5765-016 IJ4000 System Manual, Rev A

5765-016 IJ4000 System Manual, Rev A
Operations
Manual
IJ4000 Impulse Jet System
5765-016
Revision A
1 Missouri Research Park Drive • St. Charles, MO 63304 • Service Line 1-800-526-2531
Illinois Tool Works Inc © 2016
IJ4000 Impulse Jet
Ink Jet System
Operations Manual
5765-016
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.
©2016 Illinois Tool Works Inc.
All rights reserved
Printed in the United States of America
IJ4000 System
Warranty:
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.
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 Centralized Ink Delivery System (Centralized-IDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Step 5: Install IJ4000-HMI Controller and IJ4000 Connection HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Step 6: Install Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Step 7: Electrical Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Step 8: Prime Ink Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Step 9: Mount Photosensor and Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Step 10: Configure the Print Head via the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Step 11: Sample Print Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Step 12: Create a Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Step 13: Print a Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Section 3: Maintenance and Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Print Head Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
ACS - Automatic Cleaning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Centralized-IDS Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Section 4: Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Print Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
IJ4000 Impulse Jet System Trouble-Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Appendix A: System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Centralized Ink Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
IJ4000-HMI Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
IJ4000 Connection HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
384E Print Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
System Interconnect Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Appendix B: Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Impulse Jet 384E Print Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Print Head Daisy Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Print Trigger Photosensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Centralized Ink Delivery System (Centralized-IDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Centralized-IDS Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Appendix C: Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Bracketry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Fittings and Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Centralized-IDS Assembly Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Print Head Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Service Parts and Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
IJ4000 Impulse Jet
Section 1: Safety and Ink Usage
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 Centralized Ink Delivery System (Centralized-IDS) 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 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).
5765-016 Operations Manual
Page 6
IJ4000 Impulse Jet
Section 2: Quick Start
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)
• Centralized Ink Delivery System (Item 3)
• IJ4000-HMI Controller (Item 4)
• IJ4000 Connection HUB (Item 5)
• Power Cord (not shown)
• Serial Cable (not shown)
• Tubing (not shown)
• Software (not shown)
4
1
2
(Ink is not included.)
NOTE: See limitations in “Max Tubing Height
From Centralized-IDS to Last Print Head.” on
page 13.
5
3
TYPICAL INSTALLATION
5765-016 Operations Manual
Page 7
IJ4000 Impulse Jet
Section 2: Quick Start
Step 1: Assemble Bracketry to Conveyor
NOTE: Mount bracketry as square and as level as possible.
PRINT HEAD
CONVEYOR MOUNT
(5765-246)
CONTROLLER /
CENTRALIZED-IDS
MOUNT
(5765-250)
5765-016 Operations Manual
OPTIONAL T-STAND
(5765-249)
Page 8
IJ4000 Impulse Jet
Section 2: Quick Start
Step 2: Assemble Print Head onto Bracketry
RETRACTING
BRACKET CAN BE
MOUNTED ON EITHER
SIDE OF PRINT HEAD
ROLLER / RETRACTING
BRACKET MOUNT FOR
768 PRINT HEAD
(5760-388)
ROLLER / RETRACTING
BRACKET MOUNT FOR
384E PRINT HEAD
(5765-246)
SINGLE-POLE FLOOR
MOUNT
(5760-355)
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Page 9
IJ4000 Impulse Jet
Section 2: Quick Start
Print Head Mounting Limitations
768 PRINT HEAD
101,6m [4in] SOLID
CHARACTER HEIGHT
384E PRINT HEAD
ABC
27,2mm [1.07in] TO LOWEST ORIFICE
50,8m [2in] SOLID
CHARACTER HEIGHT
22,9mm [0.90in] TO LOWEST ORIFICE
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.
5765-016 Operations Manual
Page 10
IJ4000 Impulse Jet
Section 2: Quick Start
Step 3: Adjust Print Head to Substrate
Use the bracket handle to adjust print head vertically.
VERTICAL
ADJUSTMENT
BRACKET HANDLE
Loosen the adjustment knobs on the Retracting Bracket to slide the print head toward or away from substrate.
ADJUSTMENT
KNOBS
HORIZONTAL
ADJUSTMENT
3mm [.1in] GAP
RECOMMENDED
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IJ4000 Impulse Jet
Section 2: Quick Start
Step 4: Install Centralized Ink Delivery System (Centralized-IDS)
CENTRALIZED-IDS
5765-016 Operations Manual
Page 12
IJ4000 Impulse Jet
Section 2: Quick Start
Max Tubing Height From Centralized-IDS to Last Print Head.
Print Head Type
384
768
Number of Print
Heads
Maximum Tubing
Length from C-IDS
1
15,2m (50ft)
2
9,1m (30ft)
4
4,6m (15ft)
1
12,2m (40ft)
2
6,1m (20ft)
Tubing limitations:
• Maximum vertical tube length (bottom of Centralized-IDS to
bottom of highest print head) = 6,1m (20ft) (ink pump limitation).
• Maximum height of Centralized-IDS above print head(s) =
914,4mm (36in) (vacuum pump limitation).
Prohibited Conditions:
1. Do not run tubing up and over a conveyor at a height greater
than 914,4mm (36in).
2. Do not coil excess tubing during installation (cut to length
only).
914.4mm (36in) MAX
CENTRALIZED-IDS
5765-016 Operations Manual
Page 13
IJ4000 Impulse Jet
Section 2: Quick Start
Step 5: Install IJ4000-HMI Controller and IJ4000 Connection HUB
CONTROLLER
CONNECTION HUB
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Page 14
IJ4000 Impulse Jet
Section 2: Quick Start
INTERNAL CIRCUIT
BOARDS
I/O CABLE FROM
CENTRALIZED-IDS
CONNECTION HUB
PRINT HEAD
CABLE
POWER
CORD
PHOTOSENSOR
CABLE
ENCODER
CABLE
TASK 2 INTERFACE
BOARD CONNECTIONS
TASK 1 INTERFACE
BOARD CONNECTIONS
INTERNAL CIRCUIT BOARDS
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IJ4000 Impulse Jet
Section 2: Quick Start
Step 6: Install Tubing
NOTE: Do not attempt plumbing this
system before all mechanical mounting
is completed.
!
CAUTION: After mechanical mounting
is completed for the Centralized-IDS
and the print heads, remove all vent
caps and install the supplied filter.
4,6m [15 ft.] MAX
VACUUM
REMOVE AND
SAVE CAP
INK
FILTER
PRINT HEAD
DO NOT CONNECT
TO PRINT HEAD YET
CENTRALIZED-IDS
!
CAUTION: Do not connect print head
cables. This step will be completed
during the ink tubing line bleed procedure.
CONVEYOR
PRINT HEAD
1. Refer to diagram at right for typical
print head plumbing connections.
REMOVE
AND SAVE
ALL 3 CAPS
INK FITTING
(5361.329)
INK
INCORRECT
VACUUM
FITTING
(1900-405)
VACUUM
TEE FITTING
(2460-120)
DO NOT CONNECT
TO PRINT HEAD YET
CORRECT
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Page 16
IJ4000 Impulse Jet
Section 2: Quick Start
Step 7: Electrical Cable Connections
PRINT HEAD CABLE
1. Refer to the diagram for typical electrical cable
installation and routing.
2. Connect the power cord(s), photosensor(s), and
encoder(s) to their appropriate sockets.
PRINT
HEAD
ENCODER
PRINT HEAD
CABLE
PRINT
HEAD
All controller cables must be routed through the
Strain Relief Cable Clamp in the bottom of the
IJ4000 Connection HUB.
