.

e. Press .
enter

4 Perform a quick start from the system menu. When the ink jet has
started, check that the ink jet is in the correct position in the gutter (See
Figure 11-6).

Important! You must perform a quick start rather than a clean start when
you are aligning the printhead during the commissioning process. However,
if you are aligning the printhead of a printer that has already been in
operation for some time, you may perform either a quick start or a clean start
at this point.

Caution
EQUIPMENT DAMAGE. Never attempt to bend the gutter. Its
position is fixed.

Rev AA Printhead Alignment 11-7

Willett 460, 460Mi and 460Pi Service Manual

Gutter
center line

460 Si/Mi
alignment

Optimum jet position, 2 to First quarter

3 times diameter of jet of the gutter

460 Pi
alignment

First third of
the gutter

Figure 11-6. Ink Jet Gutter Position

5 Adjust the ink jet position if necessary using the lateral adjustment
screws (Item 3 in Figure 11-7) and height adjustment screw (4). When
the adjustment has been made ensure that the lateral adjustment
screws are tight and the ink jet position is correct.

11-8 Printhead Alignment Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

1
2
3

6
7
(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
4 5

Figure 11-7. Printhead Adjustment Screw Location

6 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 11-8).

(1)Equidistant gap

Figure 11-8. Ink Jet Flow Through Charge Electrode

Rev AA Printhead Alignment 11-9

Willett 460, 460Mi and 460Pi Service Manual

Caution
DAMAGE TO CHARGE ELECTRODE. Take care not to deform the
charge electrode slot when rotating the charge electrode.

Caution
CHARGE CABLE. Ensure that the charge cable is not pulled out of
its position in the rear face of the deflector block assembly.

7 To centralize the ink jet flow through the charge electrode:

8 Release the lateral adjustment screw (Item 4 in Figure 11-7).
a. Move the block until the jet is in the correct position. Secure the
adjustment screw and recheck jet position.
b. For parallel adjustment release the charge electrode clamping screw
(6).
c. Rotate the charge electrode until the jet is parallel to, and in the
centre of the slot.
d. Secure the clamping screw ensuring that the charge cable is
clamped.
9 Check that the ink jet is approximately 1 mm away from the phase
detector. To adjust, release the phase detector clamping screw (7) and
move the phase detector sensor to the correct position. Secure the
phase detector clamping screw.
10 When ink jet alignment is correct, reposition the ground potential
deflector electrode and secure.
11 From the Machine Control sub-menu:
a. Select Gutter Fault to enable Gutter Detect.
b. Select Charge Error to enable Charge Check.

11-10 Printhead Alignment Rev AA

Illustrated Parts List
12
How to Use This Parts List
1 The illustrations and the associated tables give ordering information
for the available spare parts for the 460, 460Mi and 460Pi printers.
2 Where a component is not illustrated the letters “NI” appears against
the entry for the item.
3 Items that do not have a part number listed are not orderable
individually. There are two types of such items:
• Standardized hardware items (nuts, bolts, etc.). You should be able
to find such items at a local hardware store
• Items that are only available as part of a parts kit

Optional Parts and Accessories

Table 12-8 though Table 12-12 give lists of optional parts, accessories, and
documentation. There are no illustrations associated with these tables.

