ITW Diagraph IJ3000 User manual

1 Missouri Research Park Drive  St. Charles, MO 63304  ServiceLine 1-800- 26-2 31
Illinois Tool Works Inc © 2004
760-107
Revision C
Integrated Valve
Ink Jet System
Operations
Manual

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.
©2004 Illinois Tool Works Inc
All rights reserved
Printed in the United States of America
IJ3000 Integrated Valve
Ink Jet System
Operations Manual
5760-107
Revision C
Multiple Translations: This manual has been translated into othe
r
languages. If there is an inconsistency or ambiguity as to the meaning o
f
any word or phrase in a translation, the English text will prevail.

5760-107 Operations Manual Rev C
The IJ3000 system, including all components unless otherwise specified, carries a
limited warranty.
The inks and conditioners used with the IJ3000 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:

Integrated Valve
5760-107 Operations Manual Rev C Page i of iv
Section 1: Introduction........................................................................................................................ 1
Section 2: Safety................................................................................................................................... 3
Section 3: System Components .......................................................................................................... 5
System and Component Part Numbers...................................................................................... 6
IJ3000 Controller....................................................................................................................... 8
IDS3000 Ink Delivery System................................................................................................... 8
Bracketry ................................................................................................................................... 9
Print Head Bracketry ................................................................................................... 10
Print Heads .............................................................................................................................. 11
Print Head Models ....................................................................................................... 12
Ink Regulator .......................................................................................................................... 12
Photosensor.............................................................................................................................. 13
Encoder.................................................................................................................................... 13
Ink Supply ............................................................................................................................... 13
Section 4: Installation........................................................................................................................ 15
System Overview..................................................................................................................... 15
Testing the Electrical Outlet.................................................................................................... 16
Electrical Line Transients ............................................................................................ 16
Materials Required for Installation.......................................................................................... 16
Installing Controller/IDS Bracketry ........................................................................................ 17
Print Head Bracketry ............................................................................................................... 18
Mounting the Print Heads........................................................................................................ 18
Mounting the Photosensor....................................................................................................... 19
Photosensor Operation ................................................................................................. 19
The Encoder............................................................................................................................. 20
Controller Connections ........................................................................................................... 20
CPU Connections ........................................................................................................ 21
Using the Optional Second Interface Board............................................................................ 21
Sharing an Encoder and/or Photosensor ...................................................................... 21
Configuring the IDS ................................................................................................................ 22
Attaching Ink Regulators ............................................................................................. 22
Plumbing the System ................................................................................................... 23
Connecting the Ink Supply .......................................................................................... 25
Priming the System.................................................................................................................. 26
Checking Ink Pressure............................................................................................................. 27
Setting Ink Pressure................................................................................................................. 28
Operational System Test.......................................................................................................... 29
Configuring the Print Station ....................................................................................... 29
Print Head Setup Screen .................................................................................. 29
Specifying Product Direction .......................................................................... 29
Specifying Number of Print Heads .................................................................. 30
Setting Daisy Chain Order ............................................................................... 30
Defining Print Head Properties ....................................................................... 31
Purging Print Heads ..................................................................................................... 32

