Illinois Tool Works IJ4000 User manual

Operations
Manual
1 Missouri Research Park Drive • St. Charles, MO 63304 • Service Line 1-800-526-2531
Illinois Tool Works Inc © 2021
IJ4000 Impulse Jet System
5765-018
Revision J

IJ4000 Impulse Jet
Ink Jet System
Operations Manual
5765-018
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.
©2021 Illinois Tool Works Inc.
All rights reserved

The IJ4000 Impulse Jet System, including all components unless otherwise specified, carries a limited warranty.
The inks and conditioners used with the IJ4000 Impulse 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:
IJ4000 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: Adjust Print Head to Substrate .....................................................................................................................................................11
Step 4: Install SMART-IDS ......................................................................................................................................................................12
Step 5: Install IJ4000-HMI Controller ......................................................................................................................................................15
Step 6: Electrical Cable Connections ........................................................................................................................................................16
Step 7: Install Tubing ................................................................................................................................................................................18
Step 8: Prime Ink Lines ............................................................................................................................................................................19
Step 9: Priming the Print Head and Testing Print Quality ........................................................................................................................21
Step 10: Mount Photosensor and Encoder ................................................................................................................................................24
Step 11: Configure the Print Head via the Controller ...............................................................................................................................25
Step 12: Create a Message ........................................................................................................................................................................27
Step 13: Print a Message ...........................................................................................................................................................................28
Section 3: Maintenance and Shutdowns ...........................................................................................................................................................29
System Maintenance .................................................................................................................................................................................29
Print Head Maintenance ............................................................................................................................................................................29
ACS - Automatic Cleaning System ..........................................................................................................................................................31
SMART-IDS Maintenance .......................................................................................................................................................................33
Section 4: Troubleshooting ................................................................................................................................................................................35
Print Quality ..............................................................................................................................................................................................35
IJ4000 Impulse Jet System Trouble-Shooting ..........................................................................................................................................38
Detailed Guide to Determine Proper Ink Flow Issue Resolution .............................................................................................................42
Appendix A: System Specifications ...................................................................................................................................................................48
System .......................................................................................................................................................................................................48
SMART-IDS ............................................................................................................................................................................................49
IJ4000-HMI Controller .............................................................................................................................................................................50
384E Print Head ........................................................................................................................................................................................51
768E Print Head ........................................................................................................................................................................................52
System Interconnect Diagram ...................................................................................................................................................................53
Customer System Connections .................................................................................................................................................................54

Appendix B: Theory of Operation ....................................................................................................................................................................55
Functional Description ..............................................................................................................................................................................55
Impulse Jet 384E and 768E Print Heads ...................................................................................................................................................55
Print Head Daisy Chain ............................................................................................................................................................................56
Print Trigger Photosensor .........................................................................................................................................................................56
Encoder .....................................................................................................................................................................................................56
SMART-IDS (Ink Delivery System) ........................................................................................................................................................57
SMART-IDS Ink and Vacuum Control PCB ...........................................................................................................................................64
Appendix C: Updating the HMI & SMART-IDS via USB or Ethernet ........................................................................................................71
Appendix D: InkJet Demo Software for Windows ..........................................................................................................................................71
Appendix E: Software Interface ........................................................................................................................................................................71
Appendix F: Part Numbers ................................................................................................................................................................................72
System .......................................................................................................................................................................................................72
Bracketry ...................................................................................................................................................................................................73
Fittings and Tubing ...................................................................................................................................................................................74
IJ4000-HMI ..............................................................................................................................................................................................74
IJ4000 SMART-IDS .................................................................................................................................................................................75
Cables ........................................................................................................................................................................................................76
Print Head Replacement Parts ..................................................................................................................................................................76
Consumables .............................................................................................................................................................................................77
Service Parts and Optional Equipment .....................................................................................................................................................78

IJ4000 Impulse Jet Section 1: Safety and Ink Usage
5765-018 Operations Manual Rev J 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 SMART-IDS (Ink Delivery System) contains hazardous voltage (115/230VAC). 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 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 SDS (Safety Data Sheet).
Service is to be performed by trained or ITW personnel only.
!
!

IJ4000 Impulse Jet Section 2: Quick Start
5765-018 Operations Manual Rev J Page 7
Section 2: Quick Start
The figure at right illustrates a typical installation with a controller and a print head. (Cables and ink lines are not shown.)
System Components:
• Bracketry Kit (Item 1)
• Print Head (Item 2)
•S
MART-IDS (Item 3)
• IJ4000-HMI Controller (Item 4)
• Power Cord (not shown)
• Serial Cable (not shown)
• Tubing (not shown)
• Software (not shown)
(Ink is not included.)
NOTE: See limitations in “Tubing Limitations -
Vertical” on page 13.
TYPICAL INSTALLATION
4
3
1
2

IJ4000 Impulse Jet Section 2: Quick Start
5765-018 Operations Manual Rev J Page 8
Step 1: Assemble Bracketry to Conveyor
NOTE: Mount bracketry as square and as level as possible.
PRINT HEAD
CONVEYOR MOUNT
(5765-246 for 384E Print Head)
(5765-253 for 768E Print Head)
HMI CONTROLLER /
SMART-IDS MOUNT
(5765-250) OPTIONAL T-STAND
(5765-249)