Rev AA How to Use This Parts List 12-1

Willett 460, 460Mi and 460Pi Service Manual

460 Ink Jet Printer

Figure 12-1. 460 Ink Jet Printer

12-2 460 Ink Jet Printer Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

460 Si with 90° printhead

Keypad Overlay Description 3m umbilical 6m umbilical

English/USA 200-0466-931 200-0466-961

European 200-0466-932 200-0466-962

Turkish/Scandinavian 200-0466-933 200-0466-963

Greek 200-0466-934 200-0466-964

Katakana 200-0466-935 200-0466-965

Russian 200-0466-936 200-0466-966

Bulgarian 200-0466-937 200-0466-967

Czech/Slovak/Lithuanian 200-0466-938 200-0466-968

Polish 200-0466-939 200-0466-969

Arabic 200-0466-940 200-0466-970

Korean 200-0466-941 200-0466-971

Hebrew 200-0466-942 200-0466-972

Chinese 200-0466-943 200-0466-973

Taiwanese 200-0466-944 200-0466-974

Thai 200-0466-945 200-0466-975

Farsi 200-0466-946 200-0466-976

English k/pad & [Link] S/W 200-0466-947 200-0466-977

English k/pad & [Link] S/W 200-0466-948 200-0466-978

English k/pad & VJIM S/W 200-0466-949 200-0466-979

English k/pad & Korean S/W 200-0466-950 200-0466-980

English k/pad & Chinese S/W 200-0466-951 200-0466-981

English k/pad & Arabic S/W 200-0466-952 200-0466-982

English k/pad & Middle East S/W 200-0466-953 200-0466-983

English k/pad & Hindi S/W 200-0466-954 200-0466-984

English k/pad & Farsi S/W 200-0466-955 200-0466-985

English k/pad & Thai S/W 200-0466-956 200-0466-986

Main Euro k/pad & [Link] S/W 200-0466-957 200-0466-987

Arabic k/pad & Middle East S/W 200-0466-958 200-0466-988

Table 12-1: 460 Si with 90 degree printhead

Rev AA 460 Ink Jet Printer 12-3

Willett 460, 460Mi and 460Pi Service Manual

460 Mi with 90° printhead

Keypad Overlay Description 3m umbilical 6m umbilical

English/USA 200-0467-931 200-0467-961

European 200-0467-932 200-0467-962

Turkish/Skandinavian 200-0467-933 200-0467-963

Greek 200-0467-934 200-0467-964

Katakana 200-0467-935 200-0467-965

Russian 200-0467-936 200-0467-966

Bulgarian 200-0467-937 200-0467-967

Czech/Slovak/Lithuanian 200-0467-938 200-0467-968

Polish 200-0467-939 200-0467-969

Arabic 200-0467-940 200-0467-970

Korean 200-0467-941 200-0467-971

Hebrew 200-0467-942 200-0467-972

Chinese 200-0467-943 200-0467-973

Taiwanese 200-0467-944 200-0467-974

Thai 200-0467-945 200-0467-975

Farsi 200-0467-946 200-0467-976

English k/pad & [Link] S/W 200-0467-947 200-0467-977

English k/pad & [Link] S/W 200-0467-948 200-0467-978

English k/pad & VJIM S/W 200-0467-949 200-0467-979

English k/pad & Korean S/W 200-0467-950 200-0467-980

English k/pad & Chinese S/W 200-0467-951 200-0467-981

English k/pad & Arabic S/W 200-0467-952 200-0467-982

English k/pad & Middle East S/W 200-0467-953 200-0467-983

English k/pad & Hindi S/W 200-0467-954 200-0467-984

English k/pad & Farsi S/W 200-0467-955 200-0467-985

English k/pad & Thai S/W 200-0467-956 200-0467-986

Main Euro k/pad & [Link] S/W 200-0467-957 200-0467-987

Arabic k/pad & Middle East S/W 200-0467-958 200-0467-988

Table 12-2: 460 Mi with 90 degree printhead

12-4 460 Ink Jet Printer Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

460 Pi with 90° printhead

Keypad Overlay Description Part No

English/USA 200-0468-931

European 200-0468-932

Turkish/Skandinavian 200-0468-933

Greek 200-0468-934

Katakana 200-0468-935

Russian 200-0468-936

Bulgarian 200-0468-937

Czech/Slovak/Lithuanian 200-0468-938

Polish 200-0468-939

Arabic 200-0468-940

Korean 200-0468-941

Hebrew 200-0468-942

Chinese 200-0468-943

Taiwanese 200-0468-944

Thai 200-0468-945

Farsi 200-0468-946

English k/pad & [Link] S/W 200-0468-947

English k/pad & [Link] S/W 200-0468-948

English k/pad & VJIM S/W 200-0468-949

English k/pad & Korean S/W 200-0468-950

English k/pad & Chinese S/W 200-0468-951

English k/pad & Arabic S/W 200-0468-952

English k/pad & Middle East S/W 200-0468-953

English k/pad & Hindi S/W 200-0468-954

English k/pad & Farsi S/W 200-0468-955

English k/pad & Thai S/W 200-0468-956

Main Euro k/pad & [Link] S/W 200-0468-957

Arabic k/pad & Middle East S/W 200-0468-958

Table 12-3: 460 Pi with 90 degree printhead

Rev AA 460 Ink Jet Printer 12-5

Willett 460, 460Mi and 460Pi Service Manual

460 Si with straight printhead

Keypad Overlay Description 3m umbilical 6m umbilical

English/USA 200-0466-101 200-0466-631

European 200-0466-102 200-0466-632

Turkish/Skandinavian 200-0466-103 200-0466-633

Greek 200-0466-104 200-0466-634

Katakana 200-0466-105 200-0466-635

Russian 200-0466-106 200-0466-636

Bulgarian 200-0466-107 200-0466-637

Czech/Slovak/Lithuanian 200-0466-108 200-0466-638

Polish 200-0466-109 200-0466-639

Arabic 200-0466-110 200-0466-640

Korean 200-0466-111 200-0466-641

Hebrew 200-0466-112 200-0466-642

Chinese 200-0466-113 200-0466-643

Taiwanese 200-0466-114 200-0466-644

Thai 200-0466-115 200-0466-645

Farsi 200-0466-116 200-0466-646

English k/pad & [Link] S/W 200-0466-301 200-0466-647

English k/pad & [Link] S/W 200-0466-302 200-0466-648

English k/pad & VJIM S/W 200-0466-303 200-0466-649

English k/pad & Korean S/W 200-0466-304 200-0466-650

English k/pad & Chinese S/W 200-0466-305 200-0466-651

English k/pad & Arabic S/W 200-0466-306 200-0466-652

English k/pad & Middle East S/W 200-0466-307 200-0466-653

English k/pad & Hindi S/W 200-0466-308 200-0466-654

English k/pad & Farsi S/W 200-0466-309 200-0466-655

English k/pad & Thai S/W 200-0466-310 200-0466-656

Main Euro k/pad & [Link] S/W 200-0466-311 200-0466-657

Arabic k/pad & Middle East S/W 200-0466-312 200-0466-658

Table 12-4: 460 Si with straight printhead

12-6 460 Ink Jet Printer Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

460 Mi with straight printhead

Keypad Overlay Description 3m umbilical 6m umbilical

English/USA 200-0467-101 200-0467-631

European 200-0467-102 200-0467-632

Turkish/Skandinavian 200-0467-103 200-0467-633

Greek 200-0467-104 200-0467-634

Katakana 200-0467-105 200-0467-635

Russian 200-0467-106 200-0467-636

Bulgarian 200-0467-107 200-0467-637

Czech/Slovak/Lithuanian 200-0467-108 200-0467-638

Polish 200-0467-109 200-0467-639

Arabic 200-0467-110 200-0467-640

Korean 200-0467-111 200-0467-641

Hebrew 200-0467-112 200-0467-642

Chinese 200-0467-113 200-0467-643

Taiwanese 200-0467-114 200-0467-644

Thai 200-0467-115 200-0467-645

Farsi 200-0467-116 200-0467-646

English k/pad & [Link] S/W 200-0467-301 200-0467-647

English k/pad & [Link] S/W 200-0467-302 200-0467-648

English k/pad & VJIM S/W 200-0467-303 200-0467-649

English k/pad & Korean S/W 200-0467-304 200-0467-650

English k/pad & Chinese S/W 200-0467-305 200-0467-651

English k/pad & Arabic S/W 200-0467-306 200-0467-652

English k/pad & Middle East S/W 200-0467-307 200-0467-653

English k/pad & Hindi S/W 200-0467-308 200-0467-654

English k/pad & Farsi S/W 200-0467-309 200-0467-655

English k/pad & Thai S/W 200-0467-310 200-0467-656

Main Euro k/pad & [Link] S/W 200-0467-311 200-0467-657

Arabic k/pad & Middle East S/W 200-0467-312 200-0467-658

Table 12-5: 460 Mi with straight printhead

Rev AA 460 Ink Jet Printer 12-7

Willett 460, 460Mi and 460Pi Service Manual

460 Pi with straight printhead

Keypad Overlay Description Part No

English/USA 200-0468-101

European 200-0468-102

Turkish/Scandinavian 200-0468-103

Greek 200-0468-104

Katakana 200-0468-105

Russian 200-0468-106

Bulgarian 200-0468-107

Czech/Slovak/Lithuanian 200-0468-108

Polish 200-0468-109

Arabic 200-0468-110

Korean 200-0468-111

Hebrew 200-0468-112

Chinese 200-0468-113

Taiwanese 200-0468-114

Thai 200-0468-115

Farsi 200-0468-116

English k/pad & [Link] S/W 200-0468-301

English k/pad & [Link] S/W 200-0468-302

English k/pad & VJIM S/W 200-0468-303

English k/pad & Korean S/W 200-0468-304

English k/pad & Chinese S/W 200-0468-305

English k/pad & Arabic S/W 200-0468-306

English k/pad & Middle East S/W 200-0468-307

English k/pad & Hindi S/W 200-0468-308

English k/pad & Farsi S/W 200-0468-309

English k/pad & Thai S/W 200-0468-310

Main Euro k/pad & [Link] S/W 200-0468-311

Arabic k/pad & Middle East S/W 200-0468-312

Table 12-6: 460 Pi with straight printhead

12-8 460 Ink Jet Printer Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Stands and Lamp Stacks

Figure 12-2. Stand and Traffic Light System

Fig ref. Part number Description Qty

1 378176 Lamp stack/Beacon Kit 1

Internal 100-0470-283 Traffic light cable assembly 1

2 28000170 400 series printer stand (black painted steel) 1

28000185 400 series printer stand (stainless steel)

3 28000169 Universal printhead mount, includes: 1

• vertical column
• horizontal boom
• clamps
• triangular floor plate (for mounting as free
standing unit)

Table 12-7: Stand and Traffic Light System

Rev AA Stands and Lamp Stacks 12-9

Willett 460, 460Mi and 460Pi Service Manual

Encoders and Encoder Accessories

Not illustrated.

Part number Description

41000255 2500 ppm shaft encoder (encoder only, cable not included)

41000256 5000 ppm shaft encoder (encoder only, cable not included)

527-0001-128 Measuring wheel, 6.35 cm (2.5 inch) diameter

21000217 Measuring wheel, 9.70 cm (3.82 inch) diameter

21000433 Shaft Encoder Mounting bracket

40331010 3M encoder cable

80200252 5M encoder cable

40331750 2500 pulses shaft encoder kit. Includes:

• 2500 ppm shaft encoder (41000255)
• Measuring wheel (21000217)
• Shaft encoder mounting bracket (21000433)
Cable not included

80200226 5000 pulses shaft encoder kit. Includes

• 5000 ppm shaft encoder (41000256)
• Measuring wheel (21000217)
• Shaft encoder mounting bracket (21000433)
Cable not included

Table 12-8: Encoders and encoder accessories

12-10 Encoders and Encoder Accessories Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Product Detectors and Detector Accessories

Not illustrated.

Part number Description

375085-08 Medium range proximity, beam make, detector

375085-09 Retro-reflective, beam break, detector

375085-10 Proximity fiber optic, beam make, adapter detector

375085-11 Small part proximity fiber optic, beam make, adapter detector,
bifurcated, 0.046" (1.17 mm) diameter tip

375085-12 Through beam fiber optic adapter detector, beam break,

0.125" (3.17 mm) diameter tip

375085-13 Proximity fiber optic Registration Mark Detector, beam make,

0.125" (3.17 mm) diameter tip

375085-14 Retro-reflective fiber optic Transparent Object Detector, beam

break, 0.125" (3.17 mm) diameter tip with reflector

40331830 Inductive proximity product sensor

Table 12-9: Product detectors and detector accessories

Networking Accessories
Not illustrated.

Part number Description

500-0098-416 43s RS485 Kit

500-0098-417 RS485 networking connection box

500-0098-415 PC RS485 kit

23100006 4 conductor twisted pair (22 guage) shielded cable

100-0370-157 LAN interconnector

Table 12-10: Networking accessories

Rev AA Product Detectors and Detector Accessories 12-11

Willett 460, 460Mi and 460Pi Service Manual

Other Accessories
Not illustrated.

Part number Description

200-0370-149 Message selector/opto cable assembly

100-0370-152 Volt relay cable assembly

800013 Printhead stand, quick setup

800014 Dual printhead stand, quick setup

343840 Printhead stand, adjustable

204-0335-101 Electric positive air kit

80000008 Un-interruptible power supply

100-0370-158 RS-232 interconnector cable

378337 Print head cleaning station

500-0036-578 3-way DIN plug (for custom cable assembly)

500-0036-581 4-way DIN plug (for custom cable assembly)

500-0036-582 5-way DIN plug (for custom cable assembly)

500-0036-577 6-way DIN plug (for custom cable assembly)

500-0036-583 7-way DIN plug (for custom cable assembly)

500-0036-584 8-way DIN plug (for custom cable assembly)

Table 12-11: Other accessories

Documentation
Not illustrated.

Part numbera Description

361506 460, 460Mi and 460Pi Instructions for Use

361507 460, 460Mi and 460Pi Service Manual (this book)

Table 12-12: Documentation

a. Base part number only (not orderable). The full part number includes additional
digits indicating the document language. See Page 1-2 for more information.

12-12 Other Accessories Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Software
Not illustrated.

Part number Description

500-0098-388 Blueprint (incl hardkey)

500-0098-389 Blueprint Pro (incl hardkey)

500-0098-414 License kit, entry level

200-0610-101 Connector, entry level (trial version)

500-0098-434 Editor Pro module

500-0098-435 Monitoring and configuration module

500-0098-418 Networking module

500-0098-419 Extra license

500-0098-422 Calibration and diagnostic module

500-0098-423 Production reports module

500-0098-429 Multi-access module

80200258 3M communication cable (RS-232)

Table 12-13: Software

Rev AA Software 12-13

Willett 460, 460Mi and 460Pi Service Manual

Outer Door Assembly

Figure 12-3. Outer Door Assembly

Fig ref. Part number Description Qty Remarks

1 100-0470-165 Keypad bezel 1

2 100-0470-278 Keypad overlay, UK/USA 1

100-0470-279 Keypad overlay, European

100-0470-290 Keypad overlay, Turkish/Scandinavian

100-0470-291 Keypad overlay, Greek

100-0470-292 Keypad overlay, Japanese

100-0470-293 Keypad overlay, Russian/Ukranian

100-0470-294 Keypad overlay, Bulgarian

100-0470-295 Keypad overlay, Czech/Slovakian/

Hungarian

Table 12-14: Outer door assembly

12-14 Outer Door Assembly Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Fig ref. Part number Description Qty Remarks

