Inkjet Wiedenbach MM E A4 V2

Guide Maintenance
Contents
1 SAFETY ..........................................................................................................................................................4
2 CONTINUOUS INKJET SYSTEM ..................................................................................................................4
2.1 SERIES 407.......................................................................................................................................................4
2.2 SERIES 405.......................................................................................................................................................5
2.3 SERIES 405 AND 407.........................................................................................................................................6
3 PRINTER COMPONENTS..............................................................................................................................7
3.1 CABINET VIEW – CS 407 AND CS 405................................................................................................................7
3.2 HYDRAULICS - CS 407.......................................................................................................................................8
3.3 HYDRAULICS - CS 405.......................................................................................................................................8
4 CP-PRINT HEAD ............................................................................................................................................9
4.1 RECOMMENDED PRESSURE SETTINGS:.............................................................................................................10
4.2 SETTING MODULATION .....................................................................................................................................10
4.3 SETTING DROP SEPARATION ............................................................................................................................11
4.4 SETTING THE INKJET DIRECTION FOR THE CP-PRINT HEAD................................................................................15
4.5 ADJUSTING THE PRINT HEAD BLEEDING ............................................................................................................16
4.6 CLEANING THE CP-PRINT HEAD .......................................................................................................................17
4.7 CLEANING OF ELECTRODES IN THE CP-PRINT HEAD..........................................................................................18
4.8 CLEANING OF THE NOZZLE IN THE CP-PRINT HEAD ...........................................................................................19
5 PRODUCT SENSOR CONNECTION (PRINT GO-SIGNAL) .......................................................................20
6 CONNECTIONS AND JUMPER SETTINGS................................................................................................21
6.1 ELECTROMECHANICAL CONTACT, INTERNAL POWER SUPPLY ..............................................................................21
6.2 ELECTROMECHANICAL CONTACT, EXTERNAL POWER SUPPLY .............................................................................21
6.3 ELECTRONIC SWITCH, NPN TYPE .....................................................................................................................22
6.4 ELECTRONIC SWITCH, PNP TYPE .....................................................................................................................22
7 SHAFT ENCODER CONNECTION (STROKE GO-SIGNAL) ......................................................................23
8 OUTPUT SIGNALS (ALARMS)....................................................................................................................27
9 ETHERNET - INTERFACE ...........................................................................................................................28
10 INDICATION LIGHT (OPTIONAL) ...............................................................................................................29
11 RS232 INTERFACE......................................................................................................................................30
12 SETTING THE PRINT IMAGE AND PRINT COMMAND.............................................................................31
13 REMOVAL AND REPLACEMENT OF PARTS............................................................................................33
14 ACCESS TO THE HYDRAULICS ................................................................................................................33
15 CHANGING THE HOUSING FILTER (ELECTRONICS)..............................................................................34
16 CHANGING THE HEAD FILTER..................................................................................................................35
17 CHANGING THE INK FILTER......................................................................................................................36
18 CHANGE CONDENSER FILTER .................................................................................................................37
19 CHANGING OF MAKE-UP FILTER AND INLET FILTER ...........................................................................39
20 INK ................................................................................................................................................................40
20.1 INK DENSITY....................................................................................................................................................40
20.2 MEASURING MANUALLY ....................................................................................................................................40
20.3 DENSITY CORRECTION MANUALLY ....................................................................................................................42
20.4 INK DENSITY TABLE ..........................................................................................................................................43
Page 2 Issue 2 – November 2010

All rights reserved. No part of this publication may be reproduced, stored on a retrieval system, or
transmitted in any form, or by any means, electronic, mechanical, photocopying, recording or otherwise,
without the prior permission in written form of WIEDENBACH APPARATEBAU GMBH.
Subject to technical modifications
This manual has been compiled especially for trained service personnel and not for normal operation.
© Copyright 2009 WIEDENBACH APPARATEBAU GMBH
WIEDENBACH APPARATEBAU GMBH

Industriepark 312
78244 Gottmadingen
Deutschland
Tel: +49 (0) 77 31 / 799 11 - 0

Fax: +49 (0) 77 31 / 799 11 - 90
[email protected]
www.wiedenbach.com
Issue 2 – November 2010 Page 3

1 Safety
The basic precondition for safe handling and trouble-free operation of the inkjet printer is the knowledge of
the basic safety instructions and safety regulations. The operating manual contains the most important
instructions for safe operation of the inkjet printer.
The operating manual, especially the safety instructions, must be ob-served by all persons who work on
the inkjet printer. In addition, the rules and regulations for the prevention of accidents applicable at the
respective application site must be observed.
2 Continuous Inkjet System