IJ4000 Impulse Jet Section 2: Quick Start
5765-018 Operations Manual Rev J Page 9
Step 2: Assemble Print Head onto Bracketry
ROLLER / RETRACTING
BRACKET MOUNT FOR
384E PRINT HEAD
(5765-246)
SINGLE-POLE FLOOR
MOUNT
(5760-355)
RETRACTING
BRACKET CAN BE
MOUNTED ON EITHER
SIDE OF PRINT HEAD
ROLLER / RETRACTING
BRACKET MOUNT FOR
768E PRINT HEAD
(5765-253)

IJ4000 Impulse Jet Section 2: Quick Start
5765-018 Operations Manual Rev J Page 10
Print Head Mounting Limitations
Print Head Tilt
Maximum Print Head Tilt:
• Clockwise Tilt: 5°
• Counterclockwise Tilt: 5°
NOTE: Tilt angles are given when looking at
the rear of the print head. Front to rear tilt
should be less than + 1.5°, as indicated by the
digital level LED readout on the top rear of the
print head.
AB
768E PRINT HEAD
27,2mm [1.07in] TO LOWEST ORIFICE
101,6mm [4in] SOLID
CHARACTER HEIGHT
CD
50,8mm [2in] SOLID
CHARACTER HEIGHT
ABC
22,9mm [0.90in] TO LOWEST ORIFICE
384E PRINT HEAD
± 5° MAX
± 5° MAX

IJ4000 Impulse Jet Section 2: Quick Start
5765-018 Operations Manual Rev J Page 11
Step 3: Adjust Print Head to Substrate
Use the bracket handle to adjust print head vertically.
Loosen the adjustment knobs on the Retracting Bracket to slide the print head toward or away from substrate.
BRACKET HANDLE
VERTICAL
ADJUSTMENT
ADJUSTMENT
KNOBS
3mm [.1in] GAP
RECOMMENDED
HORIZONTAL
ADJUSTMENT

IJ4000 Impulse Jet Section 2: Quick Start
5765-018 Operations Manual Rev J Page 12
Step 4: Install SMART-IDS
SMART-IDS
OPTIONAL FLOOR
MOUNT

IJ4000 Impulse Jet Section 2: Quick Start
5765-018 Operations Manual Rev J Page 13
Tubing Limitations - Vertical
Best Practices
SMART-IDS
1.5m (5ft)
(Consult Factory
if longer)
HMI
Alternate Configurations
Conveyor
SMART-IDS
1m (3ft)
1m (3ft)
SMART-IDS
HMI
Conveyor
SMART-IDS
HMI
Conveyor
• Mount Smart-IDS below the height
of the print heads.
• Do not create service loops or coils
of tubing.
•Minimize length of tubing by cutting
to length.

IJ4000 Impulse Jet Section 2: Quick Start
5765-018 Operations Manual Rev J Page 14
Tubing Limitations - Horizontal
12,2m (40ft)
Maximum Total Tubing Length
1 Print Head
2 Print Heads
6,1m (20ft)
Maximum Total Tubing Length
768E Print Heads: 384E Print Heads:
1 Print Head
15,2m (50ft)
Maximum Total
Tubing Length
2 Print Heads
9,1m (30ft)
Maximum Total
Tubing Length
3 or 4 Print Heads
4,6m (15ft)
Maximum Total
Tubing Length
SMART-IDS
SMART-IDS
SMART-IDS
SMART-IDS
SMART-IDS

IJ4000 Impulse Jet Section 2: Quick Start
5765-018 Operations Manual Rev J Page 15
Step 5: Install IJ4000-HMI Controller
CONTROLLER

IJ4000 Impulse Jet Section 2: Quick Start
5765-018 Operations Manual Rev J Page 16
Step 6: Electrical Cable Connections
All controller cables must be routed through the Strain
Relief Cable Clamp in the bottom of the SMART-IDS.
1. Refer to the adjacent diagram for typical electrical
cable routing.
2. Connect all cables to their appropriate sockets.
(Refer to the following page for SMART-IDS internal
connectivity.)
3. Route and connect cables to the conveyor compo-
nents (print heads, encoder, photocell).
4. Customer system connections are made inside the
SMART-IDS. (Refer to the following page.)
NOTE: It is recommended that the Task 1 Print Head
be closest to the IJ4000-HMI.
5. Plug the SMART-IDS into the appropriate mains
power outlet.
NOTE: Ensure that the Smart-IDS is powered off. It will
be activated as part of the ink line bleeding procedure.
SMART-IDS
PRODUCT DIRECTION
IJ4000-HMI
CONVEYOR
ENCODER
PRINT HEAD CABLES
PRINTHEAD
STRAIN RELIEF
CABLE CLAMP
OPTIONAL
BEACON
POWER CORD
PHOTO
SENSOR
PRINTHEAD
PRINTHEAD
PRINTHEAD
PRINT
HEAD
CABLES
NOTE: Connect IDS
directly to upstream
print head.