100-0470-296 Keypad overlay, Polish/Latvian/

Lithuanian

100-0470-297 Keypad overlay, Korean

100-0470-298 Keypad overlay, Arabic/Farsi

100-0470-299 Keypad overlay, Hebrew

100-0470-300 Keypad overlay, Chinese

100-0470-311 Keypad overlay, Thai

100-0470-312 Keypad overlay, Farsi

3 100-0470-137 Keypad circuit 1

4 M5 st. steel nut 2

5 M5 ET washer 12

6 Earth cable 330 mm

7 M5 blue ring terminal 2

8 Nylon standoff 4

9 100-0470-103 LCD protective window 1

10 200-0466-159 LCD assembly 1

11 M3 ET washer 4

12 M3 nut 4

13 100-0470-258 LED extension cable 1

Table 12-14: Outer door assembly

Rev AA Outer Door Assembly 12-15

Willett 460, 460Mi and 460Pi Service Manual

Inner Door Assembly

Figure 12-4. Inner Door Assembly

Fig ref. Part number Description Qty Remarks

22 500-0901-135 Fan 80mm 2

23 500-0901-101 Finger guard 2

141 Plastic fan finger guard 2

41 M4 x 12 skt cap screw 8

5 M4 ET washer 6

28 M4 nut 4

48 M4 washer 4

60 3 inch cable tie 22

Table 12-15: Outer and inner door assemblies

12-16 Inner Door Assembly Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Printhead Assembly

Figure 12-5. Printhead Assembly

Rev AA Printhead Assembly 12-17

Willett 460, 460Mi and 460Pi Service Manual

Fig ref. Part number Description Qty Remarks

1 100-0370-196 Front cover 1

2 100-0370-231 Lid switch thumbscrew 2

3 200-3900-135 Charge electrode/LED assy. 1

4 200-0467-141 Nozzle assembly (43 micron) 1 460 Mi

200-0430-141 Nozzle assembly (60 micron) 460 Si 60 micron

200-0468-141 Nozzle assembly (70 micron) 460 Si 70 micron

200-0430-171 Nozzle assembly (60 micron) 80v For 460 Si running

Ethanol Blue ink

200-0468-142 Nozzle assembly (70 micron) 80v For 460 Si running

Ethanol Blue ink

200-0468-157 Nozzle assembly (70 micron) 460 Pi high speed

200-0466-163 Nozzle assembly (60 micron) 460 Pi standard

5 100-0430-155 Insert, lid switch 1

6 200-0390-235 Cover switch assy. 2

7 200-0430-162 Head heater assy. 1

8 521-0001-177 Pico valve 1

9 500-0031-180 O-ring 25.81 x 3.53 CS 1

10 M2 5 x 6 cask head st. st. screw 2

11 Umbilical 1

12 100-0370-195 Rear cover 1

13 200-3900-298 Phase detector assy. 1

14 200-0430-131 EHT block assy (standard) 1

200-0467-131 EHT block assy, 43 micron (460 Mi)

NI 522-0080-226 22 meg EHT resistor (inside EHT 1

block)

15 100-0470-273 0 V plate 1

16 100-0430-115 Last chance filter 1 460 Si and 460 Mi

only

17 500-0122-125 Spring 1

Table 12-16: Printhead Assembly

12-18 Printhead Assembly Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Fig ref. Part number Description Qty Remarks

entire 200-0466-117 460 Si and Pi straight printhead and 1 No nozzle

figure umbilical, 3m

200-0476-117 460 Si straight printhead and umbili- No nozzle

cal, 6m

200-0466-119 460 Si and Pi 90 degree printhead No nozzle

and umbilical, 3m

200-0476-119 460 Si 90 degree printhead and No nozzle

umbilical, 6m

200-0467-117 460 Mi straight printhead and umbili- No nozzle

cal, 3m

200-0467-118 460 Mi straight printhead and umbili- No nozzle

cal, 6m

200-0467-119 460 Mi 90 degree printhead and No nozzle

umbilical, 3m

200-0467-120 460 Mi 90 degree printhead and No nozzle

umbilical, 6m

Table 12-16: Printhead Assembly

Rev AA Printhead Assembly 12-19

Willett 460, 460Mi and 460Pi Service Manual

FMS Platform

Figure 12-6. FMS Platform

12-20 FMS Platform Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Fig ref. Part number Description Qty Remarks

1 100-0370-102 VMS restrictor block 1 between V3 and FMS

2 SP200-0466-234 Venturi assembly 1

3 200-0466-124 FMS assembly, 460 Si and 460 Mi 1

200-0468-124 FMS assembly, 460 Pi

4 200-0462-125 Stirrer assembly (460 Pi only) 1

NI 531-0001-112 Magnetic follower (460 Pi only) 1 Inside Mixer Tank

5 500-0041-293 Omnifit tube connector (red) 1

6 500-0031-234 6.07 x 1.78 O-ring 4

7 500-0034-110 Non return valve 2

8s 204-0342-101 Pressure damper kit, 460 Si and 1

460 Mi

8p 200-0468-162 Pressure damper kit, 460 Pi

9 200-0468-161 460 Pi gutter pump kit 1

10 200-0430-146 Flush pump assembly 1

NI 100-0430-114 Flush pump diaphragm 1 inside flush pump

11 500-0041-291 Omnifit tube connector (black) 1

NI 500-0041-292 Omnifit tube connector (green) 1 on left side of flush

pump

12 500-0047-131 Pre-pump filter 1

13 500-0047-134 flush filter 1

14s 500-0047-134 Pre-head filter 1 460 Si and 460 Mi

14p 500-0047-105 Pre-head filter, 30 micron 1 460 Pi

15 500-0041-110 Festo tee 1

16 500-0041-296 Jaco nut 2

17 500-0047-130 Main ink system filter, 5 micron 1 460 Si and 460 Mi

500-0047-132 Main ink system filter, 20 micron 460 Pi

18 100-0370-200 System manifold 1

19 500-0031-175 4.47 x 1.78 O-ring 3

20 527-0001-125 Pressure transducer 1

21 500-0031-164 Pressure transducer front O-ring 1

Table 12-17: FMS platform

Rev AA FMS Platform 12-21

Willett 460, 460Mi and 460Pi Service Manual

Fig ref. Part number Description Qty Remarks

22 500-0031-201 Pressure transducer rear O-ring 1

23 500-0031-164 Printhead manifold 1

24 500-0031-117 1.78 x 1.78 O-ring 4

25 521-0001-174 Solenoid Valve, 3-port (V3 and V7 ) 2 white base

26 521-0001-175 Solenoid Valve, 3-port (V8) 1 black base

27 521-0001-173 Solenoid Valve, 2-port (V6) 1 460 Si / Mi

521-0001-174 Solenoid Valve, 3-port (V6) 460 Pi

NI 204-0212-101 FMS Sensor kit 1 Contains all 5 sensors

NI 500-0031-231 Valve O-rings (20 pack)

NI 204-0346-101 75 micron VMS filter (10 pack) 1 tiny white filter in FMS

Table 12-17: FMS platform

12-22 FMS Platform Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

460 Cabinet

Figure 12-7. 460 cabinet (right side)

Rev AA 460 Cabinet 12-23

Willett 460, 460Mi and 460Pi Service Manual

Figure 12-8. 460 cabinet (left side)

12-24 460 Cabinet Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Fig ref. Part number Description Qty

1 460 cabinet 1

3 Screw cap Hd M4 x 10 6

4 100-0466-108 Main harness 1

5 500-0124-104 Washer ET M4 18

6 500-0089-110 Mains cable gland 1

7 500-0082-145 Mains switch 1

8 500-0066-134 Fuse holder 2

9 500-0079-110 Fuse holder cover 2

10 500-0040-113 Handle 2

11 Glands 4

12 100-0470-198 Pump Gasket 1

13 200-0390-108 Pump, 460 Si and 460 Mi 1

200-0468-125 Pump, 460 Pi Mk III 1

14 Umbilical gland 1

15 200-0466-152 Condenser assembly 1

16 500-0008-166 M6 x 25 cap head screw 4

17 500-0901-125 Fan cover assembly 1

18 M6 spring washer 6

19 500-0082-120 Mains switch cover 1

20 500-0079-168 Switch boot 1

21 500-0077-194 M4 x 6 spacer 4

22 500-0901-135 Fan 1

24 500-0085-163 Yellow LED 2

25 (see page 12-28) PSU assembly 1

26 500-0076-133 Blanking plug 6

27 M4 x 16 cap head screw 4

28 M4 nut 12

29 500-0041-111 1/8 inch BSP festo elbow

39 100-0466-127 Fan plate 1

Table 12-18: 460 cabinet

Rev AA 460 Cabinet 12-25

Willett 460, 460Mi and 460Pi Service Manual

Fig ref. Part number Description Qty

48 M4 flat washer 8

49 M5 barb fitting 1

53 100-0470-221 RS-232 DIN cable assembly 1

54 100-0470-222 S/encoder DIN cable assembly 1

55 100-0470-228 Photocell DIN cable assembly 1

56 500-0036-578 M6 x 12 button head screw 4

58 500-0066-139 3.15 amp antisurge fuse 2

62 100-0470-224 Gland plate gasket 1

63 500-0076-134 IP67 socket cap 3

68 500-0067-115 Earth label 7

69 M4 x 20 csk screw

106 378864 Mains cable (US) 1

500-0079-154 Mains cable (international)

107 500-0085-167 Right angled LED holder 2

128 100-0470-233 Gasket

138 M4 x 8 button head screw 8

139 500-0078-147 Blanking plug 2

142 100-0466-128 IP fan cover 1

143 100-0466-131 Cover plate 1

144 100-0466-133 Cover plate gasket 1

Table 12-18: 460 cabinet

12-26 460 Cabinet Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Ink and Top-Up Filler Caps