CENTRALIZED-IDS
PRODUCT DIRECTION
POWER
CORD
CIDS I/O CABLE
NOTE: Do not connect the Centralized-IDS I/O
cable to the mother board Ethernet port.
4. Install the print head cable(s) to the appropriate
interface board sockets. Route print head
cable(s) under the conveyor for connection to
the print head(s).
PHOTO
SENSOR
PRINT
HEAD
3. Connect the I/O cable from the Centralized-IDS
to the "Output to CIDS" port in the Task 1 Interface Board.
PRINT
HEAD
CONVEYOR
PRINT HEAD
CABLE
OPTIONAL
BEACON
IJ4000-HMI
NOTE:It is recommended that the Task 1 Print
Head be closest to the IJ4000-HMI.
CONNECTION HUB
NOTE: Do not connect these cables to the print
heads. This will be completed during the bleeding
procedure.
5. Plug both the Centralized-IDS and IJ4000 Connection HUB into appropriate outlets.
5765-016 Operations Manual
STRAIN RELIEF
CABLE CLAMP
Page 17
IJ4000 Impulse Jet
Section 2: Quick Start
Step 8: Prime Ink Lines
!
CAUTION:
• Ensure all vent caps, top and bottom, have been removed from the print head(s) and CentralizedIDS.
• Ensure no tubing is connected to the print heads.
1. Remove the foil seal on the ink bottle and install it into the Centralized-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 both the IJ4000 Connection HUB and Centralized-IDS.
3. At the print head located nearest the Centralized-IDS, connect the ink supply and vacuum fittings
to form a loop.
INK QUICKDISCONNECT
VACUUM QUICKDISCONNECT
4. The Centralized-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 connectors.
6. Plug in both fittings into the back of the first print head.
CONNECTED
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/
AutoPrime button on the back of the print head for five (5) seconds. This starts an AUTOPRIME cycle. Follow steps 5 and 6.
9. Prime remaining ink supply tubing, following the steps above.
10. All print heads should have an ink supply and vacuum tubing connection.
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IJ4000 Impulse Jet
Section 2: Quick Start
11. For 384E print head, squeeze tabs to remove print head shipping cap and store on top of the print head.
SNAP SHIPPING
CAP ON TOP OF
PRINT HEAD
TABS
12. For 768 print head, loosen the two captive thumb screws, remove the shipping cover and store on side of the print head.
SHIPPING
COVER
STORAGE
THUMB SCREWS
NOTE: The shipping cap must be removed or the vacuum pull from the ACS cycle will corrupt print quality and potentially start an ink syphon of
the Centralized-IDS reservoir and bottle.
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IJ4000 Impulse Jet
Section 2: Quick Start
Confirm the print head(s) are level. The green LED indicates head is level.
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
5765-016 Operations Manual
INSERT TIE WRAP MOUNT IN
BAR AND TURN 90°. INSERT
TIE WRAPS INTO MOUNTS.
FORM AN 8" MINIMUM
SERVICE LOOP FOR
TUBING AND CABLE.
Page 20
IJ4000 Impulse Jet
Section 2: Quick Start
Step 9: Mount Photosensor and Encoder
Photosensor
1. Position the photosensor (5760-383) upstream
from the first print head. The maximum placement distance is 685,9mm [27in] from the photocell to the print head.
2. The photosensor depth range can be adjusted.
The photosensor normally has a range of
about 762mm [30in], but can be adjusted down
to about 152,4mm [6in]. (Refer to the photosensor manufacturer’s instruction sheet for
instructions on adjusting the range)
Print Head
Conveyor
Bracketry
NOTE: The shorter the range, the more sensitive photosensor triggering is, increasing the possibility of false triggers from graphics on the product. It is best not to adjust sensitivity unless the 762mm [30in] range is causing false triggers.
Encoder
The encoder uses a wheel that rolls against the conveyor line to track the speed. It
sends a signal to the controller, which makes adjustments for reported changes in
the line speed.
It is not necessary to install the encoder immediately adjacent to the print heads. It is
more important to place it where it will accurately measure the speed of the conveyor. Install it in contact with the conveyor, or with a wheel or roller moving the
same speed as the conveyor.
The encoder's mounting bracket is spring-loaded. Adjust the spring collar to ensure
that the encoder maintains stable contact with the conveyor.
CAUTION: Do not jam the encoder wheel against the surface of the conveyor. A
radial force of over 18,14 kg [40 lbs.] will reduce the life of the bearings.
Conveyor
Encoder
Encoder Wheel
Spring
5765-016 Operations Manual
Page 21
IJ4000 Impulse Jet
Section 2: Quick Start
Step 10: Configure the Print Head via the Controller
NOTE: It is recommended that there is no message printing when re-doing the print head setup. If the warning message ("Changing the print
head setup while printing may cause print problems. Continue?") is displayed, click No, then cancel the setup. Return to the Message Screen
and cancel the print message before proceeding.
1. Select the More menu option, then select Task Settings,
2
1
2. Touch the Redo Print Head Setup button.
3. Touch the box that represents the direction the product will move on the
conveyor (as seen while standing in from of the IJ4000-HMI or Task 1
Print Head).
4. Touch the up/down arrows to set the number of print heads on each side
of the conveyor.
5. Touch the Next> button.
6. Touch the first print head in the daisy chain. (If there is only one print
head, this step is bypassed.)
3
4
6
5
NOTES:
• The first print head in the daisy chain should be the top print head in the system, as this one will be printing the top line of data and will be the
first one prompted to enter data.
• The procedure may be aborted by pressing Cancel or the Escape key at any time without changing the current print head setup.
• Repeat above steps for Task 2.
• Each Task can power up to two (2) IJ384E or one (1) IJ768 print heads.
5765-016 Operations Manual
Page 22
IJ4000 Impulse Jet
Section 2: Quick Start
7. Select the Print Head Type from the drop-down box.
8. Enter the distance between the photosensor and the
vertical centerline of the print head. This may need to
be fine-tuned after print setup. The maximum sensor
offset for the IJ384E Print Head is 685,8mm (27in). If
photosensor is mounted using a print head bracket,
the offset is 53,3mm (2.1in).
9. Select the Encoder tab and touch the External
Encoder icon.
10. If Internal Encoder is selected, type in the speed.
11. Touch the next head to highlight it and continue
setup.
12. Touch the OK button. Print Head setup is now complete.
9
10
7
8
When the 384E
Print Head is
selected, the ink
type automatically
sets to Scantrue II.
11
12
Touch any print head on the display to review or change the properties for that head. Touch the Redo Print Head Setup button to repeat the
setup procedure using the new setup as the default. Touch OK to return to the Home Screen.
5765-016 Operations Manual
Page 23
IJ4000 Impulse Jet
Section 2: Quick Start
Step 11: Sample Print Quality
NOTE: Configuration needs to be set up on the IJ4000-HMI Controller prior to priming
the print heads. (Refer to “Step 9: Mount Photosensor and Encoder” on page 21.)
1. Ensure caps from the rear of the print head have been removed and stored.
2. Ensure the print engine shipping cap has been removed and stored.
3. Ensure all print heads are at operating temperature.
NOTE: Print is disabled until the print head is fully heated. Wait until the "AT TEMPERATURE" LED is illuminated on the rear of the print head prior to any print sampling.