The WIEDENBACH ink jet printer operates according to the continuous ink jet principle (Continuous Inkjet
System).
2.1 Series 407
From the ink tank (TT), ink is pressed into the diaphragm tank (TMT) with the help of the transfer pump
(UP) depending on the ink level in the diaphragm tank. On the way the ink passes through a density meter
DM. From the diaphragm tank the ink is fed into the drop generator with the help of compressed air.
Schematic diagram type 407

2.2 Series 405
For these printer versions ink is pressed by a pressure pump (DP) into the drop generator via a pressure
sensor and density sensor (DM).
Schematic diagram type 405

2.3 Series 405 and 407
The ink emerges from a fine nozzle, crosses an air gap and is captured by a gutter pipe (F). The return
pump (SP) feeds the ink from the gutter pipe to the ink tank (TT). In this way an ink circuit is produced with
a continuous ink jet from the nozzle to the gutter pipe.
In the drop generator, the ink is forced to oscillate (modulated) with the aid of an ultrasonic transducer
(piezo transducer) which is controlled by the modulation module (MS). The ink jet is separated up into
single, defined ink drops as it emerges from the nozzle, i.e. the drops are more or less torn from the initially
solid ink jet.
The drops cross the area of the charge electrode (LADE) at the moment they are torn off. The drops
required to generate the print image are electro statically charged by applying a pulsed voltage between
the charge electrode and the nozzle (ion shift in the conductive ink). The charging module (LS) generates
the necessary pulsed voltage.
All drops then cross the electrical field between the two deflection plates (HVP) which are connected to a
constant high voltage and GND. The charged drops are deflected in the direction of the electrical field and
fly past the gutter pipe onto the printing surface. The uncharged drops fly straight on, are sucked up by the
gutter pipe and remain in the ink circuit.
By adjusting the height of the pulsed voltage at the charge electrode, the drops are charged with different
voltages and deflected in different angles by the high voltage. If the charging electrode is controlled
correctly, they hit the printing surface in the shape of a vertical row of dots, called „strokes“. The
combination of strokes, e.g. the lateral movement of the printing surface, produces a printed line.
With this technique, the ink jet printer enables non-contact labelling and marking of surfaces of any shape
and of varying structures. Therefore objects are labelled with fast-drying, smear proof ink.
The object to be labelled can either be moved past the fixed print head or the print head can be moved
past the standing object on a carriage.
An external sensor is required to integrate the ink jet printer in an automatic production line. This sensor,
usually a proximity switch, must generate a Print-Go signal when the object approaches the print head and
printing is to be started.
Another sensor, usually an incremental shaft encoder, is useful if the printing speed is to be adapted
automatically to fluctuating product speeds in order to produce a print of constant length.
Print Head
Tubus HVP 1 vertical row of drops = 1 stroke
Print Head K HVP F Trajectory of the drops

3 Printer Components
3.1 Cabinet View – CS 407 and CS 405
Data input and control panel Transport handle
Compressed air connection Hydraulic cover

Print head
(only CS 407)

3.2 Hydraulics - CS 407
Main filter
Pressure gauge Diaphragm tank
Return- and
Dosing pump Ink tank
behind cover
Pressure “Make-Up” tank

regulator
Regulating stop valve „Print head
overpressure“
Transfer pump
(Toothed wheel)
Density measuring unit
3.3 Hydraulics - CS 405
Main filter
behind the tank
Dosing pump
Pressure dumper
behind the tank
Return pump
Ink tank
Transfer pump
(Toothed wheel)
“Make-Up” tank

4 CP-Print Head
The printers of the CS-series are fitted with a CP-Print head.
Warning!
! The print head may not be used without print head cover.
Air separator vent

line, yellow Print head ventilation, blue
Supply line Excentric for adjusting the inkjet edgeways

ink, red
Locking screws for inkjet adjustment
Flushing line
“Make-Up”,
transparent
Mounting bracket for print head cover
Charge electrode Nozzle
Control electrode
Basis element
Deflection plates
Gutter pipe block
Flight time
electrode
Important
The print head can be mounted at any desired position. The printing head and the supply
hose must be fixed firmly and without vibrations.
The height difference between the printer and print head is max. 3 meters.
The printing head must remain accessible for cleaning and maintenance work,
commissioning and shutdown. Incline the print head forwards/downwards for cleaning and
hang the funnel bottle onto the bottom plate.