Figure 12-9. Ink and Top-Up Filler Caps

Fig ref. Part number Description Qty

2 100-0470-308 Top up cap retainer (white) 1

31 100-0470-191 Ink filler housing (black) 1

32 100-0470-192 Top up filler housing (white) 1

40 500-0031-241 Sealing ring 2

61 100-043S-194 Ink cap (black) 1

76 500-0031-232 O-ring 2

77 100-0470-199 HSG nut, machined 2

78 100-043S-195 Top up cap (white) 1

119 100-0470-195 Ink cap retainer (black) 1

Table 12-19: Ink and top-up filler caps

Rev AA Ink and Top-Up Filler Caps 12-27

Willett 460, 460Mi and 460Pi Service Manual

PSU Assembly

Figure 12-10. PSU Assembly

Fig ref. Part number Description Qty Notes

1 PSU plate 1

2 M3 x 6 pan head screw 4

3 Washer ET M3 4

4 204-0335-101 Electric positive air kit 1 standard on 460 Pi,

optional on other models

5 100-0470-254 Power harness 1

6 PSU bracket 1

7 200-0390-239 EHT module 1

8 500-0097-128 Mains power filter 1

9 200-0390-102 Power supply unit (PSU) 1

Table 12-20: PSU assembly

12-28 PSU Assembly Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Ink and Top-up Reservoirs

Figure 12-11. Ink and Top-up Reservoirs

Rev AA Ink and Top-up Reservoirs 12-29

Willett 460, 460Mi and 460Pi Service Manual

Fig ref. Part number Description Qty

1 100-0462-006 Level detect probe 1

2 500-0041-194 Jaco Tee fitting 2

3 200-0466-143 Level detect - optical 1

4 500-0031-164 O-ring 2

5 521-0001-173 Solenoid Valve, 2 port 2

6 100-0466-114 Ink manifold

7 100-0466-115 Solvent manifold 1

8 500-0008-152 M5 x 20 cap screw 8

9 100-0430-130 Tank gasket 2

10 100-0470-118 Ink / Top-up reservoir 2

11 200-0462-125 Stirrer assembly (460 Pi only) 1

NI 531-0001-112 Magnetic follower (inside 460 Pi ink tank) 1

NI 501-0002-131 6mm x 4mm PTFE tube (1.32 M)

NI 501-0002-115 1/8” x 1/16” PTFE tube (1.47 M)

Table 12-21: Ink and Top-Up Reservoirs

12-30 Ink and Top-up Reservoirs Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Electronics Module
2
8
1
3 10
9 8
8

10
10
4
8

5
4
6

8, 9
6 8

10

7
10
10

12

8, 9 13, 11
2 2 2 3
14 10
RED WIRE AT BOTTOM
CONNECTED TO PIN 1. 10 10
10
10

Figure 12-12. Electronics module assembly

Fig ref. Part number Description Qty

1 Electronics plate 1

2 M3 x 6 ss pan head pozi screw 8

3 500-0077-179 Standoff M3 x 10 8

4 500-0077-176 Standoff M3 x 18 12

5 40331980 CPU board, 460 Si / Mi 1

200-0466-171 CPU board, 460 Pi

Table 12-22: Electronics Module assembly

Rev AA Electronics Module 12-31

Willett 460, 460Mi and 460Pi Service Manual

Fig ref. Part number Description Qty

6 200-0430-160 I/O board, 460 Si and 460 Mi 1

200-0466-167 I/O board, 460 Pi

200-0430-161 Pump motor control board, 460 Si and 460 Mi 1

200-0466-168 Pump motor control board, 460 Pi

7 200-0466-145 Levels board 1

8 M3 ss nut 8

9 M3 ET shakeproof washer 16

10 100-0470-255 Electronics harness kit 1

11 M4 ET shakeproof washer 3

12 M4 x 12 ss pan head pozi screw 1

13 M4 ss nut 2

14 100-0470-253 LCD ribbon cable - 50 way 1

Table 12-22: Electronics Module assembly

12-32 Electronics Module Rev AA

Tools and Spare Part
Kits 13
Tools
Willett recommends a variety of tools to service the 460, 460 Mi and 460 Pi
printers.

Basic start up kit

The basic start up kit (P/N 378232) includes the following:

Description Part Number

Safety glasses 28000035

Squeeze bulb 21000170

Wash bottle, 250cc 202047

Latex gloves 209953

Hand cleaner SP212321

Cleaning pan, steel 217035

Magnifier loupe 355269

Beaker, 250ml gradiated 28000006

Service tool kit

The Service tool kit (P/N 378228) consists of the following:

Description Part Number

Pipe pliers 5260001115

Tube cutter 5260001112

Nut driver set 5260001118

Allen hex driver set 5260001119

Pozi drive screwdriver #1 5260001108

Pozi drive screwdriver #0 5260001116

Rev AA Tools 13-1

Willett 460, 460Mi and 460Pi Service Manual

Description Part Number

Nozzle adjusting tool 1000370224

Manifold flush block 200-0466-247

Knife, retractable 217043

Ultra sonic bath 5260001120

Reverse action tweezers 5260001107

Syringes, with slip tips 5000118001

Wrench, open end, 8mm x 10 mm 526-0001-124

Din socket wrench 526-0001-123

IC removal tool, mini-fit 526-0001-113

Pump priming adapter 2000466246

Filler cup wrench 100-043S-193

Electronics compartment key 500-0048-133

Printhead cleaning station 378337

Blow bulb 21000170

Serial download cable 80200258

EHT trip tool 100-0370-265

EHT printhead cover 100-0370-264

Tubing, 1/4 O.D. cobothane, 3.5 ft 251410

Magnifier, illuminated 3.5x 203023

Other tools
Additional tools that may be useful for service personnel include the
following:
• a laptop computer with Windows NT 4 or greater installed
• standard field service tools, including a DVM and oscilloscope

13-2 Tools Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

Spare Parts Kits

460 Si and Mi filter kit

The filter kit for the 460 Si and Mi (P/N 80200237) contains the following:

Description Part Number

Fan filter element 500-0901-122

Main ink system filter 500-0047-130

Pre-pump filter 500-0047-131

460 Pi filter kit

The filter kit for the 460 Pi (P/N 80200334) contains the following:

Description Part Number

Filter, solvent reservoir 500-0047-105

Pre-pump filter 500-0047-131

Main ink system filter, 460 Pi 500-0047-132

Flush filter 500-0047-134

460 Si basic spare parts kit

The basic spare parts kit for the 460 Si (P/N 378378) contains the
following:

Description Part Number

460 Si and Mi filter kit (above) 80200237

Fuses, 5 amp (pack of 10) 500-0066-119

3 port solenoid valve (with white base) 521-0001-174

2 port solenoid valve 521-0001-173

Pico valve 521-0001-177

VMS restrictor block 100-0370-102

Nozzle assembly, 460 Si (60 micron) 200-0430-141

Valve O-rings (20 pack) 500-0031-231

Nozzle adjusting tool 1000370224

Printhead cleaning station 378337

Rev AA Spare Parts Kits 13-3

Willett 460, 460Mi and 460Pi Service Manual

460 Mi basic spare parts kit

The basic spare parts kit for the 460 Mi (P/N 378379) contains the
following:

Description Part Number

460 Si and Mi filter kit (above) 80200237

Fuses, 5 amp (pack of 10) 500-0066-119

3 port solenoid valve (with white base) 521-0001-174

2 port solenoid valve 521-0001-173

Pico valve 521-0001-177

VMS restrictor block 100-0370-102

Nozzle assembly, 460 Mi (43 micron) 200-0467-141

Valve O-rings (20 pack) 500-0031-231

Nozzle adjusting tool 1000370224

Printhead cleaning station 378337

460 Pi basic spare parts kit

The basic spare parts kit for the 460 Pi (P/N 378380) contains the
following:

Description Part Number

460 Pi filter kit (above) 80200334

Fuses, 5 amp (pack of 10) 500-0066-119

3 port solenoid valve (with white base) 521-0001-174

2 port solenoid valve 521-0001-173

Pico valve 521-0001-177

VMS restrictor block 100-0370-102

Nozzle assembly, 460 Pi (60 micron) 200-0466-143

Valve O-rings (20 pack) 500-0031-231

Nozzle adjusting tool 1000370224

Printhead cleaning station 378337

13-4 Spare Parts Kits Rev AA

 Willett 460, 460Mi and 460Pi Service Manual

460 Si comprehensive spare parts kit

The comprehensive spare parts kit for the 460 Si (P/N 378383) contains the
following:

Description Part Number

460 Si basic spare parts kit 378378

CPU board, 460 Si and Mi 40331980

PSU 200-0390-102

I/O board, 460 Si and Mi 200-0430-160

EHT Module 200-0390-239

Pressure transducer 527-0001-125

Pressure transducer O-ring, front 500-0031-164

Pressure transducer O-ring, back 500-0031-201

System manifold 100-0370-200

Phase detector assembly 200-3900-298

Charge electrode assembly 200-3900-135

22 Meg EHT resistor 522-0080-226

Mixer tank sensor kit 204-0212-101

460 Mi comprehensive spare parts kit

The comprehensive spare parts kit for the 460 Mi (P/N 378384) contains
the following:

Description Part Number

460 Mi basic spare parts kit 378379

CPU board, 460 Si and Mi 40331980

PSU 200-0390-102

I/O board, 460 Si and Mi 200-0430-160

EHT Module 200-0390-239

Pressure transducer 527-0001-125

Pressure transducer O-ring, front 500-0031-164

Pressure transducer O-ring, back 500-0031-201

System manifold 100-0370-200

Phase detector assembly 200-3900-298

Rev AA Spare Parts Kits 13-5

Willett 460, 460Mi and 460Pi Service Manual

Description Part Number

Charge electrode assembly 200-3900-135

22 Meg EHT resistor 522-0080-226

Mixer tank sensor kit 204-0212-101

460 Pi comprehensive spare parts kit

The comprehensive spare parts kit for the 460 Pi (P/N 378234) contains
the following:

Description Part Number

460 Pi basic spare parts kit 378380

CPU board, 460 Pi 200-0466-171

PSU 200-0390-102

I/O board, 460 Pi 200-0466-167

EHT Module 200-0390-239

Pressure transducer 527-0001-125

Pressure transducer O-ring, front 500-0031-164

Pressure transducer O-ring, back 500-0031-201

System manifold 100-0370-200

Phase detector assembly 200-3900-298

Charge electrode assembly 200-3900-135

22 Meg EHT resistor 522-0080-226

Mixer tank sensor kit 204-0212-101

13-6 Spare Parts Kits Rev AA

Circuit Diagrams
A
Overview
This section contains the following foldout circuit diagrams:
• CPU Board
• I/O Board
• Pump Motor Control Board
• Expansion Board
• Levels Board