Integrated Valve
Page ii of iv 5760-107 Operations Manual Rev C
Section 5: Frequently Asked Questions........................................................................................... 33
Section 6: Maintenance ..................................................................................................................... 35
System Maintenance................................................................................................................ 35
Print Head Maintenance .......................................................................................................... 35
Daily Startup ................................................................................................................ 35
Shutdowns of Seven Days or Longer .......................................................................... 36
Spare Print Heads ........................................................................................................ 36
IDS Maintenance ..................................................................................................................... 37
Changing Ink Containers ............................................................................................. 37
Daily Startup ................................................................................................................ 38
Intermittent (as required) ............................................................................................. 38
Annually ...................................................................................................................... 38
Section 7: Troubleshooting ............................................................................................................... 39
Troubleshooting Notes ............................................................................................................ 39
Ink Delivery System .................................................................................................... 39
Print Heads .................................................................................................................. 39
Troubleshooting Tests ............................................................................................................. 39
Purge Test .................................................................................................................... 39
Print Test .....................................................................................................................39
Photosensor Test .......................................................................................................... 40
Print Head Ink Pressure Test ....................................................................................... 40
Ink Regulator Input Pressure Test ............................................................................... 40
Encoder Functional Testing..................................................................................................... 41
Print Quality Troubleshooting................................................................................................. 43
Diagnosis ..................................................................................................................... 43
Setting Ink Pressure ..................................................................................................... 46
Ink Regulator Maintenance Procedure ........................................................................ 47
Print Head Pulse Width Adjustment ............................................................................ 48
Cleaning the Front Plate of a Clogged Print Head ...................................................... 49
Broaching the Orifice .................................................................................................. 49
Print Head Pre-Load Adjustment ................................................................................ 50
Appendix A: System Specifications ................................................................................................. 53
Ink Delivery System ................................................................................................................ 53
Appendix B: Theory of Operation ................................................................................................... 55
Functional Description ............................................................................................................ 55
Print Head Daisy Chain(s)....................................................................................................... 55
Photosensor.............................................................................................................................. 55
Encoder.................................................................................................................................... 56
Power....................................................................................................................................... 56
CPU Board ................................................................................................................... 57
I.V. Print Head Interface Board ................................................................................... 58
Display Interface Board ............................................................................................... 58

Integrated Valve
5760-107 Operations Manual Rev C Page iii of iv
Ink Delivery System Features ................................................................................................. 59
Startup Operation ......................................................................................................... 59
Normal Operation ........................................................................................................ 59
Ink Low Detection ....................................................................................................... 60
Ink Supply Replenishment .......................................................................................... 60
Print Head Broken Line Detection .............................................................................. 61
Temporary Broken Line Override Feature .................................................................. 61
Permanent Broken Line Override Feature ................................................................... 61
Overheating Protection ................................................................................................ 61
IDS Board Test Points ............................................................................................................. 62
IDS Wiring Diagrams.............................................................................................................. 63
Appendix C: Parts and Supplies ...................................................................................................... 65
Consumables............................................................................................................................ 65
Parts in Modular Kits............................................................................................................... 66
IDS Assembly Kits .................................................................................................................. 67
Appendix D: Maximum dpi Calculation for a Given Line Speed................................................. 69
Appendix G: Font Samples............................................................................................................... 71
Appendix F: Setting the IP Address of an IDS3000 ....................................................................... 79
Equipment Needed .................................................................................................................. 79
Procedure................................................................................................................................. 79
Appendix G: Testing an Electrical Outlet....................................................................................... 81
Appendix H: Electrostatic Discharge (ESD)................................................................................... 83
Appendix I: Glossary of Terms ........................................................................................................ 85

Integrated Valve
Page iv of iv 5760-107 Operations Manual Rev C

Integrated Valve Section 1: Introduction
5760-107 Operations Manual Rev C Page 1 of 86
Section 1: Introduction
This manual covers the installation, operation, and maintenance of the IJ3000 Integrated
Valve (I.V.) Ink Jet Printing System. Also included is a troubleshooting section, parts list
and glossary. The IJ3000 Controller operation is described in a separate manual: 5760-121
IJ3000 Controller Operations Manual.
Your Diagraph IJ3000 Ink Jet System consists of:
•IJ3000 Controller - An ink jet controller with color display, touch screen, and full size
QWERTY keyboard designed to work with Diagraph I.V. (Integrated Valve) print heads
and the IDS3000 Ink Delivery System. (See the IJ3000 Controller Manual, part number
5760-121.)
•I.V. Print Heads - Print Heads designed for high-speed printing applications in harsh
environments using Diagraph porous and non-porous inks.
•IDS3000 - An ink delivery system capable of supplying porous and non-porous ink to a
maximum of eight 18-dot or sixteen 9-dot I.V. Print Heads.
IJ3000 systems range from a single stand-alone print station to multiple print stations
linked together via Ethernet and controlled by a computer. Each print station can control
one or two print head daisy chains, with each daisy chain being any combination of 9- and
18-dot print heads totaling 72 dots.
Scanned sample of ink jet printing.

Integrated Valve Section 1: Introduction
Page 2 of 86 5760-107 Operations Manual Rev C