Illinois Tool Works ResMark 5000 User manual

Operations
Manual
1 Missouri Research Park Drive • St. Charles, MO 63304 • Service Line 1-800-526-2531
Illinois Tool Works Inc © 2021
ResMark 5000 High-Resolution System
400386
Revision A

ResMark 5000 High-Resolution
Ink Jet System
Operations Manual
400386
The information contained in this manual
is correct and accurate at the time of its
publication. ITW reserves the right to
change or alter any information or
technical specifications at any time and
without notice.
©2022 Illinois Tool Works Inc.
All rights reserved

The ResMark 5000 High-Resolution System, including all components unless otherwise specified, carries a limited
warranty.
The inks and conditioners used with the ResMark 5000 High-Resolution 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 or visit Diagraph.com.
Warranty:
ResMark 5000 System

Section 1: Safety and Ink Usage ..........................................................................................................................................................................6
Section 2: Quick Start ...........................................................................................................................................................................................7
Step 1: Assemble Bracketry to Conveyor ...................................................................................................................................................8
Step 2: Assemble Print Head onto Bracketry .............................................................................................................................................9
Step 3: Mount and Connect Power Supply ...............................................................................................................................................10
Step 4: Powering up the Print Heads ........................................................................................................................................................11
Step 5: Adjust Print Head to Substrate .....................................................................................................................................................12
Step 6: Print Head Level and Tilt .............................................................................................................................................................13
Step 7: Install Ink Cartridge ......................................................................................................................................................................14
Step 8: Priming the Print Head and Testing Print Quality ........................................................................................................................15
Step 9: Mount Photosensor and Encoder ..................................................................................................................................................16
Step 10: Daisy-Chain Print Heads, HMI, and/or Customer Network .......................................................................................................17
Step 11: Cap Unused Ports .......................................................................................................................................................................19
Step 12: Create a Message and Control the Print System .........................................................................................................................19
Section 3: Maintenance and Shutdowns ...........................................................................................................................................................20
System Maintenance .................................................................................................................................................................................20
Printer Module Maintenance ....................................................................................................................................................................20
Ink Supply Module Maintenance ..............................................................................................................................................................21
Printer System Shutdown ..........................................................................................................................................................................21
Cleaning Maintenance System ..................................................................................................................................................................22
Printer Module Replacement ....................................................................................................................................................................23
Section 4: Troubleshooting ................................................................................................................................................................................24
Print Quality ..............................................................................................................................................................................................24
System .......................................................................................................................................................................................................27
Appendix A: System Specifications ...................................................................................................................................................................30
System .......................................................................................................................................................................................................30
Touch Pro 2 HMI ......................................................................................................................................................................................31
Mark 2 Print Head .....................................................................................................................................................................................32
Mark 4 Print Head .....................................................................................................................................................................................33
System Interconnect Diagram ...................................................................................................................................................................34
Customer System Connection ...................................................................................................................................................................35

Appendix B: Theory of Operation ....................................................................................................................................................................36
Functional Description ..............................................................................................................................................................................36
ResMark 5000 Mark 2 and Mark 4 Print System .....................................................................................................................................36
ISM Features .............................................................................................................................................................................................37
Ink States ...................................................................................................................................................................................................38
Print Head Daisy Chain ............................................................................................................................................................................39
Print Trigger Photosensor .........................................................................................................................................................................39
Encoder .....................................................................................................................................................................................................39
Appendix C: Diagrams .......................................................................................................................................................................................40
ResMark 5000 Main CPU PCB Assembly ...............................................................................................................................................40
ResMark 5000 Internal Wiring Diagram ..................................................................................................................................................41
Appendix D: Ink ..................................................................................................................................................................................................42
Storage Life of a FACTORY SEALED Bottle of Ink ..............................................................................................................................42
Use Life of an OPENED Cartridge of Ink ................................................................................................................................................42
Appendix E: Updating the ISM via USB or Ethernet .....................................................................................................................................42
Appendix F: Software Interface ........................................................................................................................................................................42
Appendix G: Part Numbers ...............................................................................................................................................................................43
System .......................................................................................................................................................................................................43
Print Head Replacement Parts ..................................................................................................................................................................44
Bracketry ...................................................................................................................................................................................................45
Fittings ......................................................................................................................................................................................................46
Cables ........................................................................................................................................................................................................46
Service Parts and Optional Equipment .....................................................................................................................................................47

