Illinois Tool Works IJ300 User manual

Operations
Manual
1 Missouri Research Park Drive  St. Charles, MO 63304  ServiceLine 1-800- 26-2 31
Illinois Tool Works Inc © 200
760-121
Revision B
Controller

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 o
r
technical specifications at any time and
without notice.
©2005 Illinois Tool Works Inc
All rights reserved
Printed in the United States of America
IJ3000
Controlle
r
Operations Manual
5760-121
Revision B

Controller
5760-121 Controller Operations Manual Rev B
The IJ3000 Controller, including all components unless otherwise specified, carries a
limited warranty.
For all warranty terms and conditions, contact Diagraph an ITW Company for a
complete copy of the Limited Warranty Statement.
Warranty:

Controller
5760-121 Operations Manual Rev B Page i of iv
Section 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
IJ3000 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Section 2: Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section 3: Typical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
IJ3000 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Section 4: Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
IJ3000 Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Turning the Controller On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Adjusting Screen Brightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Auto Repeat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Highlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Touch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Screen Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Radio Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Check Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Value Entry Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Text Entry Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
List Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Message Selection Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Inactive Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Keypad Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
ESC (Escape): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Arrow Keys: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Tab: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Enter: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Backspace/Delete: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Ctrl (Control): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Alt (Alternate): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
F4/F8: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Input Focus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Home Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Message Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Task 1/Task 2 Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Print/Pause Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Show Menu/Hide Menu Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Moving Around the Edit Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Edit Window: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Crosshairs Pointer: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Next Field Button: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Current Position Indicator: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Side 1/Side 2 Buttons: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Controller
Page ii of iv 5760-121 Operations Manual Rev B
Section 5: Setup Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Configuring the Print Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Print Head Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Specifying Product Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Specifying Number of Print Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Setting Daisy Chain Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Defining Print Head Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Encoder Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Group Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Setting Up a Second CIDS3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
CIDS3000 Detection Feature (for Impulse Jet Only) . . . . . . . . . . . . . . . . . . . . . . . . . 29
Serial Port Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Using a Bar Code Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Network Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Message List Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Network Notification URL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Setting IP Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Defining User Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Time & Date Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
The Time Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
The Date Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
The Rollover Time Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Shifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Auto Clean Setup (for Impulse Jet Heads w/ACS only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Periodic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Set Times Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Sleep Mode (for WaxJet Tasks only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Auto Sleep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Section 6: Message Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Creating a Print Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Editing a Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Editing Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Deleting a Field: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Changing Field Properties: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Edit Screen Keyboard Shortcuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Creating and Editing a Group Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Estimating Ink Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Printing a Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Deleting a Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Making Adjustments During Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Adjusting Product Counts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Changing Variable Field Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Controller
5760-121 Operations Manual Rev B Page iii of iv
Section 7: Utility Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
User Access Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Open Access vs. Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Changing the Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Status Screen (for Impulse Jet or Integrated Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Status Screen (for WaxJet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Regional Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
System Reboot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Section 8: Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Troubleshooting Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
IJ/3000 Impulse Jet System Trouble-Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
IJ/3000 Controller: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Appendix A: System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Appendix B: Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Controller Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
CPU Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Impulse Jet Print Head Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Integrated Valve Print Head Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Interconnect Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
IJ3000 Controller CPU Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Impulse Jet Controller Interface Board Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Integrated Valve Controller Interface Board Diagram . . . . . . . . . . . . . . . . . . . . . . . . 83
Appendix C: Parts and Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Controller Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Controller Assembly Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Appendix D: Performance Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Performance Parameters of an Impulse Jet Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Performance Parameters of an Integrated Valve Controller . . . . . . . . . . . . . . . . . . . . . . . . . .89
Appendix E: Creating & Transferring Logo Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Creating a Logo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Transferring a File from a PC to an IJ3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Transferring a File from an IJ3000 to a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Appendix F: Setting the IP Address of an IDS3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Equipment Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