4.1 Recommended Pressure Settings:
Nozzle Frequency Pressure
75 µm 64 kHz 2,6 - 3,2 bar
60 µm 84 kHz 3,2 - 4,0 bar
4.2 Setting Modulation
The oscillating amplitude of the piezo oscillator determines where and how the ink jet is split up into
individual drops after emerging from the nozzle. Setting the modulation amplitude changes the position and
type of the drop separation.
The modulation can be altered.
The modulation that is set and saved last is retained when the system is switched off and back on.
Modulated jet Unmodulated jet

4.3 Setting Drop Separation
Note
Usually it is only necessary to set the drop separation at first set up, when exchanging or
renewing ink, if the printing quality is unsatisfactory and cleaning has not improved it and when
density has been set incorrectly.
Once the drop separation has been set correctly, it will only fluctuate slightly even if the operating
conditions fluctuate considerably. Nevertheless, it should still be checked regularly because it is
a decisive factor in the printing quality.
The drop separation is characterized by:
• Drop shape
The drops should be separated with the ideal shape (no satellite drops or deformations).
• Point of separation
The drops should be separated within the slit of the charge electrode (optimum charge).
The drop separation is influenced by:
• Cleaning, cleanliness
Particularly important: Only a clean nozzle produces a consistent ink jet.
• Modulation
The drops are separated earlier if the modulation values are higher.
• Ink pressure
The drops are separated later if the pressure is high.
• Ink type, ink quality

The type of ink is specified by the application; however the quality of the ink must satisfy the
requirements.
• Temperature
The operating and ambient temperatures specified in the data sheets of the ink jet printer and ink
must be complied with.
• Density
Has to be set according to the ink-card attached to the ink tank

DROP FORMATION
Good Bad
75 µm
Nozzle
Area for drop
separation
Satellite Drops
Good Bad
40-60 µm
Nozzle Area for drop
separation
Modulation good:
Drop separation
within the charge
electrode
Attention!
The precise vertical
position of the drop
Modulation too low:
separation inside the
Drop separation
electrode may vary
outside, after the
(depending on ink and
charge electrode
nozzle). Important are the
appearance and shape of
the drops as well as a
neat print image.
Modulation too high:
Drop separation
outside, before the
charge electrode

1. Check the nozzle to cleanliness.
2. Switch the printer on (see „Switching on“ in the

operating manual).
3. Set the system pressure at the display:
Nozzle Frequency Pressure

75 µm 64 kHz 2,6 - 3,2 bar
60 µm 84 kHz 3,2 - 4,0 bar
40-50 µm 120 kHz 4,2 - 4,8 bar
For Typ 405 edit system pressure at the display:

SYS – Adjust – Print Head – Modulation (See also
Reference Book – Text- and System Menu, Chapter:
System Menu – Adjust – Hydraulic pressure)
4. Turn the print head cover counter clockwise to open

the bayonet catch and pull off.
5. Position the magnifying glass by hand above the

charge electrode.
6. Decrease the modulation at the display (-)

System Menu – Print Head Modulation)
7. until no modulation of the jet can be seen.

8. Increase the modulation at the display (+)

9. The ink jet starts to contract increasingly until
individual drops break off. The uppermost free flying
drop must still be inside the slit of the charge
electrode.
10. Continue to increase the modulation at the display.

11. The drops are perfectly round initially. As the

modulation increases, they start to separate with a
’tail’. The lowest drop with a ’tail’ before the first
perfectly round drop, will also become perfectly round
as the modulation is increased.
12. If this is no longer the case then read the modulation

value at the display.
13. Reduce this value by approximately 5%. Press -5%

’Function SHIFT’ and keep it depressed, at the same = Optimum
time press ’Enter’ to save the value. The modulation
is set optimally.
14. Fit the print head cover and turn clockwise to lock the
bayonet catch.
Note:
If the modulation cannot be set successfully despite several attempts (e.g. because satellite drops
are constantly formed), increase or reduce the system pressure slightly (± 0,1 bar) and then repeat
the setting.

4.4 Setting the Inkjet Direction for the CP-Print Head
Caution!
Wear protective gloves, safety goggles and protective clothing.
1. Remove the head cover of the print head.