ResMark 5000 High-Resolution Section 1: Safety and Ink Usage
400386 Operations Manual Rev A Page 6
Section 1: Safety and Ink 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.)
CAUTION: The Ink Supply Module contains hazardous voltage (90VDC). Disconnect from mains 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 grounding cables and covers before operating the equipment.
It is extremely important to:
• Clean up all spills 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 SDS (Safety Data Sheet).
Service is to be performed by trained or ITW personnel only.
Caution: Denotes possible personal injury due to sharp object.

ResMark 5000 High-Resolution Section 2: Quick Start
400386 Operations Manual Rev A Page 7
Section 2: Quick Start
The figure at right illustrates a typical installation.
System Components:
1. Bracketry Kit (Item 1)
2. Print Head (Item 2)
3. HMI (Item 3)
4. Power Supply (Item 4)
5. Photosensor (Item 5)
6. Encoder (Item 6)
7. Power Cord (not shown)
8. Ethernet Cable (not shown)
9. Software (not shown)
10. Ink (not included)
TYPICAL INSTALLATION
4
3
1
2
5
6

ResMark 5000 High-Resolution Section 2: Quick Start
400386 Operations Manual Rev A Page 8
Step 1: Assemble Bracketry to Conveyor
1. Firmly tighten all fasteners.
NOTE: Ensure bracketry is square and level.
PRINT HEAD
CONVEYOR MOUNT
(400201 FOR Mark 2 PRINT HEAD)
(400204 FOR Mark 4 PRINT HEAD)
OPTIONAL HMI
CONTROLLER / MOUNT

ResMark 5000 High-Resolution Section 2: Quick Start
400386 Operations Manual Rev A Page 9
Step 2: Assemble Print Head onto Bracketry
ROLLER / RETRACTING
BRACKET MOUNT
(for Mark 2 Print Head)
(400201)
DOVETAIL ADAPTER AND
RETRACTING BRACKET
AND CAN BE MOUNTED
ON EITHER SIDE OF PRINT
HEAD
ROLLER / RETRACTING
BRACKET MOUNT
(for Mark 4 Print Head)
(400204)
NOTE: The dovetail adapter and mounting bracketry can be
mounted on either side of the print head system.

ResMark 5000 High-Resolution Section 2: Quick Start
400386 Operations Manual Rev A Page 10
Step 3: Mount and Connect Power Supply
1. Install power supply with power cord mains facing the conveyor and DC output facing out towards the rear of the print system.
2. Firmly tighten fasteners to bracketry or convenient location.
NOTE: One power supply pack can power up to two print heads in any combination of Mark 2 or Mark 4.

ResMark 5000 High-Resolution Section 2: Quick Start
400386 Operations Manual Rev A Page 11
Step 4: Powering up the Print Heads
1. Install the power cord into the first print head in the system (from now on called the Primary print head).
The power supply cable or jumper cable can be plugged into either power port.
Do not over-tighten with pliers.
2. If there is more than one print head, the Primary should be the print head to have product pass by it first; therefore, it should have the
photocell mounted to it on the leading edge.
3. Ensure the power connector is fully inserted and the threaded barrel is finger tight.
4. Connect any downstream print heads from the Primary. These are considered Secondary.
5. Only one Secondary print head can be powered by an upstream print head. An additional power supply will be required for every two print
heads on a daisy chain, regardless of print head type / size.
6. Plug the A/C cord into the mains.
Best practices are to plug power
into the print heads first before
the A/C mains.
TYPICAL INSTALLATION
PRIMARY PRINT HEAD SECONDARY PRINT HEAD
POWER LED POWER LED
POWER JUMPER CABLE P/N 400490
POWER SUPPLY P/N 400380