Controller
Page iv of iv 5760-121 Operations Manual Rev B
Appendix G: Configuring a PC to Communicate with the IJ3000 . . . . . . . . . . . . . . . . . . . . . . . 101
Windows XP® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Windows 2000® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Windows 98® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Windows 95® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Appendix H: Network Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
IJ3000 Network Box Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Task Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Purge Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Test Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Appendix I: Testing an Electrical Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Appendix J: Electrostatic Discharge (ESD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Appendix K: Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Controller Section 1: Introduction
5760-121 Operations Manual Rev B Page 1 of 115
Section 1: Introduction
This manual describes the operation of the IJ3000 Controller. It includes programming
instructions to create and edit print messages for the IJ3000 Controller. The IJ3000 Con-
troller is used in conjunction with high resolution Impulse Jet, WaxJet and large character
Valve Jet type print heads. WaxJet heads utilize impulse jet printing technology, combined
with solid ink (wax). References to "Impulse Jet" include WaxJet, unless otherwise noted.
System installation and hardware set-up for each is described in separate system operat-
ing manuals. For the IJ3000 Valve Jet systems, refer to manual 5760-107; for the IJ3000
Impulse Jet system, refer to manual 5760-111; and for the IJ3000 WaxJet System, refer to
manual 2466-400.
IJ3000 Controller
The IJ3000 Controller consists of printer interface electronics, a color display with touch
screen, and a QWERTY style elastomeric keypad, in a sealed industrial enclosure. The
controller incorporates a Graphical User Interface (GUI) with intuitive, easy to use soft-
ware. The controller can be used as a stand-alone device or networked through built-in
Ethernet connectivity.
The IJ3000 Controller can be configured for multiple print technologies, including large
character Valve Jet, high resolution Impulse Jet print heads and WaxJet heads. Each print
head type utilizes a common CPU board and resident controller firmware, in conjunction
with a Print Head Interface board, unique to the print technology. This allows the IJ3000
Controller to drive multiple print technologies while maintaining a common operating plat-
form.
The IJ3000 Controller is also capable of controlling the input to Diagraph Automated Label
Printers (ALP). This allows the controller to become a single point control for dual technol-
ogy (ink jet and labeling) product marking applications.
The IJ3000 has an Ethernet Controller built into the CPU. The IJ3000 Controller can be
remotely controlled via the Ethernet connection. A programming interface document is
available (P/N: 5760-113) for the IJ3000 software interface.
IJ3000 PC Networking Software is available to allow multiple IJ3000 Controllers to be con-
trolled from one central PC. The IJ3000 Networking Software is also capable of connecting
database stored information to controller generated print messages.

Controller Section 1: Introduction
Page 2 of 115 5760-121 Operations Manual Rev B

Controller Section 2: Safety
5760-121 Operations Manual Rev B Page 3 of 115
Section 2: Safety
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 equip-
ment.
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.)
CAUTION: Turn off the equipment's main power before:
• Performing preventive maintenance.
• Performing any repairs to the unit.
• Servicing the equipment in any manner.
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 conditioner 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 conditioners.
• Store inks and conditioners under the recommended conditions found on the MSDS
(Material Safety Data Sheet).
!

Controller Section 2: Safety
Page 4 of 115 5760-121 Operations Manual Rev B

Controller Section 3: Typical System Components
5760-121 Operations Manual Rev B Page 5 of 115
Section 3: Typical System Components
(The following view shows an IJ3000 Impulse Jet System.)
1 IJ3000 Controller 8 Encoder
2 CIDS3000 9 Ink Supply
3 Print Heads 10 Photo Sensor
4 Conveyor 11 Vacuum Waste Collector Bottle
5 Product 12 Encoder Cable
6 Print Head Bracketry 13 Controller to Print Head Cable
7 Ink Status Beacon 14 Throw Distance (1/8” Recommended)
4
3
2
9
7CIDS3000
8
1
3
5
6
6
10 14
13 13
6
13
13
11
6
12

Controller Section 3: Typical System Components
Page 6 of 115 5760-121 Operations Manual Rev B
The Diagraph IJ3000 Controller is available in the following configurations:
Part Number Description
IJ3000 Controller Assemblies for Impulse Jet Systems
5760-001PJ1D Painted Enclosure, Single Impulse Jet Interface, Domestic
5760-001PJ2D Painted Enclosure, Dual Impulse Jet Interface, Domestic
5760-001SJ1D Stainless Enclosure, Single Impulse Jet Interface, Domestic
5760-001SJ2D Stainless Enclosure, Dual Impulse Jet Interface, Domestic
5760-001PJ1E Painted Enclosure, Single Impulse Jet Interface, European
5760-001PJ2E Painted Enclosure, Dual Impulse Jet Interface, European
5760-001SJ1E Stainless Enclosure, Single Impulse Jet Interface, European
5760-001SJ2E Stainless Enclosure, Dual Impulse Jet Interface, European
IJ3000 Controller Assemblies for Integrated Valve Systems
5760-001PV1D Painted Enclosure, Single Integrated Valve Interface, Domestic
5760-001PV2D Painted Enclosure, Dual Integrated Valve Interface, Domestic
5760-001SV1D Stainless Enclosure, Single Integrated Valve Interface, Domestic
5760-001SV2D Stainless Enclosure, Dual Integrated Valve Interface, Domestic
5760-001PV1E Painted Enclosure, Single Integrated Valve Interface, European
5760-001PV2E Painted Enclosure, Dual Integrated Valve Interface, European
5760-001SV1E Stainless Enclosure, Single Integrated Valve Interface, European
5760-001SV2E Stainless Enclosure, Dual Integrated Valve Interface, European
Controller/IDS 3000 Bracketry
5760-350 Controller/IDS 3000 Conveyor Mounting Kit
5760-351 Controller/IDS 3000 Pedestal Mounting Kit
5760-352 Controller/IDS 3000 T-Base Mounting Kit
5760-362 Controller 90° Pivot Bracket Kit
5760-368 CIDS Mounting Kit