2. Hang a funnel bottle onto the print head.
3. Start up the printer and wait until the inkjet
runs stable.
4. Loosen the locking screw a little bit by 1 2
turning the socket head wrench (1,5 mm) 1
anti-clockwise.
5. Inkjet will be adjusted by turning the
screwdriver (Tx8) 2:
• Turning in clockwise direction Æ
direct the inkjet to the basis element
Basis element
a. Turning in anti-clockwise direction Æ
direct the inkjet away from the basis
element
6. Adjust the inkjet by fitting a socket head
wrench (1,5 mm) 1 at the excentric:
• Turning in clockwise direction Æ 1
direct the inkjet to the left
• Turning in anti-clockwise direction Æ
direct the inkjet to the right
(looking from front view)
ATTENTION
For the sideways setting with the Excenter
(Point 6.) the carrier plate must be able to rotate
freely around the pivot point.
Undo Assembly screws B by a ¼ turn ccw.
Re-tighten Lock screw A and Assembly screws B

after finished setting.
A Lock screw
B Assembly screws
C Pivot point
D Excenter
E Set screw

4.5 Adjusting the Print Head Bleeding
To prevent the ink being contaminated by dust particles sucked in with the returned ink jet, the print head
can be bled with pressed air.
Series 407 with external overpressure system (print head with overpressure)
1. The air pressure limiter valve for

adjusting the pressed air is located in
the hydraulic section of the printer.
Output of pressed air
2. The air pressure limiter valve

(standard setting: active) is more
opened by turning the adjusting
screw slowly to the left side. An
airflow, which is adjusted too
intensely, causes strong turbulences
inside the print head.
3. The air pressure is regulated by

opening or closing this screw.
Adjusting screw Air distributor
Air pressure
limiter valve
The series 405 can optionally be retro fitted with a “pressurized print head”.
Two systems are available.
Internal system (optional):

In the electronic part a pump for air transport is installed. Air is drawn in by an outside filter. A regulation of
the pressure is not required. The pump output is connected directly to the print head.
External system (optional):

At the side of the printer housing a pressure regulator is mounted, which is connected directly to the print
head. The air may only be drawn in through a measuring unit; the air flow inside the print head can be
regulated by the measuring unit. The compressed air must be dry and free of oil.

4.6 Cleaning the CP-Print Head
Attention!
Follow the safety instructions in the Operating Manual for all work carried out on the inkjet printer.
The printing head requires regular cleaning when using heavily pigmented ink:
Check the printing head before every shift and clean as follows if necessary.
Use WIEDENBACH “Wash” / “Make-Up” to clean the print head.
Ink residue usually dissolves easily so that it can simply be rinsed off, otherwise use a small brush.
Dry parts thoroughly after rinsing with “Make-Up”.
Use absorbent but lint-free papers or textiles.
Incline the print head forwards/downwards for cleaning and place the funnel bottle below the print head.

4.7 Cleaning of Electrodes in the CP-Print Head
Caution!
Important
Check electrodes at least weekly. Never tear the paper used for cleaning into strips, always cut it.
Lints are produced when paper is torn, which produce the exact opposite effect to the one you are
trying to achieve by cleaning.
1. Shut down the printer.

2. Remove the head cover of the print head.
3. While cleaning do not tilt print head upwards
or against people.
4. Rinse electrodes from outside with the

solvent funnel bottle until no more ink is
visible. Dry electrodes with paper.
5. Clean the charge and control electrode slit
with paper strips. Moisten the paper strips
with “Make-Up”. Pull the soaked paper strip
through the slits until no more traces of ink
are visible on the paper. Then dry the slits
with dry paper. Dry outer sides of electrodes
as well.
6. Use the magnifying glass to check that the

slits are lint-free. Remove lints with a dry
piece of paper if necessary.
7. Clean the flight time electrode with “Make-
Up”. Dry the electrode from the outside.
8. Close the head cover of the print head.
9. Start up the printer.

4.8 Cleaning of the Nozzle in the CP-Print Head
In case of a stubborn blockage of the nozzle an automatic cleaning process can be started:
Access level 3 required
In Standby: In Ready-Mode:
• Select System-Menu • Select System-Menu

• F3 Stop ink
• F2 Adjust • F2 Adjust
• F-Shift F1 Trouble checks • F-Shift F1 Trouble checks
• Block gutter • Block gutter
• F1 Nozzle cleaning • F1 Nozzle cleaning
• F3 Start ink
Upon pressing F1 ‘Flush Nozzle’ an automatic

process will start: Now spray ‘Wash’ onto the
nozzle until the process is finished. While doing
so observe the yellow hose (bleed line) in the
print head, air bubbles must form.
After that this hose must get clearer by the

injected ‘Wash’.
Repeat process if necessary.