Rev AB Overview A-1

Willett 460, 460Mi and 460Pi Service Manual

A-2 Overview Rev AB

 Willett 460, 460Mi and 460Pi Service Manual

Foldout 1: CPU Board

Rev AB Foldout 1: CPU Board A-3

Willett 460, 460Mi and 460Pi Service Manual

A-4 Foldout 1: CPU Board Rev AB

 Willett 460, 460Mi and 460Pi Service Manual

Foldout 2: I/O Board

Rev AB Foldout 2: I/O Board A-5

Willett 460, 460Mi and 460Pi Service Manual

0V CHARGE
HEAD_1
VCC 1 1 1
R18 R7 R5 +300 Volts
1
P LID SWITCHES 2K7 100R 1K
2
R 1 1
I 3
R106 2 2 2 R38 +15V
N 4
1K 1 1K D4
T 5
U32B R77 +15V U37 2 2 1 1 2
6 D9
H 2 4 1 2 +5V +15V VCC VCC 78L12 D2 2
E 7
6 MOUNTED ON LED1 GREEN 1 3 3 1 UF4007 UF4006
A 8 VI VO Q6
5 HEATSINK CH2 11K +24V 2 1 1 G
D 9
U31 100nF U27 L2 U6 FUSE1 R10 U5 R13 PHASE N 1 BC556 5V6 2 1 MOUNTED
10 TF1 D
74HC32 5 C53 3 8 330uH 3 1 2 1 2 1 6 10K DETECTOR C79 3 2 WITH A
VH VCC +OP D+ VCC
LCCTF1 C32 1 1 2 5 2 u/d 1 POWER 2 47uF 2 Q5 T0126
VW U/D +IP 1A
HE14 10S 0V mod1a 1 3 1 2 4 6 1 inc U20 4 680R 4 2 SHAFT ENCODER A SUPPLIES 2 MJE340 1 3 HEATSINK
VL INC COM OUT
strobe VCC 2 1 4 7 csp 18 16 cb6 2 1 2 2 1 1 1 R37
GND CS VDD A1 GND D- 2V7
HEAD_2 470nF R65 17 cb7 5 C7 5 -15V U38 D3 1 MJE350
LM675 A0 DC2 -OP OV 220K Q8
3 1 47K X9C103 2 7 db7 1 47uF R11 79L12 R6 R19
1 VOUTA DB7 47uF
mod1b 2 4 1 8 db6 NMXS0515 2 470R H11L1 VCC 2 1 470R 150R 2
2 VOUTB DB6 VI VO
1 C50 -24V 2 20 9 db5 1 0V G 2 2
3 VOUTC DB5 U7A N
47uF R63 9 1 19 10 db4 2 2 2 0V 3
4 R64 VOUTD DB4 74HC74 D
1 2 0 2 4 11 db3 VCC 2 Q4
5 1K VREF DB3
2 12 db2 SENC 3 MJE340
6 DB2 C80
47K +15V 5 13 db1 0V 4 1 1
7 AGND DB1 1 S1 S1A
0V 0V 6 14 db0 1 1 2 5 47uF -15CH R2
8 DGND DB0 2 S2 S2A D P Q
3 15 R8 R21 1 2
9 VSS WR 3 S3 S3A R
0V U26 10K 10K 3 BC546
10 7 4 S4 S4A CLK TP7
NE531 AD7226 0V Q2 1K
11 C
HEAT EXCHANGER 3 HE14 4S R9 U4 2 2 6 U40B PIN R86 C1
12 U22C L Q
6 R62 1 2 1 6 10K 3 3 1 2
D+ VCC
HE14 12D 1 2 1 2 9 cb1 PEC1 1 4 3 1 2 2 2
8 2K7 4 1uF
1 JB1 OUT Q1
FIRE SENSOR 10K 0V 10 2 JB2 1 1 1
2 S5 D- BC556
C52 R79 1 5 LINK-3 74HCT14 1 R4 R3 R1
8 4 3 A OV
H.E. temp. 1 2 1 2 74HC32 2 EXT PEC 1 1 2 1 2 1 2
B
+5V ref HE14 3S 3 H11L1 D21 2
C 1 2 3
5 R101 10pF -24V 33K +24V 4 0V 1N4148 2 150K 6R8 68R 1
U36D D
7 1 2 0V C74 5 R23 U10 C43 +24VSW 2 Q3
TL084 E C94
6 5 R78 13 PEC2 6 1 2 1 6 A B C 3 [Link]. MJE350
U25 100nF F D+ VCC
100K 2 1 1 2 14 7 0V 2nF 1 3 3
1 G Q9
U36B MOUNTED ON 4 12 8 2K7 4 +15V 3
2 S6 H OUT MJE340
D22 HEATSINK CH2 2 1 27K 9 2 2 VCC 2 TP4
TL084 Q14 3 I D- EHT/FAN
1N4148 LM675 10 5 0V PIN
. OV
1 3 1 2 3 R94 1 1 1 HE14 3S EXT PEC 2 U13 C25 1
RC1 S5A 1 7
1 12 2 R88 R89 H11L1 1 10pF 1 -15CH
LINK-10 2
1 1 -24V 10uF 47K 47K 0V 3 8 1 2 R39 R14
R100 S6A 3
1 1 R91 R71 1 27K 2 U15 6 1 6K2 100R
470K R80 4
10M 2 BC546 2 2 27 db7 Q13 FAN 2 5 R40 1 2
10R 10K D7 5
2 C76 2 2 C59 AD EOC 4 28 db6 100R 2
PA0 D6 RFP4N06L 6 NE531 CH/MOD
100nF 2 470uF 0V 3 29 db5 3
U36C PA1 D5 7
2 0V 0V LID SWITCHES 2 30 db4 1 2 HEAD
PA2 D4 8 4 1
TL084 1 31 db3 2 C31 1 R42 POWER
PA3 D3 9 2
9 0V FUSE2 +24VSW 40 32 db2 1 1 6K8 3
PA4 D2 10 3
8 1 2 39 33 db1 1 C91 -15CH 33pF 2 Q10 2 TP6
VALVES R99 PA5 D1 C26 4
R104 0V 10 38 34 db0 1 0V HE14 10D R45 2 2 VN10LM 1 PIN
1A PA6 D0 R43
1 2 1 10K 37 2 1K 1 2 1 2 1 1 C20
1 PA7 MOLEX 4
R97 R90 1 2 8 cb6 10nF 0V 2 1 R41 10uF
2 A1 4K3 LED4
68K R22 1 2 1 2 9 cb7 0V 1 100nF 1K 2
3 A0
10K 1 2 5 cb2 2 EHT R44 CC1 2 1
C98 6K2 18K 4 RD
U40E 2 +15V 0V 36 cb1 R93 1K 470pF 2 mod1a
100nF 5 R98 WR
6 PCS3 100K mod1b
6 10K CS
11 10 1 2 TP5 U33 U39 35 cb0 2
7 RES
1 PIN VCC 18 1 18 0V -15CH 0V CHARGE
REF01 2 8 O1 I1 PB0
1 D5 +15V 17 2 19 14 STRT AD CON_BM1 CON_BM2
9 O2 I2 PB1 PC0
1 74HCT14 R105 5V1 U29 1 16 3 20 15 HEATER
D17 + 10 O3 I3 PB2 PC1
C86 68K 7 INA114 15 4 21 16 PUMP DISABLE 13 12 +24V
1N4148 V 11 O4 I4 PB3 PC2
2 100nF 2 3 R61 2 PUMP 6 14 5 22 17 300V ON
+ + VOUT 12 O5 I5 PB4 PC3 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
2 1 6 1 2 PRESSURE 13 6 23 13 u/d U3 U23B +15V
R1 V OUT 13 O6 I6 PB5 PC4 CON_DA
1 0 12 7 24 12 inc DAC08-A 5 R87
R68 V 14 O7 I7 PB6 PC5 U40F
0V 0V 0V 1 1 2 8 5 1K 1 C16 1 C72 11 8 25 11 csp ad0 1 12 4 4 1 2 -15V
R2 REF 15 O8 I8 PB7 PC6 B8 IOUT 74HCT14 PUMP
0V 2 - 47uF PURGE 10 2 11 6
P/TRANS - V 100nF 16 PC7 B7
2 D18 2 2 VALVE 10 3 10 100K 1
562R 4 COM B6 8
+10 2 C75 4 1N4148 82C55 4 9 2 74HC02
1 HE14 16D B5 IOUT 7
+ve 0V 0V 0V 2803A 5 8 C69
2 1uF B4 6
-ve -15V 6 7 10uF 2 PRESSURE
3 B3 5
com R33 7 6 SETPOINT
4 B2 4
PRESSURE AMP. 1 2 0V qdac ad7 8 5 16
5 B1 COMP 3
9 0V
6 2
+5V 100K U16 1 +15V 10 14
7 VR+ 1
R107 VCC 26 17 db0 R96 2 -15V
8 IN0 D0 V V U12
1 2 27 14 db1 47K 0V 15 1 2 R27
TP3 IN1 D1 VR- + - VLC HE14 8D
R31 8 28 15 db2 U36A HEADER 20D 2R7
HE14 8D PIN IN2 D2 4 CONN,8-PIN,0.1
220R BULK INK TEMPERATURE 1 2 3 U17A 1 8 db3 2 TL084 U1 D7 0V
1 IN3 D3 1
100K 1 2 18 db4 3 0V 1 3 1 2
IN4 D4 3 3 +OP
2 1 1 2 3 19 db5 1 1 2 +15V 1 1
V OP C18 IN5 D5 C9 +IP
BC183 R51 4 20 db6 2 1 4 1N4007 -24V U9
C IN6 D6 R20 COM
C G U21 100nF 2 1 4 2272 VCC 5 21 db7 1 1 +15V 2 D1 7915
1K IN7 D7 C10 GND
3 Q7 R30 N R32 R92 3K9 2 L1 5 1 2 2 1
D LM35 1 47nF 10nF -OP VI VO -15CH
2 1 2 2 0V 22K 0V 12 25 cb7 47K 2 330uH G
REF+ A0 1
16 24 cb6 3 NMXD1205U 1N4007 N
REF- A1 XX D
1 10K 2 R36 23 cb5 2 -15CH -15CH R25 D6
3 A2
0V 1 2 10 -15V 0V LM317T 1 2 1 2 3 2
CLK YY
CABINET TEMPERATURE 0V 0V 6 0V 1 C12
START
0V 100K 9 22 shaft enc. 1 2 10K 15V 10uF
OE ALE
0V R34 7 pcs3 2 1
EOC DC1 LED3
FIRE DETECTOR 1 2 5 U17B db[0..7] U40D +15V
1 7 ADC0809 U2 2 47uF 1 YELLOW
HEAT EXCHANGER 100K 6 cb[0..7] 9 8 1 13 C24 2 DIODE 1 C62
IN1 V+ 47uF
C19 2 1 R59 d d d d d d d d pec2 16 4 220uF 0V
2272 IN2 V-
