Diagraph TJ500 User manual

Operations
Manual
1 Missouri Research Park Drive • St. Charles, MO 63304 • Service Line 1-800-526-2531
Illinois Tool Works Inc © 2009
Thermal Jet
Ink Jet System
5780-320
Revision C

TJ500 Thermal Jet
Ink Jet System
Operations Manual
5780-320
Revision C
The information contained in this manual
is correct and accurate at the time of its
publication. Diagraph reserves the right to
change or alter any information or
technical specifications at any time and
without notice.
©2009 Illinois Tool Works Inc.
All rights reserved
Printed in the United States of America
Ink Cartridge: The TJ500 has been engineered and
designed to work with Diagraph ink cartridges. The
TJ500’s Smart Level Ink Detection System, which
provides ink level monitoring to ensure complete ink
usage and product safety, will not be functional if
used with non-Diagraph ink cartridges.

The TJ500 Thermal Jet system, including all components unless otherwise specified,
carries a limited warranty.
The inks and conditioners used with the TJ500 Thermal Jet system carry a limited
warranty.
For all warranty terms and conditions, contact Diagraph an ITW Company for a
complete copy of the Limited Warranty Statement.
Warranty:
Thermal Jet

Thermal Jet
5780-320 Operations Manual Rev C
Section 1: Safety and Ink Cartridge Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 2: Quick Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Step 1: Assemble Bracketry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Step 2: Assemble Bracketry to Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Step 3: Assemble TJ500 and Power Supply to Bracketry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Step 4: Adjust TJ500 Print Head to Substrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Step 5: Insert Cartridge Pen into Print Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Step 6: Cabling, Power, and Serial Port Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Step 7: Configure the Print Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Step 8: Create a Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Step 9: Print a Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Section 3: IJ3000-ES or GUI Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Keypad or Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Home Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Section 4: Maintenance & Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Daily Maintenance, Ink Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Weekly to Monthly Maintenance, Print Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Shutdowns Less Than 3 Days . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Shutdowns More Than 3 Days . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Section 5: Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Appendix A: Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Appendix B: Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
TJ500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
IJ3000-ES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Interconnect Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Appendix C: Part Numbers - Consumables and Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Appendix D: File Backup and Restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
File Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Restoring Backed-Up Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Appendix E: Configuring a PC to Communicate with the IJ3000-ES . . . . . . . . . . . . . . . . . . . . . . . . 36
Windows XP® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Windows 2000® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Appendix F: Font Samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Appendix G: Creating Logo Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Appendix H: Uploading Files to the Print Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Thermal Jet Section 1: Safety and Ink Cartridge Usage
5780-320 Operations Manual Rev C Page 1
Section 1: Safety and Ink Cartridge Usage
Following is a list of safety symbols and their meanings, which are found throughout this
manual. Pay attention to these symbols where they appear in the manual.
Wear safety goggles when performing the procedure described!
Caution or Warning! Denotes possible personal injury and/or damage to the equipment.
Caution or Warning! Denotes possible personal injury and/or equipment damage due to
electrical hazard.
NOTE: (Will be followed by a brief comment or explanation.)
ESD protection should be worn when servicing internal printed circuit boards.
After service to the equipment is completed, replace all protective devices such as ground-
ing cables and covers before operating the equipment.
It is extremely important to:
• Clean up all spills with the appropriate solvents immediately and dispose of all waste according
to local and state regulations.
• Wear safety glasses and protective clothing, including gloves, when handling all inks and condi-
tioners.
• Store inks and solvents under the recommended conditions found on the MSDS (Material
Safety Data Sheet).
Ink Cartridge: The TJ500 has been engineered and designed to work with Diagraph ink
cartridges. The TJ500’s Smart Level Ink Detection System, which provides ink level
monitoring to ensure complete ink usage and product safety, will not be functional if used
with non-Diagraph ink cartridges.
!
!