IJ4000 Impulse Jet Section 2: Quick Start
5765-018 Operations Manual Rev J Page 17
SMART-IDS
INTERNAL CIRCUIT
BOARDS
I/O CABLE FROM
SMART-IDS
PHOTOSENSOR /
ENCODER
CABLE
TASK 2 INTERFACE
BOARD CONNECTIONS
TASK 1 INTERFACE
BOARD CONNECTIONS
PRINT HEAD
CABLES
POWER
CORD
* CUSTOMER SYSTEM CONNECTIONS
(See Appendix A for details)
COM2 *
OPTIONAL I/O BOARD
ENCODER /
PHOTOSENSOR
CABLE
NOTE: In many applications,
Photocell and Encoder may be
shared from Task 1 to Task 2
USB / FILE BACKUP &
TRANSFER ACCESS
ETHERNET
/ HMI *
COM1 *

IJ4000 Impulse Jet Section 2: Quick Start
5765-018 Operations Manual Rev J Page 18
Step 7: Install Tubing
NOTE: Do not attempt plumbing this sys-
tem before all mechanical mounting is
completed.
1. After mechanical mounting is com-
pleted for the SMART-IDS and the
print heads, remove all vent caps and
install the supplied filter.
2. Route all ink and vacuum lines, and
connect lines at the SMART-IDS.
Refer to diagram at right for typical
print head plumbing connections.
NOTE: Do not connect lines to print
heads at this time.
4,6mm [15ft] MAX
VACUUM
INK
CONVEYOR
PRINT HEAD PRINT HEAD
TEE FITTING
(2460-120)
DO NOT CONNECT
TO PRINT HEAD YET
DO NOT CONNECT
TO PRINT HEAD YET
INK FITTING
(5361-329)
SMART-IDS
INK
VACUUM
FILTER
REMOVE AND
SAVE CAP
REMOVE AND
SAVE ALL 3 CAPS
VACUUM
FITTING
(5765-721)
INK
OUTLET
VENT
VACUUM
PORT
STRAIGHT
FITTING
(5765-719)
CHECK VALVE
(5765-720) STRAINER
(5765-713)
"Y" FITTING
(5765-717)
VACUUM
FITTING
(5765-721)
ONLY USED
TO PRIME
INK LINES
CAUTION
REMOVE
INSTALL
FILTER
CAP
RED
INCORRECT
CORRECT

IJ4000 Impulse Jet Section 2: Quick Start
5765-018 Operations Manual Rev J Page 19
Step 8: Prime Ink Lines
CAUTION:
• Ensure all vent caps, top and bottom, have been removed from the print head(s) and SMART-IDS.
• Ensure no tubing is connected to the print heads.
1. Remove the foil seal on the ink bottle and install it into the SMART-IDS reservoir. Clean and save
the reservoir cap.
NOTE: Never mix ink types because they are not miscible. Irreversible internal damage will occur.
2. Turn on the SMART-IDS.
3. At the print head located nearest the SMART-IDS, connect the ink supply and vacuum fittings to
each other to form a loop.
4. The SMART-IDS vacuum cycle will be running as the print heads come up to temperature.
5. Disconnect the loop as soon as ink has flowed through the connected fittings. Wipe off both con-
nectors.
6. Cut off the vacuum line fitting (5765-721) noted in red on the previous page. Remove the plug
from the print head vacuum line and push the now raw tubing end into the print head vacuum fit-
ting.
NOTE: It is critical that all air be purged out of the ink lines prior to connection to the rear of the print heads.
7. Form a loop for the next closest print head. If the vacuum cycle is still running, allow ink to pass through the loop. Follow steps 5 and 6.
8. If the vacuum cycle stops running and ink lines need to be primed, form the fitting loop at the next print head, then press and hold the ACS/
Prime button on the back of the print head for five (5) seconds. This starts a PRIME cycle. Follow steps 5 and 6.
9. Prime remaining ink supply tubing, following the steps above.
10. Level print heads and secure cables and tubing lines according to diagrams on the next page.
CAUTION
REMOVE
INSTALL
FILTER
CAP
RED


INK QUICK-
DISCONNECT
VACUUM QUICK-
DISCONNECT
CONNECTED
!

IJ4000 Impulse Jet Section 2: Quick Start
5765-018 Operations Manual Rev J Page 20
Confirm the print head(s) are level. The green LED indicates head is level. (384E Print Head is shown.)
WHEN UPPER LED IS
RED, PRINT HEAD IS
POINTED UP TOO FAR
WHEN CENTER LED IS
GREEN, PRINT HEAD IS
READY TO PRINT
WHEN LOWER LED IS
RED, PRINT HEAD IS
POINTED DOWN TOO FAR

BRACKETRY KITS COME
WITH TIE WRAP MOUNTS
INSERT TIE WRAP MOUNT IN
BAR AND TURN 90°. INSERT
TIE WRAPS INTO MOUNTS.
FORM AN 8" MINIMUM
SERVICE LOOP FOR
TUBING AND CABLE.