5 Product Sensor Connection (Print Go-Signal)
To release the printing process a ’NO’ (normal open) contact is required which is actuated when the
product to be marked moves past the print head.
A WIEDENBACH product sensor needs simply to be plugged in. The necessary adjustments have already
been made at the factory.
Other product sensors must comply with following specifications:
• Electromechanical ’NO’ contacts

• Proximity switch / light barrier with NPN or PNP OC output with or without
• Internal voltage supply +24 VDC, max. 310 mA (Encoder and Product Sensor together)
• Sensors with shielded cables
• Connection plug with compatible cable shield
• Cable shield has to be clamped to the printer connection plug
~ 50 mA Connection for product sensor

6 Connections and Jumper Settings
6.1 Electromechanical contact, internal power supply
NPN Contact Jumper

settings
STB 407 +PG-
Factory settings
PNP Contact
6.2 Electromechanical contact, external power supply
NPN Contact Jumper

settings
STB 407 +PG-
Factory settings
PNP Contact

6.3 Electronic switch, NPN Type
NPN Contact Jumper

settings
STB 407 +PG-
6.4 Electronic switch, PNP Type

Jumper
settings
STB 407 +PG-

7 Shaft Encoder Connection (Stroke Go-Signal)
If product speeds fluctuate, then shaft encoders must be used to control the printing speed.
A WIEDENBACH shaft encoder needs simply to be plugged in. The necessary adjustments have already
been made at the factory. The connection is isolated through optocoupler electrically.
Other shaft encoders must comply with the following specifications:
• Supply voltage +24 VDC, max. 300 mA (Encoder and Product Sensor together)
• Output signal types A, (A, B) or A A / (A A / B B)
• Output circuits Push-Pull, Open-Collector (NPN, PNP), Line-Driver (TTL) optional, with converter
• Shaft encoder with shielded cable
• Connection plug with compatible cable plug
• Cable shield has to be clamped to the printer connection plug
Connection for shaft encoder
Pin connection:
external supply, for electrical decoupling
electromagnetic malfunction of the shaft encoder signals
Shaft encoder Printer

STB 107 Jumper and settings
The PrintGo is triggered by shaft encoder signals.
PPC-operation allows continuous print; print release (PrintGo) without product sensor, alternating print
(mirror / standard print) within one message, forward and backward motion of the product is registered and,
if required, compensated.
For the following examples the jumpers of Encoder A and B have to be set identically and the signals for A
and B must both be wired up.
Shaft encoder Signal Wiring with Wiring with Jumper settings

type power supply external power STB 407
supply
J107
A-signal
J108
B-signal
NPN A and B A A
B B
+V -V
-V
PNP A and B A A
B B
-V +V
+V
Push / Pull A, Ā, B, B/ A A
Ā Ā
B B
+V
-V

STB 407 Jumper and settings
Example:
Shaft encoder connection using the signals A and / or Ā on J107 A-signal.
The same applies for B and on J108 B-signal.

supply
J107
A-signal
J108
B-signal
NPN only A (signal) A A

+V -V
-V
NPN only Ā (signal) Ā Ā

+V -V
-V
PNP only A A A
-V +V
+V
PNP only Ā Ā Ā
-V +V
+V
Push / Pull only Ā A A

+V +V
-V

from supply
CS 407, J107
CS 405 A-signal
J108
B-signal
Push / Pull only Ā Ā Ā

+V +V
-V
Push / Pull A and Ā A A

Factory Ā Ā
settings +V
-V

8 Output Signals (Alarms)
Following output signals are displayed from the printer as standard: READY, INK / “MAKE-UP” EMPTY,
ERROR. As an option, busy could be placed on one of the just mentioned signals.
Output-Signals
The voltage to be switched must be applied externally, with the plus pole connected to the OUTCOM
contact. The voltage must be 40 VDC maximum, the current 50 mA maximum. The protective diodes
guarantee a constant current flow in the case of reverse polarity. The maximum current here must not
exceed 100 mA. The logic of the PB software and external wiring must be chosen so that a fail-safe
mechanism exists.
A through-connected channel means there is no error. If the connecting cable is broken, this has the same
effect as interrupting the channel and therefore signals an error.
Pin connection:
Pin 4 (OUTCOM)
Pin 1 (OUT1, READY)
Pin 2 (OUT2 INK/ MAKE-UP

EMPTY)
Pin 3 (OUT3, ERROR)

9 Ethernet - Interface
The Ethernet interface (TCP/IP interface) allows the printer to be connected to a network.
This offers the possibility, to control the text output of a printer on PC by a TCP/IP network or realize
service tasks.
Pin connection:
Ethernet Interface