384E PRINT HEAD
(See next page for 768 Print Head)
LEAVE THE RED
VENT FILTER IN
PLACE
REMOVE AND
SAVE WHITE INK
INLET PLUG
REMOVE CAP
REMOVE AND
SAVE ORANGE
VACUUM CAP
NOTE: Do not use lint-free wipes in the print channel; use foam swabs instead.
4. Slowly pass a lint-free wipe horizontally across the front of
the print head. For a 384E Print Head, press the All Channel
purge button on the back of the print head. For a 768 Print
Head, press the All Channel purge button on the HMI Controller. A 3-second print sample will result (see next page).
5. If the 384E sample is 50,8mm (2in) tall with no gaps, the print
head is ready.
ALL CHANNEL
PURGE
BUTTON
HEATER ON
ACS / AUTOPRIME
BUTTON
If the 768 sample is 101,6mm (4in) tall with no gaps, the print
head is ready.
AT TEMPERATURE LIGHT
IS ILLUMINATED
5765-016 Operations Manual
Page 24
IJ4000 Impulse Jet
Section 2: Quick Start
768 PRINT HEAD
REMOVE AND
SAVE WHITE INK
INLET PLUG
ACS / AUTO-PRIME
BUTTON
OUTPUT TO
PRINT HEAD
REMOVE AND
SAVE ORANGE
VACUUM CAP
INPUT FROM
CONTROLLER
INK INLET
PURGE
AT TEMPERATURE
LIGHT IS ILLUMINATED
AT
TEMPERATURE
HEATER ON
VACUUM /
RETURN
VENT
REMOVE CAP, BUT
LEAVE THE WHITE
VENT FILTER IN PLACE
RESERVOIR
ACCESS
HEATER ON
Missing Print
1. Hold a light-colored, absorbent towel under the front of the print head to catch potential ink overflow. The light-colored towel will reflect light,
making the face of the print head easier to see.
2. Press and hold the ACS/AutoPrime button for five (5) seconds until the Centralized-IDS beacon light flashes once. Observe the 1-second
ink flow out of the print head.
3. Inspect for very small air bubbles flowing out of the top of the print head and down the face.
a. If bubbles are evident, repeat steps 1 to 3 three times.
4. Perform an ACS cycle, then slowly swipe a cloth in front of the print head while pressing the All Channel Purge button on a 384E Print Head,
or while pressing the All Channel Purge button on the HMI Controller for a 768 Print Head. 100% print should be 50,8mm (2in) tall for a
384E Print Head or 101,6mm (4in) tall for a 768 Print Head.
5. If any print is still missing after all air bubbles are purged, allow the print head to remain heated.
6. Every 15 minutes, run another All Channel Purge sample to confirm 100% print.
5765-016 Operations Manual
Page 25
IJ4000 Impulse Jet
Section 2: Quick Start
Step 12: Create a Message
NOTE: Additional information on messages can be
found in the IJ4000-HMI Controller Manual (5765355).
From the Home Screen, select the Messages button, then select the New button.
Create and save the message, then exit the message editor.
Time Code
Date Code
Message Display Area
Carton Ruler
Next Field Button
Message Info
Cursor
Field Properties
Cursor / Field Coordinates
Font Selection
On-screen Keyboard
Zoom
Text
Delete Button
Quick Save
Menu
Line Field
Product Side
Product Setup
Bar Codes
Count Code
Variable Field
5765-016 Operations Manual
Logo
Page 26
IJ4000 Impulse Jet
Section 2: Quick Start
Step 13: Print a Message
1. From the Home Screen, press the Print button.
2. Select the desired message to print, and press the Print button.
3. The message will print on the next photosensor
trigger.
GREEN PAUSE INDICATOR =
READY TO PRINT
RED PLAY INDICATOR =
NOT READY TO PRINT
5765-016 Operations Manual
Page 27
IJ4000 Impulse Jet
Section 3: Maintenance and Shutdowns
Section 3: Maintenance and Shutdowns
Following are the recommended maintenance procedures to keep the IJ4000 Impulse Jet 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 O-rings on the encoder wheel are present and not worn.
3. Be sure the nuts and bolts holding the bracketry in place remain tight.
Annually:
Replace encoder O-rings (5765-206).
Recalibrate Touch Screen.
Print Head Maintenance
Daily/Shift Startup
Wear safety goggles when working with industrial inks or solutions!
Spray the appropriate cleaning solvent on a lint-free cloth and lightly wipe the front of the print head to remove foreign debris.
Spray n-propanol on a clean foam swab to clean the slot in the front of the print head. Immediately follow-up with an ACS cycle.
Inspect lines and connections for leaks. Make repairs if needed.
If system is equipped with the Automatic Cleaning System (ACS), run the cleaning cycle for each print head. (Refer to “ACS - Automatic Cleaning
System” on page 31.)
It is recommended that the system remain powered on for normal day to day operation.
5765-016 Operations Manual Rev A
Page 28
IJ4000 Impulse Jet
Section 3: Maintenance and Shutdowns
Preventive Maintenance
Periodically
1. Occasionally there will be debris build up on the front of
the print engine face that will require more attention. Typically this debris comes in the form of corrugate, dust,
glue, or the like.
2. The method for flushing the debris down will require the
Automatic Cleaning System (ACS), Impulse Jet Maintenance Spray (5760-695), a soft sponge swab (5760-832)
and lint-free cloths (6600-171).
3. Wipe debris and "angel hair" glue off the front plate area
SWAB UP
AND
DOWN
with a lint-free cloth and Impulse Jet Maintenance Spray.
4. Lightly soak a sponge swab with maintenance spray and
rub up and down in print channel.
5. Press and hold the ACS/AutoPrime button on the rear of the print head for 1/2 to 1 second. The ACS cycle will initiate.
6. Wipe the front of the print head with the lint-free cloth and maintenance spray to remove any excess ink.
7. Repeat steps 3 through 6 as required.
ACS/AUTOPRIME
BUTTON
Annually
1. Replace the vent filter on the rear of the
print head.
2. Depending on desired quality of print, print
heads may need to be returned to the factory for ultrasonic cleaning of the orifice
plate and review of the print head plumbing.
384E
VENT FILTER
(5765-241)
768
VENT FILTER
(5760-373)
5765-016 Operations Manual Rev A
Page 29
IJ4000 Impulse Jet
3. Disassemble the Combo Fitting in the vacuum line
as shown, clean and re-assemble.
Section 3: Maintenance and Shutdowns
SCREEN FILTER
COMBO
FITTING
INK FLOW
BULKHEAD FITTING
Shutdowns of Seven Days to 3 Months
Shutdown:
1. Turn off the IJ4000 Connection HUB.
2. Spray the appropriate cleaning solvent on a lint-free cloth and, before installing ship cap, lightly wipe the front of the print head to remove foreign debris. Install shipping cap (Kit: 5765-242) on print head.
Startup:
1. Remove shipping cap before power up and allow the print engines to heat up (approximately 5 minutes). Spray the appropriate cleaning solvent on a lint-free cloth and lightly wipe the front of the print head to remove foreign debris.
2. Run the Automatic Cleaning System (ACS) cycle for each print head.
NOTE: The shipping cap must be removed or the vacuum pull from the ACS cycle will corrupt print quality and potentially start an ink syphon of
the Centralized-IDS reservoir and bottle.
Shutdowns of 3 Months or Longer
During planned long-term storage of 3 months or more, as well as when storing spare print heads:
1. Follow recommendations for Seven Days or Longer.
2. It is recommended that the print head system be flushed with ScanTrue Flush Solution and that ScanTrue Flush Solution be left in the print
head during the storage period. (See “Consumables” on page 67 for part numbers.)