ResMark 5000 High-Resolution Section 2: Quick Start
400386 Operations Manual Rev A Page 12
Step 5: Adjust Print Head to Substrate
1. Tighten bracketry to conveyor such that the print head is perpendicular to the carton; however,
ensuring that the print head is level from front to back. See “Step 6: Print Head Level and Tilt”
on page 13.
2. Use vertical tool-less handles to adjust print head to approximate printing height position.
Tighten handles.
3. While horizontal adjustment slide bracketry screws are loose, adjust vertical bracket with print
head horizontally to within 6 mm (1/4 in) of the carton.
4. Use the dovetail tool-less handle to make fine adjustments between the print head rollers and
carton to within 1 mm - 2 mm (.04in - .08 in).
NOTE: Print head print gap can be adjusted to be larger in heavy debris environment but must be
balanced with print quality.
CLEAN / PRIME
BUTTON
AT TEMPERATURE LED
RECIRCULATION
LED
HEATER ON LED RECIRCULATION
BUTTON
WASTE BOTTLE
STATUS LED
INK CARTRIDGE
STATUS LEDs
PRINTER LEVEL
LEDs
CLEAN / PRIME
LED
ALL CHANNEL
PRINT BUTTON
HORIZONTAL ADJUSTMENT
SLIDE BRACKETRY SCREWS
CONVEYOR
CARTON
1 mm - 2 mm (.04in - .08in)
PRINT GAP RECOMMENDED
DOVETAIL
TOOL-LESS
HANDLE
VERTICAL ADJUSTMENT
TOOL-LESS HANDLES

ResMark 5000 High-Resolution Section 2: Quick Start
400386 Operations Manual Rev A Page 13
Tool-less Locking
Handle
Rotate PM to
Adjust Tilt
Step 6: Print Head Level and Tilt
Print Head Level
1. Slightly loosen the Slide Bracketry Screws shown in the diagram in “Step 5: Adjust Print Head to Substrate” on page 12.
2. When the print head is perpendicular to the substrate, tighten the Slide Bracketry Screws.
3. Observe the LED indicators on the rear top of the print head on the ink supply. The green LED should be illuminated, and if not, adjust the
bracketry up or down as needed.
4. The print head is calibrated to within +/-1.5°
Print Head Tilt
1. Loosen the tool-less handle on the side of the Printer
Module.
2. Rotate the Printer Module to an angle that creates
perpendicular print on the product.
3. Tighten the tool-less handle.
Maximum Print Head Tilt from Vertical When Viewed
from the Rear of the Print Head:
• Clockwise Tilt: 85° (Printer Module disengages from
the Ink Supply Module at 90°)
• Counterclockwise Tilt: 90°
Cleaning and priming features are effective up to ±15 °
Print Head Level Print Head Not Level
85° MAX 90° MAX
Usable Tilt

ResMark 5000 High-Resolution Section 2: Quick Start
400386 Operations Manual Rev A Page 14
Step 7: Install Ink Cartridge
1. Remove the shipping plugs from the rear and top of the Ink Supply Module.
Retain plugs for potential later use.
2. Install the ink cartridge and vent filter as shown.
Warning! Opening the cartridge door exposes sharp needles used to
puncture the cartridge rubber seal. Extreme caution should be used during
the cartridge insertion.
3. Install the cartridge in the orientation shown with safety information label
facing towards the rear of the print head.
Note: The cartridge is equipped with smart chip technology that will detect the
presence of the cartridge. The cartridge can only be installed in one orientation as
it is keyed to the Ink Supply receiver which will guarantee connection to the smart
chip.
When the cartridge is installed, the state of the ink gauge LED indicators on the
top of the Ink Supply and the LED on the top of the Printer Module will change
from flashing to solid green as shown below.
For a full description of the LED / Button panel on the top of the of Ink Supply
Module see “Ink States” on page 38.
Ink Cartridge
Shipping Plug
Vent Plug
Vent Filter
Ink Cartridge
INSTALL
REMOVE
Flashing Solid