10 Indication Light (optional)
The three coloured WIEDENBACH indication light is connected to the „INDICATION LIGHT“ connection.
The indication colours have the following meanings:
Signal 1 Green: Printer is ready or printing

Signal 2 Yellow: Warning
Signal 3 Red: Alarms (Error messages)
Signal 4 Buzzer (optional)
Top view Connection for indication light
Pin connection:
24 VDC / 200 mA each signal
1 - Signal 1+
2 - Signal 1-
3 - Signal 2+
4 - Signal 2-
5 - Signal 3+
6 - Signal 3-
7 - Signal 4+
8 - Signal 4-

11 RS232 interface
For remote operation using a computer, the ink jet printer is addressed via the RS232 interface.
The remote operation function is used for processing text and creating new text with help from the Terminal
7 program. Detailed information can be found in the manual for Terminal 7.
There is also an option to save texts and symbols already stored in the printer, using the archiving
software.
RS232 Interface
Pin connection:
Standard null modem cable

Pin 2 - RXD
Pin 3 - TXD
Pin 5 - GND

12 Setting the Print Image and Print Command
The print image is determined by properties such as character height and width, character spacing and
character position.
The print image can be set by parameter changes through the front panel.
Additionally the setting of the print image depends on two external signals:
Print-go signal (print command) determines when printing starts
Stroke-go signal (printing speed) determines the stroke output frequency
Print image
Input panel Printing speed:

Parameter setting Shaft encoder
Print command
sensor
The print control electronics of the ink jet printer requires an external Print-go signal to start printing.
Inductive, capacitive and optical sensors can be used to generate the signal.

Mounting the sensor:
The sensor has to be mounted in front of the print head with a relatively short distance to the print head
(see sketch). Since the sensor triggers the immediate printing, the parameter “Print Delay” is used to set
the distance to the print head.
Sensor
Distance to print head

13 Removal and replacement of parts
Warning
! For all work on the ink jet printer’s electrics the printer must be switched off and disconnected
from the power supply system.
Carefully read and observe Safety Instructions of the Operating Manual. Please note the risk of
electrostatic charging (ESD). Take precautionary measures.
Work on the electrical system may only be performed by qualified personnel or your local
WIEDENBACH representative.
14 Access to the Hydraulics

By lifting the locking lever the tanks can be swivelled forward for refill. To ease access to the hydraulics
compartment, the tanks can be lifted out completely. The Locking screw has to be loosened with a
screwdriver (torx, TX 20), to lift the tanks out.
Locking lever
Locking screw

15 Changing the Housing Filter (Electronics)
Important
Change housing filter at least six-monthly. Dispose the old filter properly according to local
regulations. Use only WIEDENBACH filters.
1. Loosen quick lock screw by a ¼

turn counter clockwise.
Filter mat
2. Slightly tilt cover plate and lift off
upwards.
3. Exchange filter mat and close
cover in reverse order.
In a very dusty environment it can be necessary to change the filter more often. At the beginning it is
recommended to check the filter weekly and find out the most ideal filter changing interval.

16 Changing the Head Filter
Caution!
Wear protective gloves, safety goggles and protective clothing
Important
Change head filter at least six-monthly. Dispose the old filter properly according to local
regulations. Use only WIEDENBACH filters.
1. Shut down the printer. 407

2. Type 407: set pressure to 0 bar.
3. Open hydraulic cover.
4. Type 407: Loosen screw at
manometer cover ½ drilling and turn
the cover down forwards. Screw
5. Place a paper below the white
connection block for splashes.
6. Loosen screw cap, remove filter and
O-ring.
7. Rinse filter housing with a funnel 407

bottle.
8. Exchange O-ring and filter.
9. Close all covers in reverse order and
Screw cap
start the printer.
10. When display shows ‚Ready’ the
system has to be bled. (see Reference
Book: Text- and System Menu).
CS 405
Screw cap

17 Changing the Ink Filter
Caution!
Important
Change ink filter at least six-monthly. Use only WIEDENBACH filters. Dispose the old filter
properly according to local regulations. Use only WIEDENBACH filters.
The ink filter is in the hydraulic section. To change the ink filter, proceed as follows:

2. With series 407 bring the system pressure down to 0 bar.
3. Empty the ink tank by:
(a) Suction cleaning with the aid of a pump or a spray bottle.
(b) Disconnect the condensate pipe at he upper tee connector or at condenser (option) and allow
it to run off into a suitable container until the tank is empty.
4. Loosen the connection fittings at the inlet (top) of the filter. Tilt the filter forward and downward over a
cleaning tub. Now loosen the outlet fittings and remove the filter.
Fittings
Warning:
Observe the direction of flow!
Condensate pipe
Ink filter change at the 407
5. Fit the filter in the reverse order.

