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

Integrated Valve Section 2: Safety
5760-107 Operations Manual Rev C Page 3 of 86
Section 2: Safety
Following is a list of safety symbols and their meanings, which you will find 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.)
Only Diagraph trained personnel should operate and service the equipment.
CAUTION: The IDS3000 Ink Delivery System contains hazardous voltage (115/230VAC).
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 equipment.
WARNING: This equipment contains ink under pressure. Be sure to depressurize the sys-
tem before servicing.
TSO ink contains ethanol and isopropanol. MEK ink contains methyl ethyl keytone. TWP
ink contains ethylene glycol. It is extremely important to:
• Clean up all spills with the appropriate conditioners 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).
!
!
!

Integrated Valve Section 2: Safety
Page 4 of 86 5760-107 Operations Manual Rev C

Integrated Valve Section 3: System Components
5760-107 Operations Manual Rev C Page 5 of 86
Section 3: System Components
26
17
24
24 24
16
3 3
3
3
45
7
8
10
15
2
14
12
13
11
18
19
22
23
25
24
20
21
21
27
17
17 17
66
6
6
15 Ink out to Print Heads
16 Ink Supply Tubing
17 Ink Regulator
18 Encoder Cable
19 Photosensor Cable
20 Controller to Print Head Cable
21 Print Head to Print Head Cable
22 Ink Filter (5700-026)
23 Throw Distance
24 Ink T Fitting (5700-509)
25 Male Quick Disconnect (5700-508)
26 Ink Supply Cap Assembly
27 Ethernet Cable (5760-240)
1
1 IJ3000 Controller
2 IDS3000
3 Print Heads
4 Conveyor
5 Product
6 Print Head Bracketry
7 Ink Status Beacon
8 Encoder (5700-731)
9 Ink Supply Container
10 Photosensor (5760-383)
11 Ink Level Detect
12 Power Cord
13 Ethernet Connection
14 Beacon Cable
9

Integrated Valve Section 3: System Components
Page 6 of 86 5760-107 Operations Manual Rev C
System and Component Part Numbers
The Diagraph IJ3000 Ink Jet System is available with the following components, options
and service kits:
Part Number Description
IJ3000 System Includes: Controller, IDS, Effluent Bottle, & Tubing Kit
5760-PDV1P Painted Controller & IDS, Single Interface, Porous IDS, Domestic
5760-PDV1N Painted Controller & IDS, Single Interface, Non-Porous IDS, Domestic
5760-PDV2P Painted Controller & IDS, Dual Interface, Porous IDS, Domestic
5760-PDV2N Painted Controller & IDS, Dual Interface, Non-Porous IDS, Domestic
5760-SDV1P Stainless Controller & IDS, Single Interface, Porous IDS, Domestic
5760-SDV1N Stainless Controller & IDS, Single Interface, Non-Porous IDS, Domestic
5760-SDV2P Stainless Controller & IDS, Dual Interface, Porous IDS, Domestic
5760-SDV2N Stainless Controller & IDS, Dual Interface, Non-Porous IDS, Domestic
5760-PEV1P Painted Controller & IDS, Single Interface, Porous IDS, European
5760-PEV1N Painted Controller & IDS, Single Interface, Non-Porous IDS, European
5760-PEV2P Painted Controller & IDS, Dual Interface, Porous IDS, European
5760-PEV2N Painted Controller & IDS, Dual Interface, Non-Porous IDS, European
5760-SEV1P Stainless Controller & IDS, Single Interface, Porous IDS, European
5760-SEV1N Stainless Controller & IDS, Single Interface, Non-Porous IDS, European
5760-SEV2P Stainless Controller & IDS, Dual Interface, Porous IDS, European
5760-SEV2N Stainless Controller & IDS, Dual Interface, Non-Porous IDS, European
IJ3000 Controller Assemblies (Included w/ IJ3000 System)
5760-001PV1D Painted Enclosure, Single Interface, Domestic
5760-001PV2D Painted Enclosure, Dual Interface, Domestic
5760-001SV1D Stainless Enclosure, Single Interface, Domestic
5760-001SV2D Stainless Enclosure, Dual Interface, Domestic
5760-001PV1E Painted Enclosure, Single Interface, European
5760-001PV2E Painted Enclosure, Dual Interface, European
5760-001SV1E Stainless Enclosure, Single Interface, European
5760-001SV2E Stainless Enclosure, Dual Interface, European
IDS3000 Ink Delivery Assemblies (Included w/ IJ3000 System)
5760-012PDP Painted Enclosure, Domestic, Porous
5760-012PDN Painted Enclosure, Domestic, Non-Porous
5760-012SDP Stainless Enclosure, Domestic, Porous
5760-012SDN Stainless Enclosure, Domestic, Non-Porous
5760-012PEP Painted Enclosure, European, Porous
5760-012PEN Painted Enclosure, European, Non-Porous
5760-012SEP Stainless Enclosure, European, Porous
5760-012SEN Stainless Enclosure, European, Non-Porous