Thermal Jet Section 2: Quick Start
5780-320 Operations Manual Rev C Page 2
Section 2: Quick Start
Contents:
• TJ500 Print Head
• Bracketry Kit
• Power Supply, 15 V
• Power Supply Bracket
•PowerCord
• Software CD
OPTIONAL IJ3000-ES
CONTROLLER
TYPICAL INSTALLATION

Thermal Jet Section 2: Quick Start
5780-320 Operations Manual Rev C Page 3
Step 1: Assemble Bracketry
Step 2: Assemble Bracketry to Conveyor

Thermal Jet Section 2: Quick Start
5780-320 Operations Manual Rev C Page 4
Step 3: Assemble TJ500 and Power Supply to Bracketry
Ensure bar is
behind front
face of TJ500

Thermal Jet Section 2: Quick Start
5780-320 Operations Manual Rev C Page 5
Step 4: Adjust TJ500 Print Head to Substrate
ADJUST TJ500
VERTICALLY
WITH EITHER
OF THESE TWO
BRACKETS
ADJUST THE PRINT
HEAD TO THE
SUBSTRATE WITH
THIS BRACKET
.1" (2.5mm) GAP
RECOMMENDED
Adjust TJ500 vertically to meet requirement.
Adjust TJ500 horizontally to set print gap.

Thermal Jet Section 2: Quick Start
5780-320 Operations Manual Rev C Page 6
Step 5: Insert Cartridge Pen into Print Head
Rotate Cover
Open
Rotate Pen Cartridge down until it
snaps in place
NOTE: The pen is released by press-
ing down on the Finger Release Tab
and pulling up on the rear of the car-
tridge.
Close Cover
PEN STOP
When inserting cartridge, aim nose at an
angle towards black pogo pin component.
Slide pen cartridge up to Pen Stop.
Insert Pen Cartridge at an angle up to
Pen Stop
FINGER RELEASE TAB
PEN STOP
After pen cartridge
is installed

Thermal Jet Section 2: Quick Start
5780-320 Operations Manual Rev C Page 7
Step 6: Cabling, Power, and Serial Port Setup
Cabling
CAUTION: Power should be disconnected from the print head prior to connecting or dis-
connecting any external devise, including: PC, handheld, controller or print head daisy
chain cables. Electrical arcing may occur if external cabling is connected or disconnected
while power is supplied to the unit.
Connect the included serial cable between a computer or an IJ3000-ES COM port to the
input port of the first TJ500 in the daisy chain. Connect up to four total TJ500 print heads
(per COM port) with their included serial cables in a daisy chain from the output port of the
first TJ500 to the input port of the next TJ500 and so on.
IJ3000-ES
OUTPUT PORT
INPUT PORT
COM PORT
PC OR LAPTOP

Thermal Jet Section 2: Quick Start
5780-320 Operations Manual Rev C Page 8
Power
CAUTION: Power should be disconnected from the print head prior to connecting or dis-
connecting any external devise, including: PC, handheld, controller or print head daisy
chain cables. Electrical arcing may occur if external cabling is connected or disconnected
while power is supplied to the unit.
Install the power plug from the previ-
ously mounted power supply into the
power jack on the rear of the TJ500.
Press and hold the "PURGE" button on
the rear of the TJ500 while slowly mov-
ing a piece of paper, cardboard, or com-
parable material in front of the TJ500
print cartridge. Print several purge
images and validate that all channels
are printing. If not, refer to “Section 4:
Maintenance & Shutdowns” on page 21.
At this point, the power supply for the
IJ3000-ES or the computer may be
installed.
Serial Port Setup
NOTE: Depending on GUI / IJ3000-ES status, this step may already be complete.
If a computer will be used, install the TJ500 / IJ3000-ES PC software using the CD
included with the print head. Follow the installation prompts, and then launch the program.
Ensure the home screen menu is present via the Hide Menu / Show Menu button, and
then press the Control Panels button.
NOTE: Do not rub the ink car-
tridge face with the print sample
material as this will scratch the
orifice array and affect print
quality.

Thermal Jet Section 2: Quick Start
5780-320 Operations Manual Rev C Page 9
Press the first Port/Baud button and ensure the baud rate is set for 57600. Press the OK
button to exit the Serial Port Setup screen.
Press the first Function button and select the Serial Print Head option. Press the OK but-
ton to exit the COM 1 Function screen.
Press the System Setup button, and then the Serial Ports tab.

Thermal Jet Section 2: Quick Start
5780-320 Operations Manual Rev C Page 10
Step 7: Configure the Print Head
Print head setup complete. Next, select the Encoder tab, and choose the desired encoder
type.
Auto Speed Detect:
Line speed
automatically
detected via TJ500
photocells
External Encoder:
Linespeedmeasured by
an externally mounted
encoder and connected
to the last TJ500 in the
daisy chain
Touch this
box, then type
in the desired
speed
Select the number of print heads and identify the first in the daisy chain.
Press the Print Heads tab and then the Redo Print Head Setup button. Select the desired
direction.
Fixed Speed:
User types in the
desired line speed