5765-016 Operations Manual Rev A
Page 30
IJ4000 Impulse Jet
Section 3: Maintenance and Shutdowns
ACS - Automatic Cleaning System
NOTE: If the beacon on the Centralized-IDS is in any way illuminated or flashing, the ACS will not activate. Make sure all ink faults are corrected
before attempting an ACS.
The ACS is an invaluable tool for routine cleaning of loose debris from the print engine face. The images below demonstrate print before and
after the ACS.
BEFORE ACS
5765-016 Operations Manual Rev A
AFTER ACS
Page 31
IJ4000 Impulse Jet
Section 3: Maintenance and Shutdowns
The ACS feature can be accomplished by three methods.
1. From the rear of the print head: Press and hold the ACS/AutoPrime button for 1/2 to 1 second. The ACS cycle will initiate.
2. From the controller Purge Screen:
•On the IJ4000 Home Screen, touch the More menu
MORE MENU
button to open the More Menu.
BUTTON
•Touch the Purge button to open the Purge Screen.
•Select the print head to be cleaned by touching that
print head.
•Touch the Clean Print Head button to clean the
selected print head.
Once a print head has been cleaned, verify that all
channels are printing properly by touching the All
Channel Purge button located on the back of the print
head. Swipe a sheet of cardboard or other material
across the front of the print head, at about the normal
printing distance, as the head purges. The print head
purges for three seconds each time the All Channel
Purge button is touched.
HOME SCREEN
PRINT MENU
BUTTON
PURGE
BUTTON
MORE MENU
3. From the controller Auto Clean Setup: The IJ4000 can
also be programmed to automatically clean the print
heads during regular down times in the production
schedule in increments of 30 minutes..
TOUCH THE
DESIRED HEAD
CLEAN PRINT
HEAD BUTTON
PURGE SCREEN
5765-016 Operations Manual Rev A
PURGE
BUTTON
Page 32
IJ4000 Impulse Jet
Section 3: Maintenance and Shutdowns
Centralized-IDS Maintenance
Changing Ink Containers
!
CAUTION: Replace ink only with the same type of ink as originally shipped with the unit.
The Ink Status Beacon illuminates when the ink bottle is empty, and the pump is disabled. This alerts the operator to ready a new bottle of ink,
and allows the operator at least five minutes to change the bottle before printing is disabled. If the ink bottle is not replaced within five minutes,
print will be disabled on all "Tasks" and the beacon will flash slowly.
Shutdowns of 1 Week to 3 Months
During planned shutdown periods of 1 week to 3 months, as well as when storing spare print heads:
1. Remove the ink bottle, close the reservoir vent cap and install the reservoir ship cap.
2. It is recommended that the shipping cap be installed on the print head orifice plate. This will prevent dust and debris from entering the print
head, prevent scratches to the nozzle plate and prevent overexposure to high humidity conditions.
Annually
Replace the vent filter on the Centralized Ink Delivery System (Centralized-IDS).
5765-016 Operations Manual Rev A
Page 33
IJ4000 Impulse Jet
Section 3: Maintenance and Shutdowns
Storage Life of a FACTORY SEALED Bottle of Ink
•
•
Recommended storage temperature: 4° to 40°C (40° to 104°F).
Recommended storage relative humidity: 5 - 90% relative humidity with no condensation.
At these conditions, the ink will have a storage life of 12 months from the date of manufacture. Temperatures above the recommended storage
temperature for a period greater than one week will reduce the storage life of the ink.
NOTE: Do not shake the bottle of ink before use. Agitating the ink may introduce air into the Print Head. If shaken, the bottle must sit for at least
two hours before use.
Use Life of an OPENED Bottle of Ink
The life of an opened bottle of ink, or ink exposed in the ink reservoir, is less than the storage life (expiration date). Exposure to air, temperature
and relative humidity, as well as flow of ink through the reservoir, will affect the useful life of the ink.
The ink can, under certain circumstances, absorb water; and a small percentage of water absorption can cause the ink to thicken or form a gel.
NOTE: The ink should be consumed within three months of opening the bottle.
5765-016 Operations Manual Rev A
Page 34
IJ4000 Impulse Jet
Section 4: Troubleshooting
Section 4: Troubleshooting
The IJ4000 ink jet system incorporates advanced designs, both in hardware and in software. However, if the system ever fails to perform properly, some built-in indicators will help in troubleshooting. This section will help minimize system downtime and explain some of the diagnostic features built into the system.
Print Quality
This section shows examples of various print problems and actions which should be taken to improve the print.
Problem: Minor fractures in print channels.
Possible Cause: Debris on front plate, air in channel.
Action: Run Automatic Cleaning System (ACS). Add brushes to minimize debris
build-up.
Problem: Missing Channels and Channel fractures in print channels.
Possible Cause: Excessive debris on front plate, air in channel.
Action: Wipe front plate and run Automatic Cleaning System. Add brushes to minimize debris build-up.
Problem: Missing print channels.
Possible Cause: Air in channel.
Action: Run Automatic Cleaning System. If air cannot be removed by running an
ACS cycle, run an Auto-Prime Cycle per instructions in “Missing Print” on page 25.
5765-016 Operations Manual Rev A
Page 35
IJ4000 Impulse Jet
Section 4: Troubleshooting
Problem: Missing bottom print channels.
Possible Cause: Ink build-up on lower orifices.
Action: Wipe front plate and run Automatic Cleaning System.
Problem: Fuzzy Print.
Possible Cause: Print head too far away from substrate.
Action: Move print head to within 1/8" from product.
Problem: Occasional checkerboard print pattern.
Possible Cause: Encoder slipping or bouncing on belt.
Action: Tighten encoder on belt; replace encoder o-rings, if required; replace conveyor belt with smooth seamless type belt.
5765-016 Operations Manual Rev A
Page 36
IJ4000 Impulse Jet
Section 4: Troubleshooting
Problem: Stretched out, light print, checkerboard pattern.
Possible Cause: Incorrect encoder, or incorrect line speed (set too low) if using
internal encoder.
Action: Check for correct encoder (must use Diagraph Encoder, part # 5760-820-IJ).
Problem: Short image, dark print, checkerboard pattern.
Possible Cause: Incorrect encoder or wheel size, or incorrect line speed (set too high) if
using internal encoder.
Action: Check for correct encoder (must use Diagraph Encoder, part # 5760-820-IJ).
Problem: Backwards print.
Possible Cause: Incorrect print direction specified in set-up.
Action: Re-do print head set-up to specify correct direction.
5765-016 Operations Manual Rev A
Page 37
IJ4000 Impulse Jet
Section 4: Troubleshooting
IJ4000 Impulse Jet System Trouble-Shooting
Centralized-IDS:
System Symptom
Possible Cause
Operational Test Method
Ink not pumping to
Print Head
Power Supply
Ensure Centralized-IDS switch is turned on.
Check for Power LED on Internal Power Supply Board. If LED is illuminated, check power supply
output on P2. It should be 12VDC.
PC Board
Check the LED indicators and connector voltages on the board.
LED4: Green; indicates a print head is signaling for the Liquid Pump to turn on.
LED5: Red; indicates the Waste Bottle is full.
LED7: Yellow; indicates ink is low in the Centralized-IDS Reservoir.
J3: Liquid Pump connector; 12VDC when Liquid Pump is on.