Fittings
Warning:
Ink filter change at the CS 405

7. Check for possible leakages.
18 Change condenser filter
Caution!
Important
Condenser filter at least six-monthly. Use only WIEDENBACH filters. Dispose the old filter properly
according to local regulations. Use only WIEDENBACH filters.
The ink filter is in the hydraulic section. To change the ink filter, proceed as follows:

2. With series 407 bring the system pressure down to 0 bar.
3. Loosen the connection fittings at the inlet (top) of the filter. Tilt the filter forward and downward over a
cleaning tub. Now loosen the outlet fittings and remove the filter.
4. Fit the filter in the reverse order.
6. Check for possible leakages.

Condenser
Warning:
Fittings
Wechsel des Kondensiererfilters

19 Changing of Make-up Filter and Inlet Filter
Caution!
Important
Change make-up filter and inlet filter at least six-monthly. WIEDENBACH Filter. Use only
WIEDENBACH filters. Dispose the old filters properly according to local regulations. Use only
filters of the same type.
To change the filters, proceed as follows:

2. Open the hydraulic cover.
3. Empty the supply tank using the spray bottle.
Make-up filter
4. Remove the dosage / rinse duct. Screw the

connection nipples out of the bottom plate of
the tank.
5. Carefully press the make-up filter from the
top downward through the tank, using a long
object and remove it.
6. Fit the new make-up filter in the O-ring.
7. Screw the connection nipples back in (do not
damage the nylon seal).
8. Connect the duct and refill the container.
9. Check for leakages
Make-up filter
10. Replace the inlet filter.

Inlet filter

20 Ink
Caution!
Warning
! Read carefully and observe Safety Instructions of the Operating Manual.
Work on the electrical system may only be performed by qualified personnel or your local
WIEDENBACH representative.
Clean up spilled ink immediately. Do not let the ink dry.
Make sure the room is ventilated, especially at the floor level. The solvent vapours are heavier
than air and tend to accumulate on the floor.
20.1 Ink Density
Note
There must be enough make-up in the make-up container. Check and refill make-up if necessary at
least every three days.
The ink density is a decisive parameter for the formation of drops and print quality. It may change through
evaporation of the make-up content of the ink or due to operating errors (too much make-up added to the
ink circuit). It is therefore measured automatically at regular intervals. Normally the density is controlled by
a measuring system in the printer and if necessary make-up is added.
20.2 Measuring manually

The density of the ink is determined outside the ink jet printer with the aid of a glass measuring cylinder
and an aerometer (densimeter).
Proceed as follows:
1. Approximately 40 ml of ink is required in the glass measuring cylinder in order to take the
measurement. Hold the glass measuring cylinder under the running ink jet. The required amount of ink
will be collected in the glass measuring cylinder after approximately 5 minutes.
2. Place the glass measuring cylinder on a level surface.
3. Immerse the aerometer carefully in the ink in the glass measuring cylinder until it floats.
4. Read the value on the aerometer at the point of intersection with the surface of the ink in g/ml and
record it.
5. Remove the aerometer from the glass measuring cylinder. Now measure the ink temperature inside of
the glass measuring cylinder. Put the ink back into the ink tank. Clean the glass measuring cylinder
and the aerometer carefully.
Note: Observe the ink temperature. The aerometer is calibrated to an ink temperature of 20°C.
Temperature fluctuation produces incorrect measurement values, i.e. if the ink is warmer it will produce a
lower density reading (thinner) than the same ink measured at reference temperature 20ºC. In order to
compensate this, the following formula is used:

1ºC difference equals approximately 0,0013 g/ml.
Example:
Target density at 20ºC – 0,865 g/ml
Measurement value at 30ºC – 0,852 g/ml
Measurement value at 10ºC – 0,878 g/ml
Difference between reference temperature and ink temperature

= 10ºC 10 x 0,0013 = 0,013
0,878 - 0,013 = 0,865 – corresponds to the correct target density
0,852 + 0,013 = 0,865 – corresponds to the correct target density
(1) (2) (3) (4)