Integrated Valve Section 3: System Components
5760-107 Operations Manual Rev C Page 7 of 86
Standard Integrated Valve (I.V.) Print Heads
5700-406 1/2”, 9-Dot, Porous
5700-407 1/2”, 9-Dot, Non-Porous
5700-404 7/8”, 9-Dot, Porous
5700-405 7/8”, 9-Dot, Non-Porous
5700-402 1", 18-Dot, Porous
5700-403 1", 18-Dot, Non-Porous
5700-448 2", 18-Dot, Porous
5700-452 2", 18-Dot, Non-Porous
Print Head Bracketry
5760-353 Single Print Head Conveyor Mounting Kit
5760-354 Multi Print Head Conveyor Mounting Kit (Requires Single Print Head Kits)
5760-355 Print Head Floor Mounting Kit (Requires Single Print Head Kits)
5760-356 Multi Print Head Floor Mounting Kit w/24" Bar (Requires Single Print Head Kits)
5760-357 Multi Print Head Floor Mounting Kit w/44” Bar (Requires Single Print Head Kits)
5760-360 Print Head Angle Bracket w/T-Nuts
Controller/IDS Bracketry
5760-350 Controller/IDS Conveyor Mounting Kit
5760-351 Controller/IDS Pedestal Mounting Kit
5760-352 Controller/IDS T-Base Mounting Kit
5760-014 Controller/IDS Floor Cart
5760-362 Controller 90° Pivot Bracket Kit
Print Head Cables
5700-245 Print Head Cable Assembly, 2’
5700-727 Print Head Cable Assembly, 10’
5700-934 Print Head Cable Assembly, 25’
Encoder
5700-731 Encoder Assembly w/Mounting Bracket
5760124-10 Encoder Extension Cable, 10’
5760124-25 Encoder Extension Cable, 25’
Photosensor
5760-383 Photosensor, Diffuse Type
5700-933 Photosensor Extension Cable, 10’
Ink Cap Assemblies
5760-307 5 Gallon Ink Cap Assembly
5760-309 30 Gallon Ink Cap Assembly

Integrated Valve Section 3: System Components
Page 8 of 86 5760-107 Operations Manual Rev C
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 stainless steel or painted metal case that makes it splash-proof
and resistant to electromagnetic interference. A hinged cover provides access to replace-
able parts.
The IJ3000 Impulse Jet Controller can control up to two 32-channel print heads or one 256-
channel print head per interface board. With the optional second interface board, the sys-
tem can control up to four 32-channel heads or two 256-channel heads.
IDS3000 Ink Delivery System
The Ink Delivery System (IDS) provides ink to the
print heads. The IDS contains an Ink Pump, Accumu-
lator, and printed Circuit Board to control ink supply to
the print heads. Ink is pumped into an internal accu-
mulator to supply constant ink pressure to the print
heads.
The IDS includes system connectivity to supply oper-
ational data including Ink Low, Ink Out, and Broken
Line safety information. See Appendix B, Theory of
Operation, for a complete operational description.
IDS3000
Power
Prime