Controller Section 3: Typical System Components
5760-121 Operations Manual Rev B Page 7 of 115
IJ3000 Controller
The controller gathers and stores all the informa-
tion required for printing a message. This informa-
tion can come from the following sources:
1. The user interface, which tells the controller
what message to print on the product.
2. The photosensor, which tells the controller
when to print.
3. The encoder, which tells the controller how fast
to print. There are two types of encoders:
•A built-in fixed speed encoder is used when
the conveyor speed does not change.
•An optional, conveyor-mounted variable
speed encoder is used when the line speed
varies or has frequent starts and stops.
With this information, the controller knows exactly
when the leading edge of the product will reach the
print head and at what rate of speed.
The controller comes in a stain-
less steel or painted metal case
that makes it splash-proof and
resistant to electromagnetic inter-
ference. A hinged cover provides
access to replaceable parts.
The IJ3000 Impulse Jet Control-
ler can control up to two 32-chan-
nel print heads or one 256-
channel print head per interface
board. With the optional second
interface board, the system can
control up to four 32-channel
heads or two 256-channel heads.
NOTE: If the controller is config-
ured for dual technologies (Inte-
grated Valve and Impulse Jet) the
Impulse Jet Interface Board must
be the first board plugged into the
CPU Board. The Impulse Jet
Interface Board requires use of
the 24 VDC Power Supply. The
Integrated Valve Jet Interface
Board requires use of the 15 VDC
Power Supply.
Optional 2nd
Interface Board
Interface Board
CPU Board
Keypad
Cable
Connector
Display
Board
Cable
Connector Battery

Controller Section 3: Typical System Components
Page 8 of 115 5760-121 Operations Manual Rev B

Controller Section 4: Getting Started
5760-121 Operations Manual Rev B Page 9 of 115
Section 4: Getting Started
IJ3000 Keypad
Turning the Controller On
The power keys are located at the top left corner of the keypad. Press the I key to turn the
controller on. Press the Okey to turn it off. (To prevent accidental turn-off, the system will
prompt for confirmation.)
CAUTION: If the system is in the Print mode when it is turned off, it will resume printing
when it is turned back on. Anything that is in front of the print heads when printing resumes
may get ink on it.
Adjusting Screen Brightness
The screen brightness control keys are at the top right corner of the keypad. Press the up
arrow key to make the screen lighter; press the down arrow key to make the screen darker.
Auto Repeat
The IJ3000 keypad has an auto repeat feature that activates when a key is held down for
more than one half second. Not all keys have the auto repeat feature. Those that do not
have this feature are the power, ESC, Tab, Caps Lock, Shift, Ctrl, Opt, Alt, and Enter keys.
F5 F4 F8
F3
F7
F6
F2
F1
ESC
Tab
Caps
Lock
Shift
Ctrl Opt Alt
!12365 79
80
4
@#$^&*()+=- _
QWERTYU IOP{[}]|\
ASDFGHJKL;
:‘
“Enter
Shift
Del
ZXCVBN,
<. >/ ?
M
Escape
Key
Backspace/
Delete Key
Arrow Keys
Power On
LED
Caps Lock
Key
Lighter Darker
OFF ON
POWER KEYS BRIGHTNESS KEYS
!

Controller Section 4: Getting Started
Page 10 of 115 5760-121 Operations Manual Rev B
Commands
There are three main commands given in this manual: Highlight, Press, and Touch.
Highlight
Highlight a display control to select it for further action, or to give it input focus. Different
types of display controls are highlighted differently. For example, highlighted text is dis-
played in inverse video (light characters on a dark background), while highlighted screen
buttons and message fields are displayed with a box around them.
Inverse video example:
Press
Press a keypad key to do or complete a particular action. Examples: Press Enter, press
ESC, or press the Up/Down arrows to scroll through the list of items.
Touch
Touch a screen control to do or complete a particular action. Examples: Touch the Status
button to display the Status Screen or touch a print head to view or change that print head’s
properties.
Screen Controls
Buttons
There are three types of screen buttons, Text, Bitmap, and Decorated. Touch a button to
actuate its function:
• Text button: contains a text description of its function.
• Bitmap button: contains a graphic illustrating its function.
• Decorated button: contains text and graphics.