Thermal Jet Section 2: Quick Start
5780-320 Operations Manual Rev C Page 11
Step 8: Create a Message
File Menu
Variable Field
Product Setup Product Side Zoom
Field
Coordinates
Field
Selection
Font
Selection
Count Code
Date Code
Time Code
Alpha / Numeric
Quick Save
Create and save the message, and then exit the message editor.
Message
Display
Area
From the home screen, select the Messages button and then the New button to enter the
message editor.
Logo
Barcode

Thermal Jet Section 2: Quick Start
5780-320 Operations Manual Rev C Page 12
Step 9: Print a Message
From the home screen, push the Print button.
Select the desired message to print, and push the Print It button.
The message will print on the next photocell trigger.

Thermal Jet Section 3: IJ3000-ES or GUI Functionality
5780-320 Operations Manual Rev C Page 13
Section 3: IJ3000-ES or GUI Functionality
Keypad or Keyboard
ESC (Escape):
• Closes the current window, a dialog box, or menu.
• Restores the original contents of any input entry box, if Enter has not been pressed.
Arrow Keys:
• Shifts focus between screen controls.
• Moves highlighted fields or the cursor around in the Message Editor.
Tab:
• Shifts focus between screen controls.
• Shifts focus between fields in the Message Editor.
Backspace in Message Editor:
• Normal functionality as QWERTY keyboard.
• Deletes a highlighted field.
Ctrl (Control) in Message Editor:
• Amplifies the movement of the arrow keys.
• Holding the Ctrl key while pressing the Enter key at the end of a text line enable paragraph func-
tionality.
F4/F8:
The F4/F8 key pulls up the extended characters dialog.
POWER SCREEN BRIGHTNESS
BACKSPACE

Thermal Jet Section 3: IJ3000-ES or GUI Functionality
5780-320 Operations Manual Rev C Page 14
Home Screen
Message Window:
• Displays the current print message.
• Updated approximately every seven seconds, so it likely will not show each print.
• Long print messages can be viewed by using the F1 and F2 keys to scroll the message left and
right, respectively.
• White or beige bars represent a print head in the daisy chain and are identified by their respec-
tive numbering.
• The header displays the task number and file name of the message being printed. If no mes-
sage is loaded to print, "None" is displayed.
Task Select Button:
• Places focus on the selected task. This allows one to view what is being printed on either task in
the home screen. Additionally, items in the main menu vary from one task to the other.
Task Print / Pause Button:
• Starts and Stops print after an operator response to a confirmation dialog popup box.
• If a message is currently printing, pressing the Pause button will discontinue printing after the
message completes printing.
• If the Play button is pushed, print will resume on the next product detected.
Zoom
Button
Task 1
Print / Pause
Button
Message
Window
Show / Hide
Main Menu
Button
Task 1
Select
Button
{
Quick Print
Menu
Button Counter
Button
Variable
Field
Button
Task 1
Select
Button
Task 2
Print / Pause
Button
Status
Screen
Access
Button
Task 1 & Task 2
Ink Status
Print Head
Daisy Chain
Identifier
Play State
Pause State
{

Thermal Jet Section 3: IJ3000-ES or GUI Functionality
5780-320 Operations Manual Rev C Page 15
Quick Print Menu Button:
• Allows one to access the Print Menu directly even with Restricted User Access enabled.
• Simply select the desired message and press the Print It button. The message will print after the
next photocell trigger.
Zoom:
• Expands the message window to full screen andmagnifies the print message so that fine details
may be seen.
•F1, F2, F5 and F6 keys, or the Arrow keys, scroll the message left, right, up and down.
•Zoom button or the ESC key to zoom back out.
Counter:
• Count codes can be printed but can not be adjusted from the Home Screen.
Variable Field:
• Function not available on TJ500 system.

Thermal Jet Section 3: IJ3000-ES or GUI Functionality
5780-320 Operations Manual Rev C Page 16
Main Menu
Print Menu
Messages Menu & Editor
Main Menu Expanded
Main Menu Collapsed
Print Menu Button
Cancels print immedi-
ately after a confirmation
dialog popup box
Closes this menu
immediately
Fires all jets for
a short period
of time on the
selected TJ500
Returns to
Home
Message List
Selected
Message
Returns to
Home Screen
DeletesSelected
Message
Opens Selected
Message in the
Editor
Startsa newmessage
in the Editor
Message Menu
NOTE: The Variable Field but-
ton is not available. In order to
update a variable field, reselect
the message to Print.