STROBE 100nF R35 1 2 CONTRAST b b b b b b b b c c c c c c c c phase det 9
7 6 5 4 3 2 1 0 b b b b b b b b IN3
22K print/phase 74HCT14 8
7 6 5 4 3 2 1 0 IN4
SIL3B +5V 1 0V 100K pec1 -15CH 0V -24 Volt Power Supply CAP,POL
ink low SIL3A 3 1 R58 2 VCC 74HC02 3 2
S1 D1
2 1 U41A 1K U23C 3 [Link]. 14 15
CON_DB S2 D2
SIL2B SIL7A R66 0V 8 cb2 8 1 3 11 10
U28A HEADER 20D S3 D3
3 1 1 2 1 2 lev1 2 1 2 3 10 6 7
C41 S4 D4
1 1 9 2
2 1 1 1 1 1 1 1 1 1
47K_RN 1 100K 2 DG411
0 9 8 7 6 5 4 3 2 1
C88 74HCT14 0V C70 2 1 adc 0V 1K_RN SIL1A U7B VCC
SIL3D 2 100nF 100nF R60 4 2272 0V LEDs 1 2 74HC74
U23D 1 2 3 4 5 6 7 8
ink ok 5 1 0V 22K 11
SIL3C 0V U41B EHT CURRENT 0V 13 1K_RN SIL1B 1
HE14 8D
4 1 SIL7B 2 R54 cb1 12 3 4 0
SIL2D 3 4 3 4 lev2 VCC 1 2 12 9
74HC02 D P Q
5 1 0V VCC 1K_RN SIL1C
39K R
47K_RN 1 R52 8 SIL6A 0v 5 6 cb3 11
U18A CLK
SIL3F C95 74HCT14 FAN FAILURE 1 2 3 5 U18B 1 2
3 3 3 3 3 2 2 2 2 2 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 9 8 7 6 5 4 3 2 1 C
7 1 2 100nF 1 7 SIL6B +24V 1K_RN SIL1D 8
4 3 2 1 0 9 8 7 6 5 4 3 2 1 0 9 8 7 6 5 4 3 2 1 0 L Q
SIL3E 100K 1 2 6 1 3 7 8 0V
LEVELS
ink high 6 1 0V U41C 24V DC TACHO C34 2272 1 2272 SIL6C CON_B1 HEADER 34D 1
SIL7C 2 4 1 4 CONTROL & DATA 3 TP2
1 100nF 1
R53
SIL2F 5 6 5 6 lev3 1 SIL6D PIN
2 10K 2
7 1 R102 0V 0V 1 5 T/LIGHT
3 3
47K_RN 1 4K7 2 SIL6E R74 R56 11K
4 1 S7 S7A
C96 74HCT14 1 6 VCC cb4 1 2 1 2
5 CON_EX 2 S8 S8A B/LIGHT
2 100nF 2 R67 0V SIL6F 300 Volts
6 U28B 3 S9 S9A
SIL3H 1 2 5 1 7 HE14 3S 10K
7 1 4 S10 S10A
9 1 0V U41D 100nF 7 db0
8 2 5 S11 S11A
SIL3G SIL7D 1 1 C51 1 100K 1 6 db1 U32A +24V
9 D23 3 6 S12 S12A VR1
8 1 7 8 9 8 lev4 R103 db2 1 100nF 1 1
10 10uF 2272 4 U24 D13 D14
SIL2H 1K 2 R50 db3 HE14 6D 1 50K. C64 5 R15 R16
11 5 C36
9 1 47K_RN 1 5V1 2 C71 1 2 db4 U19 3 2 1 2 1 TF2 2 1 2 1 220K 360K
12 6
vms low C99 74HCT14 2 2 0V db5 1 18 2 4 1 2 1 3
13 7 I1 O1
2 100nF R48 100K db6 2 17 1 2 2 2
14 XX 8 I2 O2
0V 1 2 5 db7 3 16 1 R73 LM675
15 9 I3 O3 74HC32 470nF
SIL5A 0V U41E R29 7 U8 4 15 R76 3 22K 1 3
16 100K YY 10 I4 O4 D16 D15
vms high SIL5B 2 1 SIL4A 1 2 1 6 U22A db0 3 2 5 14 10K 2 4 2
17 U14B 11 D0 Q0 I5 O5
3 1 1 2 11 10 lev5 1 1 db1 4 5 6 13 0V 2 -24V 2 1 2 1 1 LED2 1
18 2272 12 D1 Q1 I6 O6
SIL2C U30 1K C33 2 R49 3 db2 7 6 7 12 2 R72 ON HEATSINK 9 1 C30 RED R17
19 13 D2 Q2 I7 O7 0
4 1 47K_RN 1 lev1 3 2 db0 100nF 22K cb2 2 db3 8 9 8 11 R75 3 1K 2 CH1
20 D0 Q0 14 D3 Q3 I8 O8
ink low C73 74HCT14 lev2 4 5 db1 db4 13 12 1 2 2 2
21 D1 Q1 15 D4 Q4 LCCTF2
2 100nF lev3 7 6 db2 2 74HC32 db5 14 15 10 4.7uF 1 2 4K7
22 D2 Q2 16 D5 Q5 COM
U41F lev4 8 9 db3 db6 17 16 C60 1 10K 1 0V 4 X UF4006 450V
23 D3 Q3 17 D6 Q6
SIL4B 0V lev5 13 12 db4 0V 0V U22D db7 18 19 2803A Q12
24 D4 Q4 18 D7 Q7 47uF
solvent low 3 4 13 12 lev6 lev6 14 15 db5 12 +24V BC546 0V CHARGE
25 D5 Q5 19 D19
SIL5C lev7 17 16 db6 11 1 2
26 D6 Q6 20 OC 1N4007
4 SIL5D
1 47K_RN 1 lev8 18 19 db7 cb1 13 11 D20 0V 0V
27 D7 Q7 G
5 1 C77 74HCT14 0V 2 1 1 2
28 IDC 20
SIL2E 2 100nF 1 VCC 74HC32 74HC373 0V
29 +15V OC
6 1 11 cb6 1 1N4007 +15V' 0V
30 G
0V U40A U22B cb7 0V
31 -15V C37
SIL4C cb2 4 74HC373 cb0 -24V -15V' +5V'
32
5 6 1 2 lev7 6 TACHO U23A 2200uF 2 +5V +15V
33 FAN_FAIL
SIL5E 5 3 +24V
34
SIL5F 6 1 47K_RN 1 1 7
PIGS 6
0V 7 1 C84 74HCT14 74HC32 2 2 R28 3 R26
5 + +
HEADER 34D SIL2G
RESNET,9-PIN 2 100nF R57 BULK 1 2 1 6 1 2
1 4 R1 V OUT
8 1 U40C 74HC02 100R HEAT
2 3
SIL4D 0V 2K2 8 5 4K7 1
3 2 R2 - REF
+5V 7 8 5 6 lev8 1 PIG A 2
4 1 1 1 1 1 9 8 7 6 5 4 3 2 1 1 - V
+15V D8
5 4 3 2 1 0
U35 1 47K_RN 1 +24V 4 PIG B 4 5V1
6 HE14 6D U11
78L05 R55 C93 74HCT14 VCC 3 0V 0V CON_PO HEADER 14D 0V 2
INA114
1 3 47K 2 100nF VCC VCC 1 R24 5 1 1 -15V
VI VO D10 HE14 6S
G C81 75K VCC 1 C29 C35
N D12
2 0V 0V 2 1 Q15 1 1N4148 1 8 +24VSW TP9 100nF 2 2 100nF +5V' C89 +5V -15V' C97 -15V 0V
D R12 1N4148
3 6 PIN 3 [Link]. 3 [Link].
C83 47uF 2 3M3 2 8 U14A 7 +15V' -15V' 1 3 1 3
2 POWER
LOCAL 1 2 0V 3 R46 2 1 +5V VCC VDD V+ V- P +5V' +24V'
GND
POWER R95 1 BC546 2 1 1 2 2 2 VCC O CONN,6-PIN,0.1 0V 2 2
1 RL1 W 1
ONLY U34 10uF STROBE 1 2 2 2
4 VCC +15V -15V E 2
0V 0V 47K LED5 BT 53 AGND DGND 0V GND VSS
10R 2272 R 3
1 2 3 1 cb4 TP1 TP8 1 4 1 GREEN 0V 0V
56K R69 QA V A 4
1 2 4 2 cb3 PIN PIN R47 D11 I
30K R70 QB C B 5
1 2 5 4K7 2V7 N
QC C S1A S2A S3A S4A S5A S6A S7A S8A S9A S10A S11A S12A 6
24K R84 P
1 2 6 0V 1
22K R85 QD U 7
1 2 10 2 1 2 3 T +15V' C90 +15V
24K R82 QE C27 S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S12 8
1 2 11 8 1 1 1 1 1 1 1 1 2 Q11 3 [Link].
30K R83 QF CLK
1 2 12 0V EC1 EC2 EC4 EC5 EC6 EC8 EC7 EC3 47uF MPSA13 NC1 NC6 NC5 NC3 NC2 NC4 NC7 NC8 NC9 NC12 NC10 NC11 TG1 TG3 TG2 0V 1 3
56K R81 QG MOLEX 8
13 9 2 47nF 2 47nF 2 47nF 2 47nF 2 47nF 2 47nF 2 47nF 2 47nF 2 1 3T CAP 3T CAP 3T CAP 3T CAP 3T CAP 3T CAP 3T CAP 3T CAP 3T CAP 3T CAP 3T CAP 3T CAP
QH CLR
0v 1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3 2
HS1 HS2
74HC164 0V -24V
0v 2 2 2 2 2 2 2 2 2 2 2 2 1 1
+24V +15V MT7 MT8 0V
+5V +24V' C100 +24V
1 1 1 1 1 1 1 1 1 3 [Link].
C68 1 C44 C46 C38 C67 C61 C5 C22 C3 C78 2 2 1 3
10uF 10uF 10uF 10uF 10uF 10uF 10uF 10uF 10uF 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
470pF
2 2 2 2 2 2 2 2 2 2 C15 C42 C49 C82 C23 C65 C8 C6 C13 C11 C63 C40 C87 C56 C85 C57 C17 C28 C54 C39 C58 C55 MT1 MT2 MT3 MT4 MT5 MT6 2
1 1 1 1 1 1 1 1 1 2 47nF 2 47nF 2 47nF 2 47nF 2 47nF 2 47nF 2 47nF 2 47nF 2 47nF 2 47nF 2 47nF 2 47nF 2 47nF 2 47nF 2 47nF 2 47nF 2 47nF 2 47nF 2 47nF 2 47nF 2 47nF 2 100nF
C45 C47 C48 C66 C92 0V C21 C14 C2 C4 HEAT SINK
0V 10uF 10uF 10uF 10uF 10uF 10uF 10uF 10uF 10uF MOUNTING HOLES 0V
2 2 2 2 2 2 2 2 2 0V
0V
-24V -15V -15CH