Integrated Valve Section 3: System Components
5760-107 Operations Manual Rev C Page 9 of 86
Bracketry
Bracketry is the structure that supports
the controller, IDS, print heads, and
other accessories. This manual details
instructions for mounting all system
components to a conveyor. Other
mounting options for the controller and
IDS include the T-stand, pedestal, and
cart mount, shown below. Assembly
instructions are included with parts kits.
CART WITH CONTROLLER/IDS
(5760-014)
T-STAND
WITH CONTROLLER/IDS
(5760-352)
PEDESTAL WITH
CONTROLLER/IDS
(5760-351)

Integrated Valve Section 3: System Components
Page 10 of 86 5760-107 Operations Manual Rev C
Print Head Bracketry
There are numerous options for mounting print heads. Diagraph bracketry is modular and
can assume several configurations:
• Single-pole conveyor mount
• Double-pole conveyor mount
• Single-pole floor mount
• Double-pole floor mount
• Multi-panel floor mount
SINGLE POLE
CONVEYOR MOUNT DOUBLE POLE
CONVEYOR MOUNT
SINGLE
POLE
FLOOR
MOUNT
MULTI-PANEL
FLOOR MOUNT
DOUBLE POLE
FLOOR MOUNT

Integrated Valve Section 3: System Components
5760-107 Operations Manual Rev C Page 11 of 86
Print Heads
The Diagraph Integrated Valve (I.V.) print
head uses a flexible membrane sand-
wiched between two plates, which pro-
pels ink droplets onto moving surfaces
by solenoid activation.
This design keeps the ink between the
front-plate and membrane, away from
the solenoids.
The I.V. print head is capable of printing
at very high line speeds with a minimum
of required maintenance. It can produce
highly legible ¼" to 2" tall alphanumerics,
special characters, barcodes, and logos.
Each type of I.V. print head
has specific distances above
and below the orifices, spaces
in which the print head cannot
print. These non-printing
zones are critical when
designing print head layout in
multi-head applications. The
figure at right shows the print
and non-print areas obtained
when two 9-dot print heads
are stacked on a vertical
bracket, as in the "Single Pole
Floor Mount" illustration on the
previous page. See the table
on the next page for specific
non-printing zones for each
print head model.
PRINTING
ZONE
A
B
A
B
PRINTING
ZONE
ORIFICES
[A] Non-print Top Area [B] Non-print Base Area

Integrated Valve Section 3: System Components
Page 12 of 86 5760-107 Operations Manual Rev C
Print Head Models
The following table lists the eight models of Diagraph I.V. print heads and their characteris-
tics.
Ink Regulator
The ink regulator, supplied with the print head, regulates ink pres-
sure to the print head. The regulator is preset at the factory to the
correct output pressure.
Part
Number Type Characteristics Non-Print Base
Area (B)
Non-Print
Top Area
(A)
Total Non-
PrintArea
(A+B)
5700-406 1/2" 9-Dot
Porous Prints 1/4", 5/16" and 1/2" tall characters on porous
substrate
.800" 1.14" 1.94"
5700-407 1/2" 9-Dot
Non-Porous Prints 1/4", 5/16" and 1/2" tall characters on non-
porous substrate.
.800" 1.14" 1.94"
5700-404 7/8" 9-Dot
Porous Prints 7/16", 5/8" and 7/8" tall characters on porous
substrate.
.610" .93" 1.54"
5700-405 7/8" 9-Dot
Non-Porous Prints 7/16", 5/8" and 7/8" tall characters on non-
porous substrate.
.610" .93" 1.54"
5700-402 1" 18-Dot
Porous Prints 1/4", 3/8", 1/2" and 1" tall characters on
porous substrate.
2.14" 2.10" 4.24"
5700-403 1" 18-Dot
Non-Porous Prints 1/4", 3/8", 1/2" and 1" tall characters on non-
porous substrate.
2.14" 2.10" 4.24"
5700-448 2" 18-Dot
Porous Prints 1/4", 3/8", 1/2", 1" and 2" tall characters on
porous substrate
1.64" 1.42" 3.06"
5700-452 2" 18-Dot
Non-Porous Prints 1/4", 3/8", 1/2", 1" and 2" tall characters on
non-porous substrate
1.64" 1.42" 3.06"