Liquid Pump
Check for 12VDC at the pump. If there is no pumping, or pump sounds weak, replace the pump.
Power Supply
Ensure Centralized-IDS switch is turned on.
Check for power LED on Internal Power Supply Board. If LED is illuminated, check power supply
output on P2. It should be 12VDC.
PC Board
Check the LED indicators and connector voltages on the board.
LED3: Green; indicates a print head is signaling for the Vacuum Pump to turn on.
LED5: Red; indicates the Waste Bottle is full.
LED6: Red; turns on, off, and flashes with the beacon. Off indicates ink is OK, On indicates ink is
low, Slow Flash (1Hz) indicates ink is out, and Fast Flash (6Hz) indicates that the Waste Bottle is
full or the pump was turned on for more than 15 seconds.
J4: Vacuum Pump connector; 12VDC when Vacuum Pump is on.
Vacuum Pump
Ensure all tubing is connected between the Print Head and the Centralized-IDS. Make sure the Ink
Separator Bottle is fully tightened. Open Centralized-IDS and remove any clogs in the line. Initiate
an ACS Cycle, and listen for the pump.
Check for 12VDC at Vacuum Pump.
No vacuum at Print
Head during ACS
Cycle. Ink is overflowing the Print
Head
5765-016 Operations Manual Rev A
Page 38
IJ4000 Impulse Jet
Section 4: Troubleshooting
Centralized-IDS (continued)
System Symptom
Possible Cause
Operational Test Method
Liquid Pump and
Power Supply
Vacuum Pump do
not turn on, and light
is off on power
switch
Ensure Centralized-IDS switch is turned on.
Check for power LED on Internal Power Supply Board. If LED is illuminated, check power supply
output on P2. It should be 12VDC.
Beacon light does
not illuminate at ink
out
Power Supply
Ensure Centralized-IDS switch is turned on.
Check for power LED on Internal Power Supply Board. If LED is illuminated, check power supply
output on P2. It should be 12VDC.
PC Board
Check the LED indicators and connector voltages on the board.
LED5: Red; indicates the Waste Bottle is full.
LED6: Red; turns on, off, and flashes with the Beacon. Off indicates ink is OK, On indicates ink is
low, Slow Flash (1Hz) indicates ink is out, and Fast Flash (6Hz) indicates the Waste Bottle is full or
the pump was turned on for more than 15 seconds.
J5: Power connector; 12VDC when power is turned on.
J1: Beacon connector; 12VDC when Beacon is on.
12V Beacon Bulb
Unplug the Beacon from the board and check the resistance of the bulb. If the bulb is open,
replace it.
5765-016 Operations Manual Rev A
Page 39
IJ4000 Impulse Jet
Section 4: Troubleshooting
Impulse Jet Print Head:
System Symptom
Possible Cause
Operational Test Method
ACS Cycle will not operate
No Centralized-IDS to Controller
Cable connection. No CentralizedIDS power. No Controller to Print
Head connection.
Inspect Centralized-IDS communication cable and ensure connection to Interface Board. See “Step 7: Electrical Cable Connections” on page 17.
Ink overfills and drips after ACS
Cycle
Waste Bottle not tightened. Vacuum Inspect Waste Bottle and ensure bottle is tight. Inspect vacuum
line disconnected, exceeded maxi- line and connections. See “ACS - Automatic Cleaning System” on
mum vacuum line length, or vacuum page 31 for maximum line lengths and installation requirements.
line coiled.
Combo Fitting/Filter needs to be
Cleaned
Clean Combo Fitting. see “ACS - Automatic Cleaning System” on
page 31.
Print Head will not heat, “At Temperature” LED never turns on
Print Engine or PC Board
Return print head to Diagraph.
Missing print.
Air in Print Head
Air in the Print Head is the most likely cause of missing channels.
Refer to “Missing Print” on page 25 for bleeding procedures.
Ink Reservoir in Print Head does not Solenoids or PC Board
refill, or no ink pumps out during an
ACS or Auto-Prime Cycle. (384E)
Return print head to Diagraph.
Print Head will not print. (384E)
Return print head to Diagraph.
PC Board
Ink Reservoir in Print Head does not Solenoids
refill, or no ink pumps out during an
ACS or Auto-Prime cycle. (768)
5765-016 Operations Manual Rev A
Remove power from the Print Head. Disconnect solenoid cable
harness. Purge, intake, and return solenoids are pinned on 1-2,
3-4, and 5-6, respectively. The Intake Valve controls ink into the
Reservoir, and the Purge Valve controls ACS and Auto-Prime.
Check the respective valve pins for resistance. An open coil
should be replaced.
Page 40
IJ4000 Impulse Jet
Section 4: Troubleshooting
Impulse Jet Print Head (continued):
System Symptom
Possible Cause
Ink Reservoir in Print Head does not PC Board
refill, or no ink pumps out during an
ACS or Auto-Prime cycle. (768)
(Continued.)
Operational Test Method
Check the LED indicators on the board.
LED2: Green; indicates Print Head is requesting Centralized-IDS
to turn Liquid Pump on.
LED9: Green; indicates Intake Solenoid Valve is open.
LED8: Green; indicates Print Head Reservoir is full.
LED3: Green; indicates Print Head Reservoir is low and Ink Out
Timer has expired.
Print Head will not print. (768)
PC Board
Make sure all print head cables and the print engine cable are
seated at each end. Check the Test Points and LED indicators on
the board.
TP1: High voltage supply to driver IC (U9). The voltage level is
set via a sense resistor in the print engine (40-150 VDC).
LEFD6: Green; indicates high voltage is low.
Photosensor Sensitivity Test
This test will determine if the photosensor sensitivity is adjusted correctly for the application.
1. Place object approximately 6,4mm (.25in) in front of photosensor; photosensor should sense object.
2. Place object near the center of the guide rails; photosensor should sense object.
3. Place object on far guide rail; photosensor should not sense object.
4. Check that objects on the far side of conveyor do not trip the photosensor.
5. Check that color differences in product do not cause multiple photosensor trips at the farthest sensing distance.
NOTE: The test object should be a sample of the actual product. For photosensor sensitivity adjustment procedure, refer to the photosensor
manufacturer’s instructions.
NOTE: If the red LED on the photosensor fails to illuminate when an object is placed in front of (but not touching) the photosensor, it indicates
that the photosensor is disconnected, or the power supply or photosensor has failed.
5765-016 Operations Manual Rev A
Page 41
IJ4000 Impulse Jet
Section 4: Troubleshooting
Encoder
Navigate the IJ4000 to the status screen. If the line speed displays a value comparable to the known line speed, then the encoder is functioning
correctly. If the line speed displays "0", then check electrical connections to the encoder and IJ4000 PCB. Refer to “Encoder” on page 51 for additional information.
5765-016 Operations Manual Rev A
Page 42
IJ4000 Impulse Jet
Appendix A: System Specifications
Appendix A: System Specifications
System
116,8mm
[4.6in]
475mm
[18.7in]
207mm
[8.1in]
247,5mm
[9.7in]
114,7mm
[4.5in]
371,3mm
[14.6in]
845,2mm
[33.3in]
669,5mm
[26in]
355,6mm
[14in]
5765-016 Operations Manual Rev A
Page 43
IJ4000 Impulse Jet
Appendix A: System Specifications
Centralized Ink Delivery
360,2mm [14.18in]
Size
Height: 518,7mm [20.42in]
Width: 371,1mm [14.61in]
Depth: 181,1mm [7.13in]
Weight: 8.2kg [18lbs]
Cable and Tubing Clearance: 127mm (5in) from the bottom of the enclosure
419,6mm
[16.52in]
IP Rating
IP54 (estimated)
Enclosure
Sealed stainless steel industrial enclosure.