A-6 Foldout 2: I/O Board Rev AB

 Willett 460, 460Mi and 460Pi Service Manual

Foldout 3: Pump Motor Control Board

Rev AB Foldout 3: Pump Motor Control Board A-7

Willett 460, 460Mi and 460Pi Service Manual

A-8 Foldout 3: Pump Motor Control Board Rev AB

 Willett 460, 460Mi and 460Pi Service Manual

Foldout 4: Expansion Board

Rev AB Foldout 4: Expansion Board A-9

Willett 460, 460Mi and 460Pi Service Manual

W1
LINK-3
C1 POWER1
1

1
2
3
1 3
emc 2
3
4

2
VCC C2 W2
VCC LINK-3 H E 144S
DC1 1 3
emc

1
2
3
U2

2
47nF SIL1 0V
78M12 VCC VCC VCC U1A 0V
DC2 10K_RN_SIL
2 1 C3
MODEM1 2 1
R1 VOUT VIN 74HC14 U1B
1 1 3
0V emc

GND

3
5
7
9
8
6
2
4
14 47nF 4 3 C4
CON_EX1 0V MSG_A1
2

2
15 U3 U1C 74HC14 U4 1 3
4K7 1 emc 1
3 2 3 6 5 16 1 C5
2 Q0 D0 O1+ I1+ 2

3
16 D1 5 4 15 2
3 Q1 D1 O1- I1- 3

2
4 GREEN LED 6 7 74HC14 U1D 14 3 1 3
4 Q2 D2 O2+ I2+ emc 4
17 9 8 8 9 13 4 C6
5 Q3 D3 O2- I2- 5
5 12 13 12 5 DIL1
6 Q4 D4 O3+ I3+ 6

2
18 15 14 U1E 74HC14 11 6 1 16 1 3
7 Q5 D5 O3- I3- emc 7
6 16 17 10 11 10 7 2 15
8 Q6 D6 O4+ I4+ 8
19 19 18 9 8 3 14
9 Q7 D7 O4- I4-

2
7 74HC14 U1F 4 13 HE14 8D
10
20 1 12 13 PC847 5 12
11 OC
8 11 U6 6 11 C7
DC3 12 G U5A 74HC14 M S G_B1
21 16 1 7 10
13 O1+ I1+
9 74HC373 2 1 15 2 8 9 1 3
47nF 14 O1- I1- emc 1
22 14 3 C8
15 74HC14 U5B O2+ I2+ 2
10 13 4 3K3_RN_DIL
16 O2- I2- 3

2
23 D2 4 3 12 5 1 3
RED LED 17 VCC O3+ I3+ emc 4
11 11 6 C9
18 DC4 74HC14 O3- I3- 5
24 10 7
19 O4+ I4+ 6

2
12 9 8 1 3
20 O4- I4- emc 7
25 C10
U21 8
13 R2 20 PIN 47nF PC847

2
0V 1 3
emc HE14 8D
MALE DB25 U7
M T G5 4K7 3 2 1 18
D0 Q0 I1 O1

2
.
4 5 2 17
D1 Q1 I2 O2
7 6 3 16
D2 Q2 I3 O3

1
8 9 4 15 C11
0V D3 Q3 I4 O4
13 12 5 14 1 3
D4 Q4 I5 O5 emc
S1 14 15 6 13

1
POWER2 D5 Q5 I6 O6
1 8 17 16 7 12
D6 Q6 I7 O7

2
2 7 C12 18 19 8 11 C13
1 D7 Q7 I8 O8
3 6 R3 1 3
2 47uF 0V 2K2 emc C14
4 5 1 10
3 OC COM

2
11 9 1 3
4 G GND

2
S W DIP-4 R4 emc
5 2803A 2K2 C15
74HC374

2
HE14 5S 0V 0V 1 3
emc
R5 U9 C16

2
2K2 1 16 1 3
I1+ O1+ emc
D3 2 15 C17
I1- O1- OPTO_OUT1
3 14
I2+ O2+

2
C18 1 2 R6 4 13 1 3
I2- O2- emc 1
2K2 5 12 C19
R7 I3+ O3+ 2
1 3 6 11
emc I3- O3- 3

2
C20 YELLOW LED 7 10 1 3

1
4K7 I4+ O4+ emc 4
8 9 C22
I4- O4- 5

2
1 3 U10
emc 6

2
1 5 PC847 1 3
.. C21 emc 7
2 4
.. 8

2
VCC 6 220uF
.

2
DC5 HE14 8D
VCC 4N26
DC6 0V RL1
47nF C23
0V
W3 47nF 1 3
0V emc
LINK-5 C24

2
1 3
U11 OMRON G5L emc
C25

8
1
2
3
4
5
H C P L4200 D4
1N4148 RELAYS1

2
1 3

VCC
1 emc
+ 20MA1 1
2

2
7 2 RL2
ROP - 1 3
2 C26 4

OV
6
C29 EN 3 5
1 3
4 emc 6
10uF C28
2

8
C O N_LAN1 5

5
U13 C32 HE14 6D
6

2
C27 10uF 1 3

VCC
1

C33 MAX232 1 7 emc

10uF 3 OMRON G5L C30
2 + 8
16

10uF U5C
1

3 D5
1

2
6 4 HE14 8S 6 5 1 3
C31 4 TIN - emc
1 1N4148
VCC
2

C1+ 5 U12

OV
10uF
2

2 74HC14
V+ 6 H C P L4100

2
3
C1- 7
2

4 U5D
C2+ 8

5
6 8 9
V-
1

5 H E 14 8D
C2- 74HC14
0V 14 11
TOR1 TIL1 U5E
8 U14
7 10 10 11
TOR2 TIL2
1
VCC
RO 74HC14
13 12 7
RIR1 ROL1 A
2 R8 W 1 A N D W2 SELECT SUPPLY
RE
8 9 1 W4 2 RS1 U5F F O R M E S S A G E SELECT SWITCHES
RIR2 ROL2 -ve
3 LINK 12 13
DE 1
GND

GND

6 270R +ve U15A I N T E R N A L SUPPLY (24 V) 1-2

B 2 common 74HC14
4
DI 3
3 2 E X T E R N A L SUPPLY (10 V - 30 V) 2 - 3
MAX485 0V
15

HE14 3S
5

U16A
1 4050
3
2 U15B W 3 S E L E CTS :-

0V 4070 5 4 MODEM 1-2

20 mA LOOP 4 - 5
U16B RS485 3-4
RS232 5 4050
4
6 U15C
1
2
4070 7 6 S 1 S E L E C T S M O DEM POWER SUPPLY

1
3 VDD
4 R9 R10 DC7 VDD
5 INTERNAL SUPPLY 1 & 4 ON, 2 & 3 OFF
680R 10K DC8 4050
6 C34 R11 U17 EXTERNAL SUPPLY 1 & 4 OFF, 2 & 3 ON
1 emc 3 1 2 1 6 ISO_0V VDD
D+ VCC 47nF
2