ResMark 5000 High-Resolution Section 2: Quick Start
400386 Operations Manual Rev A Page 15
Step 8: Priming the Print Head and Testing Print Quality
1. Ensure all print heads are at operating temperature.
2. Ensure that the shipping cap is installed for priming, otherwise ink will overflow and
cause a mess.
NOTE: Print is disabled until the print head is fully heated. Wait until the "AT-
TEMPERATURE” LED is illuminated green on the rear of the print head prior to any print
sampling.
3. Press and hold the Recirculation button (10 seconds) on the rear top of the ISM until its
LED turns on. The ink gauge will count up during this time.
4. Allow the print head to recirculate for at least 2 minutes. To turn off the recirculation
feature, press the Recirculation button once, and the LED will turn off. After 15 minutes,
the recirculation feature will automatically turn off.
5. Wait three seconds and remove the ship cap and store on the top of the print head.
NOTE: Do not use common wipes in the print channel; use foam swabs instead.
6. Use a foam swab to lightly wipe the orifice plate in a vertical downward motion. Prime
the print head by pressing and holding the Clean / Prime button up to 5 seconds. The
Clean / Prime button LED will illuminate during this time and print will be disabled. After
an additional 5 seconds, the LED will turn off and print will be re-enabled.
7. Print can be tested by slowly passing a sheet of paper in front of the print head after
pressing the All Channel Print button. A solid image will print for approximately 3
seconds.
8. If the Mark 2 sample is 50,8 mm (2 in) tall with no gaps, the print head is ready.
If the Mark 4 sample is 101,6 mm (4 in) tall with no gaps, the print head is ready.
Missing Print
1. Press and hold the Clean / Prime button for five (5) seconds.
2. Inspect for very small air bubbles flowing out of the top of the orifice plate. If bubbles are
evident, repeat the previous step. one more time.
3. Press the All Channel Print button on the rear of the print head.
4. If any print is still missing after all air bubbles are purged, clean the orifice plate and ship
cap seal with a clean foam swab, and then recap the print head with the ship cap.
5. Repeat the above steps up to three more times as necessary (starting at step 1). When
stubborn channels are present, allow the Recirculation system to run for the full 15
minutes.
CLEAN / PRIME
BUTTON
ALL CHANNEL
PRINT BUTTON
AT TEMPERATURE LIGHT
GREEN - AT TEMP
RED - NOT AT TEMP
RECIRCULATION
BUTTON
RECIRCULATION
LED
HEATER ON RECIRCULATION
BUTTON
SHIP CAP INSTALLED
SWAB
DOWN
SHIPPING CAP STORAGE
CLEAN / PRIME
LED

ResMark 5000 High-Resolution Section 2: Quick Start
400386 Operations Manual Rev A Page 16
Step 9: Mount Photosensor and Encoder
Photosensor
1. Mount the photosensor (kit 400203) in the roller bracket attached to the Printer Module and
route the cable as shown in one of the two shown configurations depending on the application.
2. Insert the photosensor cable connector into the appropriate connector on the rear of the
Primary print head Ink Supply Module.
Encoder
1. Install the encoder (kit 400504) in a location where it will accurately measure the speed of the
conveyor.
2. Install it in contact with the conveyor belt or with a roller moving the same speed as the
conveyor.
3. Insert the encoder cable into the Primary print head Ink Supply Module.
CAUTION: Do not excessively pre-load the encoder wheel. A radial force of over 18,14 kg [40
lbs] will reduce the life of the bearings.
Encoder
Input
Photosensor
Input
Conveyor
Encoder Spring
Encoder Wheel
Photosensor
Mounting &
Cable
Routing

ResMark 5000 High-Resolution Section 2: Quick Start
400386 Operations Manual Rev A Page 17
Step 10: Daisy-Chain Print Heads, HMI, and/or Customer Network
1. Install secondary print heads as shown in the previous steps.
2. Secondary print heads should be connected between the upstream print head Ethernet out port to the input port
on its print head as shown as shown in the diagrams below. Up to eight print heads can be daisy chained
together.
3. Install the HMI / Controller on appropriate bracketry.
4. Connect the HMI or Laptop / PC via Ethernet cable (400374-2.0) as shown in the below diagrams.
NOTE: Alternatively, the Primary print head can be connected to the HMI via wireless. Consult the create and control
manual (400463).
Standalone System with HMI - One Print Head
Standalone System with HMI - Two or More Print Heads
OPTIONAL
HMI
FROM UPSTREAM
PRINT HEAD
TO DOWNSTREAM
PRINT HEAD OR HMI
HMI PRIMARY PRINT HEAD
HMI SECONDARY PRINT HEAD PRIMARY PRINT HEAD
SECONDARY PRINT HEAD