Ink Filtration
25 micron built in supply reservoir
Electrical
Non-European: 103VAC to 122VAC, 60Hz, 1.0 Amp max.
European: 207VAC to 253VAC, 50Hz, 0.5 Amp max.
Normal Operating Pressure Range
0 psi to 30 psi (approximately) pump output when operating
Cable Ports
• Communication to controller
• Power cord
• Optional ink status beacon
Environment
Ambient operating temperature: 10°C to 40°C (50°F to 104°F)
Operating humidity:
• ScanTrue II Ink: 5-80% non-condensing
Tubing Limitations
Maximum vertical tube length (bottom of Centralized-IDS to bottom of highest
print head) = 6,1m (20ft) ink pump limitation.
Maximum height of Centralized-IDS or tubing above print head= 914,4mm
(36in) vacuum pump limitation.
(See “Step 6: Install Tubing” on page 16.)
Number of Heads Allowed
4
5765-016 Operations Manual Rev A
509,8mm
[20.07in]
277,6mm
[10.93in]
OPTIONAL INK
STATUS BEACON
PORT
I/O COMMUNICATION
WITH CONTROLLER
4X M6 X 25,4mm
[4X M6 X 1in]
114,3mm
[4.50in]
122,9mm
[4.84in]
38,1mm
[1.50in]
215,6mm
[8.49in]
113,5mm
[4.47in]
Page 44
IJ4000 Impulse Jet
Appendix A: System Specifications
IJ4000-HMI Controller
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.
4
[
m
m
4
,
5
1
1
]
n
i
2
0
.
3
1
[
m
m
7
,
0
3
3
]
n
i
0
5
.
1
[
m
m
1
,
8
3
]
n
i
4
9
.
3
[
m
m
0
,
0
0
1
]
n
i
2
7
.
7
[
m
m
1
,
6
9
1
]
n
i
0
5
.
4
[
m
m
3
,
4
1
1
]
n
i
6
0
.
2
[
m
m
4
,
2
5
]
n
i
1
5
.
6
[
m
m
4
,
5
6
1
]
n
i
2
6
.
1
[
m
m
3
,
1
4
4X M4 X 17,8mm
[4X M4 x .7in]
2X M8 X 31,8mm
[2X M8 X 1.25in]
Size
Weight: 2,18kg [4.6lb]
Height: 196,1mm [7.72in]
Width: 330,7mm [13.02in]
Depth: 41,3mm [1.62in]
User Interface
Graphical User Interface
with on screen keyboard
IP Rating
IP34 (estimated)
Display
259,08mm [10.2in] LCD with touch
screen, 800 x 480 pixels
Enclosure
Stainless Steel
5765-016 Operations Manual Rev A
Fonts
Unicode
Storage
512 MB flash memory
Ports
(2) RS-232 ports, 1 USB port,
(1) 100 Base-T Ethernet port
Electrical
15 VDC from power supply to controller.
power supply: 90-260 VAC, 50/0 Hz, 1.5A
max.
Environment
Ambient operating temperature: 5°C to
40°C (40°F to 104°F)
Operating humidity: 10% - 90%, non condensing
Page 45
IJ4000 Impulse Jet
Appendix A: System Specifications
IJ4000 Connection HUB
309,4mm
[12.18in]
135,6mm
[5.34in]
38,1mm
[1.50in]
38,1mm
[1.50in]
271,3mm
[10.68in]
335,0mm
[13.19in]
72,1mm
[2.84in]
3X M8 X 31.8mm
[3X M8 X 1.25in]
119,1mm
[4.69in]
Size
Weight: 5,22kg [11.5lb]
Height: 335,0mm [13.19in]
Width: 309,4mm [12.18in]
Depth: 119,1mm [4.69in]
Fonts
Unicode
IP Rating
IP54 (estimated)
Ports
(2) RS-232 Ports, (1) USB Port
(1) 100 base-T Ethernet Port
5765-016 Operations Manual Rev A
Storage
512 MB flash memory
Electrical
24 VDC, 100W, Internal Power Supply.
90-260 VAC, 50/0 Hz, 1.5A max.
Environment
Ambient operating temperature: 5°C to
40°C (40°F to 104°F)
Operating humidity: 10% - 90%, non condensing
Page 46
IJ4000 Impulse Jet
Appendix A: System Specifications
384E Print Head
Size - IJ384E Head
L: 300,8mm [11.84in]
W: 69,9mm [2.75in]
H: 127,0mm [5.0in]
Weight: 2,7kg [6 lbs]
116,8mm
[4.60in]
IP Rating
IP65 (estimated)
66,5mm
[2.62in]
280,3mm [11.04in]
Enclosure
Anodized aluminum
22,9mm [0.90in]
Electrical
24 VDC input from Connection HUB
Ink Filtration
75 micron external ink filter
25 micron in-line system inlet filter
10 micron built-in filter in print engine
Print Speed
Alpha/Numeric Text: Up to 60,96 meters per minute [200 feet per minute] @ 200 dpi; 38,1 meters per minute [125 feet per minute] @ 300
dpi.
Barcode: Up to 45.72 meters per minute [150 feet per minute].
* Higher line speeds achievable with reduction of dpi.
Print Resolution
384/128 Head: 128 addressable channels, 50,8mm [2in] solid print
height
146,8mm
[5.78in]
Ink Type
ScanTrue® II, Pigmented Ink for porous substrates, black
Environment
Ambient operating temperature: 10°C to 40°C (50°F to 104°F)
Operating humidity: 5 - 80% non-condensing
ACS (Automatic Cleaning System) Consumable usage
ScanTrue II Ink: .38mL
Throw Distance
Up to 12,7mm [1/2in]. (1,6mm [1/16in] recommended for best print
quality.)
5765-016 Operations Manual Rev A
Page 47
IJ4000 Impulse Jet
Appendix A: System Specifications
768 Print Head
Size - IJ768 Head
L: 337,6mm [13.29in]
W: 71,1mm [2.80in]
H: 160,5mm [6.32in]
Weight: 4,3kg [9.5 lbs]
198,5mm [7.81in]
IP Rating
IP54 (estimated)
Enclosure
Anodized aluminum
160,5mm [6.32in]
187,0mm [7.36in]
Electrical
24 VDC input from Connection HUB
Ink Filtration
25 micron in-line system inlet filter
10 micron built-in filter in print engine
71,1mm [2.80in]
27,1mm [1.07in]
TO LOWEST ORIFICE
Print Speed
Alpha/Numeric Text: Up to 60,96 meters per minute [200 feet per minute] @ 200 dpi; 38,1 meters per minute [125 feet per minute] @ 300
dpi.
Barcode: Up to 45.72 meters per minute [150 feet per minute].
* Higher line speeds achievable with reduction of dpi.
Print Resolution
768/256 Head: 256 addressable channels, 101,6mm [4in] solid print
height
Throw Distance
Up to 3,2mm [1/8in]. (1,6mm [1/16in] recommended for best print quality.)