2
HE_14_6S C35 VSS 47nF DC9
1 emc 3 680R 4 VSS
OUT ISO_0V
2

C36 2
D-
1 emc 3 5 VDD 47nF
OV
2

TIME OF FLIGHT COMPENSATION CIRCUIT VSS

H11N1 ISO_0V
2

SENC_IN SENC_OUT
+12 Volts
1 1
2 2

14
RV1 R12

1
3 VDD U16C U15D 3
200K_POT U18A
4 DC10 4
4538 8
C L O C K W I S E R O T A TION 10K C37 10 9 10
HE14 4S HE14 4S
C38 2 6 9
1 emc 3 47nF
I N C R E A SES 100pF RC Q
1

VSS R E S I S T ANCE 1 4070 4050

CX

8
C39 ISO_0V R13
2

1 emc 3 2K7 R14 4

+T
5
R15 -T
U19 U16D 7

R
PEC1_IN Q
2

1 2 1 6 12 39K
D+ VCC R16
11
1 620k PEC1_OUT

3
2K7 4 13 U18B Note: U15 is connected U15E
2 OUT C40
2 4538
3 D- pin 1 to +12 Volts (VDD) 100nF 1
JB1 5 4070 14 10 11 12
OV RC Q 2
HE14 3S 1
1

A pin 7 to ISO 0 Volts (VSS) 3

2 H11L1 15
C41 B R17 CX
3 4050 HE14 3S
C
1 emc 3 4 2K7 12 U16 is connected
D +T C42
5 11
C43 E R18 -T 100pF pin 14 to +12 Volts (VDD)
6 U20 9

R
F Q
2

1 emc 3 7 1 2 1 6
G D+ VCC C44 pin 7 to ISO 0 Volts (VSS)
8

13
H 2K7 precision 10nF
9 4
PEC2_IN I OUT
2

10 2 capacitor U18 is connected

J D-
5
1 OV pin 16 to +12 Volts (VDD)
1 0 W AY
2
H11L1
3 pin 8 to ISO 0 Volts (VSS) PEC2_OUT
HE14 3S 1
ISO 0 Volts 2
3
VDD U15F HE14 3S
DC11
VSS 14 15

47nF
VSS 4050
ISO_0V TG1 TG2 TG3

0V GND
MTG1 MTG2 MTG3 MTG4

.
1

1
A-10 Foldout 4: Expansion Board Rev AB
 Willett 460, 460Mi and 460Pi Service Manual

Foldout 5: Levels Board

Rev AB Foldout 5: Levels Board A-11

Willett 460, 460Mi and 460Pi Service Manual

F1 +15V JP16
Notes. R1
U3B IDC 50W

12
1. All 470R resistors to be 470R LM339
50mA
vitreous enammeled. 25W WW D3 D6 4 R32 DOOR PCB

10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
-
C16 R34 2 4K7

1
2
3
4
5
6
7
8
9
13V 5W 13V 5W D31 VCC
2. Fuses are 1500A breaking 5 +
current,240V fast type. VREF
100nF 100K IN4148
3. Zeners are 1N5350B. R39 R10 VCC

1
D4 D5 470K C8 10M
4. Maintain an infallable gap between 13V 5W 13V 5W 100nF RPACK1 C3

2
input and output. 1k5 100nF
LEVELS OUT REF1
5. PCB to be conformally coated LM336Z2.5V
after assembly. JP1
chgnd U3A

9
8
7
6
5
4
3
2
1
F2

12

1
R2 LM339 2
6 3
470R
-
4
Mixer Low
50mA C17 R35 D32 1
25W WW D9 D12 7 + 5
6
13V 5W 13V 5W

1
2
3
4
5
6
7
8
7
100nF 100K IN4148
8
Mixer OK
R36 R11

3
470K C9 10M 9
100nF 10 JP13
chgnd 11
D10 D11 Mixer High HE14 2X4
12
13V 5W 13V 5W 13
LED CONNECTOR
JP4
14 1)RED LED
1 15 2)YELLOW LED
2 U3C 16
VMS Low
3)GREEN LED

12
3 LM339 17
4
chgnd 18
F3 8 - 5)RED LED
5 R3 C18 R37 14 19 6)YELLOW LED
6
D33
20
vms High
9 7)GREEN LED

10
11
12
13
14
15
16
17
18
19
20
21
22
+
7 470R 21

1
2
3
4
5
6
7
8
9
50mA
8 25W WW D13 D16 22
IN4148

10
11
12
13
14
15
16
17
18
19
20
21
22

20
19
18
17
16
15
14
13
12
11
10
100nF 100K

1
2
3
4
5
6
7
8
9

9
8
7
6
5
4
3
2
1
R38 R9 23
13V 5W 13V 5W Ink Low

3
HE14 8W

1
2
3
470K C10 10M 24
100nF 25
RES-LEVELS 26 JP14 JP15 JP12
27
IO/ KBD IO/LCD
Solvent Low HE14 3W FLAT 22 IDC 20W
D14 D15 28
29
IO/B_LIGHT
13V 5W 13V 5W 30
U3D 31
+15V
JP5

12
LM339 32
U2A
1 10 - 33 1 16
2 C19 R33 13 34 9 IN OUT
D34
3 11 COM
4
chgnd F4 + IDC 34
R4 ULN2003A
5
470R 100nF 100K IN4148
6 R31 R12
50mA -15V +15V U2B

3
7 25W WW D17 D20 470K C11 10M 2 15
8 100nF 9 IN OUT
9 13V 5W 13V 5W COM
10
chgnd
ULN2003A VCC +15V
HE14 2X5 REG1
U2C
FMS-LEVELS D18 D19 3 14 78L05
U4B IN OUT
C4 C5 9 3 1

12
13V 5W 13V 5W LM339 COM VOUT VIN
100nF 100nF
4 - ULN2003A

GND
C20 R20 D35 2
5 + U2D C1
chgnd 4 13 100nF C2
9 IN OUT 100nF
F5 IN4148

2
R5 100nF 100K COM
R19 R15 VCC

3
470K C12 10M ULN2003A
470R 100nF
50mA
chassis boltholes barrier and peripheral ring 25W WW D21 D24 U2E
13V 5W 13V 5W 5 12
9 IN OUT
COM

U4A ULN2003A

12
D22 D23 LM339 +15V U2F
chgnd 13V 5W 13V 5W 6 - 6 11
C21 R17 1 R24 9 IN OUT
D36 U1A COM Supply rail labeled VCC is not
7 +
TL082 C15 150K connectedto the supply rail

8
ULN2003A
H1 IN4148 3 R23 labeled +5V.
MTGHOLE 100nF 100K +
chgnd R16 R18 1 U2G

3
470K 10M 15K
F6 C13 2 U1B 7 10
H2 R6 100nF - 100nF IN OUT
R22 9
TL082 COM

4
MTGHOLE 100K 8
470R GND
50mA 6

4
-
H3 25W WW D25 D28 R26 7 ULN2003A
MTGHOLE 13V 5W 13V 5W + 5
22K
-15V
H4
MTGHOLE

8
H5 D26 D27 C7
MTGHOLE 100nF R25 C6
13V 5W 13V 5W
100nF
H6 100K
MTGHOLE R27
R119
22K
H7 chgnd
MTGHOLE 100K
+15V STIRRERS
H8 Flying lead pad
MTGHOLE JP103
U103A
TL084 C107 1

4
H9
MTGHOLE 3 2
JP2 +
1 3
1 2 4
chgnd 2
DOOR_SWITCH - 1uF 5
3
HE14 1X5
HE14 3W

11
SAFE_CON1 R102 R120 R121
1M +15V 100R 100K
JP3 -15V R122 R123
TG1 1)POW ON SOURCE C101 10R 10R
TARGET 2)AIR FAIL SINK 1
3)AUTO OF SOURCE 2 R113
4)SAFETY BOX GND 3 JP7 1K
2.2uF
2
4
6
TG2 5)5V SAFETY SWITCHED SOURCE 4
5 HE14 3X2 Q101
TARGET 6)PELTIER SINK
7)THERMISTER SOURCE 6 Z T X 450 U101
7 U103B
8)PURGE SINK 6 1
1
3
5

I/O FAN_FAIL

11
TG3 9)UNUSED 8 TL084 5 VCC INP 2
TARGET 10)UNUSED 9 6 R103 4 COLL C1 3
10
EHT -
EMIT C2
R101 7 8 7 R124
JP8 100K GND F/B
+ 5
HE14 10W 2K7 100K
+5V LM2917 R117
1 R104 27K C104
2 100nF
+5V

4
JP6 3 100K
U103C
R106
1 HE14 3W R105 TL084 C108

4
F102 1K R114
2 10K C103 10
2.5A TR5 SERIES 3 9K1 +
1uF 8
4 9
PELTIER -15V +15V - 1uF
PURGE_VALVE R107
HE14 4W
CONDENSER JP102 JP9
10

1M
2
4
6
8

CONTROL HE14 2X5

11
R127 1 C102 R115 R125 R126
2
+15V
10K 1K 100R 100K
JP101 3
1
3
5
7
9

4
1 R128 5 2.2uF U102
2
I/O FAN/EHT Q102
HE14 5W 6 1
3 100K Z T X 450 VCC INP
U103D 5 2
4 Q103 C109 JP10 4 COLL C1 3

11
2
4
6
8

5 RFP4N06L 100nF TL084 8 EMIT C2 7

6 HEADER 4X2 R109 GND F/B
- 13
R108 14 R118
HE14 6W 100K LM2917
12 27K C106
1
3
5
7

LEDS/OPTICAL 2K7
+
R129 JP11 F101 100nF
100R R110
1 250mA

4
2 100K
R116
3 R112 10K C105
R67 4 R111
5
FANS 1K 1uF
470R 9K1
HE14 5W
R66 +15V -15V
470R

A-12 Foldout 5: Levels Board Rev AB