ResMark 5000 High-Resolution Section 2: Quick Start
400386 Operations Manual Rev A Page 18
Networked System with Optional HMI - One Print Head
Networked System with Optional HMI - Two or More Print Heads
HMI PRIMARY PRINT HEAD
FROM UPSTREAM
PRINT HEAD OR
CUSTOMER NETWORK
TO DOWNSTREAM PRINT
HEAD OR HMI
CUSTOMER NETWORK
HMI SECONDARY PRINT HEAD PRIMARY PRINT HEAD
SECONDARY PRINT HEAD
CUSTOMER NETWORK

ResMark 5000 High-Resolution Section 2: Quick Start
400386 Operations Manual Rev A Page 19
Step 11: Cap Unused Ports
After the installation is complete, it is recommended that all unused ports be capped to prevent accidental electrostatic discharge into
a connector.
Step 12: Create a Message and Control the Print System
Reference manual Create & Control 400463.
PHOTOSENSOR
ETHERNET TO
DOWNSTREAM
PRINT HEAD
OR HMI
24VDC
POWER
ENCODER
USB DEVICE OR
FIRMWARE UPGRADE
(HAS BUILT-IN CAP)
ETHERNET FROM
UPSTREAM PRINT HEAD
OR CUSTOMER NETWORK
The Primary print head should have all ports populated with a
cable.
Exceptions:
• Only one head in the daisy chain - cap Ethernet and one
power port.
• No encoder - cap encoder port.
• Wireless communication - cap Ethernet ports.
• No HMI - cap Ethernet port.
Secondary print heads will have most ports capped excluding
one power port.
Exceptions:
• Wired Ethernet port - cap other Ethernet port.
• Second power port is connected to HMI.
See “Service Parts and Optional Equipment” on page 47 for
plug and cap kits.

ResMark 5000 High-Resolution Section 3: Maintenance and Shutdowns
400386 Operations Manual Rev A Page 20
Section 3: Maintenance and Shutdowns
Following are the recommended maintenance procedures to keep the ResMark 5000 High-Resolution system printing cleanly and efficiently.
System Maintenance
Intermittent (as required):
1. Be sure the photosensor is clean and free of debris.
2. Be sure the nuts and bolts holding the bracketry in place remain tight.
3. Ensure all cable connections are secure but not overtightened.
4. Adjust Printer Module level and throw distance as necessary.
Annually:
Clean the encoder and review the wheel for excess wear.
Printer Module Maintenance
Daily / Shift Startup / Periodic
Wear safety goggles when working with industrial inks or solutions!
The majority of print quality degradation is due to excessive debris deposits on the
print head orifice plate that disrupt the ink droplet path. For best preventative
maintenance practices, do the following:
1. Remove excessive debris build-up (corrugate dust, glue strands, and the like) on and
around the front of the print head by using maintenance spray (5760695) on a clean lint-
free cloth (6600171) and wiping the front plate and enclosure. If debris build-up is noted
on the enclosure and rear of the print head, then wipe those clean too.
NOTE: DO NOT SPRAY MAINTENANCE SPRAY DIRECTLY ON THE PRINTER MODULE OR ANYWHERE NEAR THE ORIFICE PLATE.
2. Using a sponge swab (5760832), rub the orifice plate lightly from top down in a vertical direction while ink is flowing during a clean cycle. The
Clean / Prime button is located on the rear of the print head. DO NOT USE n-Propanol directly on the orifice plate.
3. Press the Clean / Prime button one more time to ensure channel priming, but do not swab this time.
4. Wipe the front plate with a clean lint-free cloth to remove any excess ink.
SWAB
DOWN
SHIPPING CAP STORAGE
CLEAN / PRIME BUTTON