5765-016 Operations Manual Rev A
337,6mm [13.29in]
Ink Type
ScanTrue® II, Pigmented Ink for porous substrates, black
Environment
Ambient operating temperature: 10°C to 40°C (50°F to 104°F)
Operating humidity: 5 - 80% non-condensing
ACS (Automatic Cleaning System) Consumable usage
ScanTrue II Ink: .38mL
Solvent: .18mL
Page 48
IJ4000 Impulse Jet
Appendix A: System Specifications
System Interconnect Diagram
1. IJ4000 HMI-Controller
2. Centralized Ink Delivery System
3. Print Head
4. Conveyor
5. Product
6. Print Head Bracketry
7. Ink Status Beacon
8. Encoder
9. Ink Supply
10. Photosensor
11. Vacuum Waste Collector Bottle
12. Encoder Cable
13. Print Head Cable
14. IJ4000 Connection HUB
15. Throw Distance (3mm [1/8in]
Recommended)
13
6
3
15
1
8
10
4
5
3
9
7
14
6
12
13
5765-016 Operations Manual Rev A
2
11
Page 49
IJ4000 Impulse Jet
Appendix B: Theory of Operation
Appendix B: Theory of Operation
Functional Description
The IJ4000 ink jet system prints text, autocodes (such as product counts or time and date stamps), barcodes, and/or graphics onto products as they travel by
conveyor past stationary print heads. Print can be on any one of, or a combination of, the product's sides. The conveyor speed is monitored using a variable
speed encoder or a built-in fixed speed encoder. Products are detected using a photosensor. The information to be printed is defined as a message and is programmed into the controller via a user interface.
Impulse Jet 384E Print Head
The IJ4000 Impulse Jet print head assembly consists of a piezoelectric impulse jet print engine, a small ink reservoir, intake, purge, and return solenoid valves,
and an electronic controller board to control both printing and fluidic management functions of the print head.
The piezoelectric impulse jet print engine has a nozzle plate with an array of orifices and a corresponding array of piezoelectric crystals. Piezoelectric crystals
expand and contract rapidly based on voltage being supplied to and removed from crystals. Very small ink droplets are ejected as a result of piezoelectric crystals expanding rapidly, creating a pressure pulse to force ink droplets out the orifices. The print engine also incorporates a heater to control the head temperature, allowing ink viscosity to be maintained over a wide spread of ambient temperatures. The head must be at the correct operating temperature before
printing. The head temperature can be monitored via the LEDs located on the back of the print head. LEDs are provided to show when the heater is on and
when the head is at appropriate temperature.
The print head electronics receive power, as well as clock, data, and latch signals from the controller, to drive the heater and the imaging capabilities of the print
engine. The print head electronics also control the ink management functions.
At the print head, ink flows in through the intake solenoid valve to fill a small print head reservoir. The ink level in the print head reservoir is maintained by a
level detect, sensing the ink level and sending a signal to the Centralized-IDS to turn on/off the ink pump. The reservoir is vented allowing atmospheric pressure
to be maintained inside the reservoir. The vent is located on the back of the print head and is filtered to ensure debris can not enter the ink reservoir. Ink is fed
from the print head ink reservoir to the print engine via gravity. Capillary action is then utilized to supply the orifices in the nozzle plate with ink.
NOTE: Since ink is fed to the print engine via gravity, it is important to maintain the print head at a level position during operation.
The print head also incorporates an Automatic Cleaning System (ACS) to remove dirt and debris from the orifice plate. A small vacuum channel has been
designed into the bottom of the nozzle plate. During an ACS cycle, a small amount of ink is pulsed through the orifices. The ACS cycle turns the vacuum pump
on in the Centralized-IDS, and pulses both the ink pump and purge solenoid to control the flow of ink out the nozzle plate. The ink and debris is vacuumed off
the nozzle plate, and drawn back to the waste collection bottle located in the Centralized-IDS. An ACS cycle can be manually initiated by pushing the ACS/
AutoPrime button located on the back of the print head. The ACS can also be programmed to run at specified times by using the IJ4000-HMI Controller.
When print head priming is required, the ink is pumped directly into the print engine, through the purge solenoid, and out through the return solenoid valve,
allowing air to be pushed out of the head. This is required only during initial set-up and when the print engine has been replaced. The ink is returned and collected in the Centralized-IDS waste collection bottle. This function can be initiated by pushing in and holding the ACS/AutoPrime button located on the back of
the head for 5 seconds.
Another function is the ability to check for 100% print from the print head. This function can be performed by momentarily pressing the All Channel Purge button on the rear of the print head while passing a substrate in front of it in a horizontal direction.
A digital level indication is provided by three LEDs located on the top rear of the enclosure. The print head is considered level, as indicated by a central green
LED, when it is within +/- 1.5° front-to-back, level to the horizon. The digital level is factory calibrated to within 0.2° absolute.
The print head is sealed at many points to protect against liquid ingress that could damage internal components.
5765-016 Operations Manual Rev A
Page 50
IJ4000 Impulse Jet
Appendix B: Theory of Operation
Print Head Daisy Chain
Print heads attach to the IJ4000 in a daisy chain configuration. The first print head plugs into a Print Head Interface Board (P1), the second print
head plugs into the first print head, the third print head plugs into the second, and so on, without exceeding the maximum number of print heads.
The maximum number of print heads for a 384E daisy chain is two. An IJ4000-HMI Controller can have one or two daisy chains (one for each
Print Head Interface Board).
Electrically, a print head daisy chain is a shift register. A shift register moves bits of information along a line one bit at a time in step with a clocking signal. It works like this: A bit is placed at the entrance to the line of bits and waits for the clock (step) signal. When the clock signal is given,
the bit steps into the first spot on the line. The bit that occupied the first spot in line steps to the second, the second steps to the third, the third to
the fourth, and so on until the last bit in line steps off the end of the line and is lost. Repeat the process enough times and all of the information in
the shift register is replaced. Repeat the process for all dots in the column. A latch (print) signal sent after the dots have been shifted prints the
column.
All daisy chain signals - DATA, CLOCK and LATCH - are generated and controlled by circuitry in the FPGA (Field Programmable Gate Array,
used as a print head driver chip) on the Print Head Interface Board.
Please note that power is applied to the print heads even when the IJ4000 is "turned off." The only way to remove power from the print heads is
to pull the plug.
Print Trigger Photosensor
The photosensor detects when a product is about to pass by the print heads and signals the IJ4000-HMI Controller to start a print cycle. The photosensor signal is active low, and it must remain low for at least one encoder pulse. Once a print cycle starts, it continues to completion regardless of what the photosensor signal does.
The IJ4000 is compatible with through-beam, retro-reflective, and diffused photosensors that work at 24VDC and have a current sinking (or open
collector) output. The photosensor plugs into the Print Head Interface Board (P2).
Encoder
The encoder determines the time period between the printing of individual columns, or the print speed. As a product's speed increases, the time
period between columns must decrease, that is, the print speed must increase, to maintain consistent column-to-column spacing. The IJ4000
has two encoder options, external and internal. Use the external encoder when the conveyor speed fluctuates. Use the internal encoder when
the conveyor speed is constant.
The external encoder is a 24VDC optical encoder. The encoder's wheel is sized such that the encoder outputs 300 pulses per inch of product
travel. The external encoder plugs into the Print Head Interface Board (J4), and its signal goes to the FPGA where it is used to time the sending
of column data to the print head.
The internal encoder signal is a constant frequency pulse stream generated on the Print Head Interface Board. A programmable counter circuit
in the FPGA divides the board's 32 MHz clock by a value calculated from a line speed entered during system setup. When the user selects the
internal encoder, a switch in the FPGA disconnects the external encoder signal from the print timing circuits and connects the output from the
counter circuit.