20.3 Density Correction manually
Proceed as follows:
1. Measure ink density.
2. Compare the measured value with the values in the "Ink density table" below.
3. Calculate the amount of make-up required (an example of such a calculation is provided on the
following page).
Kindly note that the data in the table refers to 1 litre of ink. The ink jet printer has an ink capacity of
1.25 litres, but as a standard is filled with 1 litre. For CS 407 a certain amount of ink is always inside
the diaphragm tank.
4. Dose the calculated amount of make-up into a separate vessel.
5. Refill the make-up in the ink circuit.
Check the density of the thinned ink but only after the ink and the make-up have been well mixed, in case
of doubt allow printer to “bleed” for about 10 minutes with reduced pressure (ca. 2 bar).
If the automatic make-up dosing unit does not work, make-up must be added every day after shutting down
the ink jet printer. The following rule of thumb applies:
7 ml make-up per operating hour and print head at an ambient temperature of 20 °C
Since this is a small volume, we recommend the following procedure:
Put the required dose into a suitable measuring cup and refill the ink tank.
If the measuring cup or glass measurement cylinder has a different scale:

3
1 ml (Millilitre = 1/1000 Litre) corresponds to a volume of 1 cm .

20.4 Ink density table
Determining the additional needed make-up volume for ink that is too thick:
Example with diagram for a typical ink (W52-100-1K)
1. Take the target density from the inspection certificate or the ink label in the hydraulics section of the
printer (e.g. target density 0,865 g/ml).
2. Determine the actual density using the aerometer (e.g. actual density: 0,872 g/ml).
3. Mark the actual density (e.g. point 1) on the vertical axis in the diagram and draw a horizontal line.
4. On the diagram, draw a line vertically downwards from the point of intersection of this line with the
curve to the point of intersection with the horizontal axis (e.g. point 2).
5. The value read there is the required volume of make-up which corresponds to one litre of make-up.
6. Fill the appropriate amount of make-up into the ink tank.
g/ml
0.890
0.880
0.870
0.860
0.850
7. In the following diagram are not all the available inks are listed for better readability. But you can
include the line for the required ink manually.

Required density in g / ml
Make-up in ml / Litre
The target density of the ink should be taken from the inspection certificate of the printer.

WIEDENBACH APPARATEBAU GMBH
Industriepark 312
78244 Gottmadingen
Germany
Tel: +49 (0) 77 31 / 799 11 - 0

Fax: +49 (0) 77 31 / 799 11 - 90
[email protected]
www.wiedenbach.com

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Guide Maintenance

Page 2 Issue 2 – November 2010

© Copyright 2009 WIEDENBACH APPARATEBAU GMBH

WIEDENBACH APPARATEBAU GMBH

Tel: +49 (0) 77 31 / 799 11 - 0

Issue 2 – November 2010 Page 3

2 Continuous Inkjet System

2.1 Series 407

Schematic diagram type 407

Page 4 Issue 2 – November 2010

Schematic diagram type 405

Issue 2 – November 2010 Page 5

Tubus HVP 1 vertical row of drops = 1 stroke

Print Head K HVP F Trajectory of the drops

Page 6 Issue 2 – November 2010

Data input and control panel Transport handle

Compressed air connection Hydraulic cover

Issue 2 – November 2010 Page 7

Pressure gauge Diaphragm tank

Pressure “Make-Up” tank

3.3 Hydraulics - CS 405

Page 8 Issue 2 – November 2010

Air separator vent

Supply line Excentric for adjusting the inkjet edgeways

Mounting bracket for print head cover

Charge electrode Nozzle

Issue 2 – November 2010 Page 9

4.2 Setting Modulation

Modulated jet Unmodulated jet

Page 10 Issue 2 – November 2010

The drop separation is characterized by:

The drop separation is influenced by:

• Ink type, ink quality

Issue 2 – November 2010 Page 11

Page 12 Issue 2 – November 2010

2. Switch the printer on (see „Switching on“ in the

3. Set the system pressure at the display:

Nozzle Frequency Pressure

For Typ 405 edit system pressure at the display:

4. Turn the print head cover counter clockwise to open

5. Position the magnifying glass by hand above the

6. Decrease the modulation at the display (-)

7. until no modulation of the jet can be seen.

8. Increase the modulation at the display (+)

Issue 2 – November 2010 Page 13

10. Continue to increase the modulation at the display.

11. The drops are perfectly round initially. As the

12. If this is no longer the case then read the modulation

13. Reduce this value by approximately 5%. Press -5%

Page 14 Issue 2 – November 2010

1. Remove the head cover of the print head.

Re-tighten Lock screw A and Assembly screws B

Issue 2 – November 2010 Page 15

1. The air pressure limiter valve for

Output of pressed air

2. The air pressure limiter valve

3. The air pressure is regulated by

Adjusting screw Air distributor

Two systems are available.