5765-016 Operations Manual Rev A
Page 51
IJ4000 Impulse Jet
Appendix B: Theory of Operation
Centralized Ink Delivery System (Centralized-IDS)
System Features
1. Centralized ink delivery. Ink is pumped from one location through a single tubing line that is subsequently teed downstream to all print heads
in the system. As the print heads demand more ink, the liquid pump delivers ink to the requesting print head. Although the ink line is pressurized, a print head will not receive the ink unless its intake solenoid is opened. Each print head controls its own ink level in its own reservoir.
2. Ink supply "low" detection. When the Centralized-IDS detects ink low via the float in the ink reservoir, it disables the ink pump, leaving a safe
amount of ink. The Centralized-IDS then alerts the operator by turning on the attached beacon light, and by sending a signal via I/O to the
IJ4000-HMI Controller.
3. Ink supply "out" detection. If the ink supply bottle is not replaced in a timely fashion, the next time that a print head requests ink, a timer in the
print head will start. If the ink supply has not been replaced within five minutes, print will be disabled on all print heads, and a signal will be
sent to the Centralized-IDS that will cause a slow flashing of the beacon.
4. Centralized vacuum and ink waste collector. Like the centralized ink, vacuum is supplied to all the print heads via a single tubing line that is
subsequently teed. The Centralized-IDS is equipped standard with a heavy-duty vacuum pump to assist in the Automatic Cleaning System
(ACS). Additionally, it will assist in the removal of waste ink while bleeding the tubing.
5. Ink capacity. Both the 500 mL and 1 L bottles are accommodated by the Centralized-IDS.
6. Safety. The on-board microcontroller will prevent an excessive duty cycle on the liquid pump. It also disables the liquid pump when ink is low,
and both pumps when any ink anomaly is encountered such as ink out or ink faults.
Startup Operation
After all plumbing and electrical connections have been made, toggling the power switch will initiate the Centralized-IDS. The system only
responds to input from the I/O connection to the IJ4000. This I/O connection is essentially a pass through connection to the print head bus. In
other words, the print heads control the ink pump and vacuum pump on/off states. If the print heads are not requesting ink for reservoir refill or
vacuum from an ACS cycle, then the Centralized-IDS will remain idle.
5765-016 Operations Manual Rev A
Page 52
IJ4000 Impulse Jet
Appendix B: Theory of Operation
Normal Operation
The ink bottle supplies the open-vented reservoir. The reservoir
creates the first of three stages of ink filtration. When the print
head demands ink from the Centralized-IDS, the ink pump
turns on. The ink is pulled through the reservoir filter through a
check valve and into the pump. As the ink is pulled from the
reservoir, a vacuum is created in the bottle. To equalize this
pressure differential, air is pulled through the vent into the reservoir. In order to prevent ink from spilling out the vent, the
Centralized-IDS incorporates a long vent tube with an in-line
check valve.
The pump will then push the ink to the print head that is
requesting ink until the float in the print head reservoir is satisfied. Each print head controls its own ink level by opening and
closing an intake solenoid. The Centralized-IDS operates in
this state until it encounters a different ink status.
If the Centralized-IDS includes the pressurized solvent supply,
the print head will open and close an internal solenoid to allow
flow of solvent down the face of the print head. As with ink and
vacuum, a separate tubing line is required from the Centralized-IDS. A pressurized can of solvent is the main source of
solvent. The solvent flows through a regulator into the Centralized-IDS. This supply line has a pressure sensor to detect
when the pressurized solvent can is empty. When the can is
empty, the beacon light will illuminate steady. One must determine the state of the beacon lamp by determining whether the
ink supply is visually empty or the solvent can is empty, and
then replace the appropriate material.
CAUTION
REMOVE
CAP
BEACON
INSTALL
FILTER
AIR INLET
INK PUMP
INK RESERVOIR
VACUUM PUMP
ENCLOSURE
INK WASTE
COLLECTOR
(SEPARATOR)
REMOVABLE
INK WASTE
COLLECTOR
BOTTLE
Ink Low Detection
When the ink bottle empties into the ink reservoir, a float will
drop in the reservoir. After the float drops in the reservoir, the
microcontroller will disable the liquid pump and turn on the beacon steady. This alerts the operator that it is time to replace the
ink bottle. When the ink bottle has been replaced, the Centralized-IDS will automatically extinguish the beacon light.
NOTE: The ink pump is disabled in order to inhibit an ink / airbubble mixture from getting into the impulse jet print engines.
INK BOTTLE
INK OUTLET
PORT WITH
SHIPPING CAP
VACUUM PORT WITH
SHIPPING CAP
REPRESENTS INK FLOW
SOLVENT SUPPLY TO PRINT
HEAD, WITH SHIPPING CAP
NOTE: DOOR NOT SHOWN.
5765-016 Operations Manual Rev A
Page 53
IJ4000 Impulse Jet
Appendix B: Theory of Operation
Ink Out Detection
If the steady beacon light is ignored and a print head requests ink, a timer is started in the print head microcontroller. If the ink bottle is not
replaced within five minutes, then the beacon changes to a slow flash. In addition, print is disabled on all print heads on both IJ4000 tasks.
Ink Waste Collector Full
Upon filling the ink waste collector (separator) bottle, a float level detect raises inside the separator assembly. The feature disables both pumps
inside the Centralized-IDS and illuminates the beacon with a fast flash. By disabling the pumps, overflow is not only prevented at the separator
bottle, but also at the print head by disabling the ACS feature. Additionally, the vacuum pump is prevented from pulling the ink into itself.
Once the ink separator bottle has been replaced or emptied, the Centralized-IDS power switch must be toggled off then on to reset.
Ink Fault Detection
If an ink line is not plugged into a port or is broken, the pump will turn on for a maximum of twenty seconds and then shut itself off if the print head
float sensor has signalled for shut off. After the pump cycle, the beacon will flash quickly. Functionality will emulate Ink Waste Collector Full.
Once the ink fault has been remedied, the Centralized-IDS power switch must be toggled off then on to reset.
NOTE: Never mix ink types because they are not miscible. Irreversible internal damage will occur.
Performance Parameters of an Impulse Jet Controller
The performance of an Impulse Jet controller is limited by
the DPI setting and the sum of the maximum field stacks on
each side of a message. The maximum field stack for a side
is defined as the maximum number of vertically aligned
fields. In the following example, Task1:Side1 has a maximum field stack of three fields and Task1:Side2 has a maximum field stack of two fields. Thus, the sum of the maximum
field stacks for Task1 is five fields.
Task1:Side1
(Task1:Side1) + (Task1:Side2) = 3 + 2 = 5 fields
If Task1 and Task2 are printing this same message, the sum
of the maximum field stacks of Task1 and Task2 is ten fields.
Thus, the maximum field stack the controller has to process
is ten fields.
Task1:Side2
(Task1) + (Task2) = 5 + 5 = 10 fields
5765-016 Operations Manual Rev A
Page 54
IJ4000 Impulse Jet
Appendix B: Theory of Operation
The absolute maximum line speed for an Impulse Jet task is 200 fpm. The following table can be used to determine the maximum line speed of a
controller given a maximum field stack and dpi.
Max. Field Stack
of Controller
Max. Line Speed
@ 100 dpi
Max. Line Speed
@ 150 dpi
Max. Line Speed
@ 200 dpi
10
200
200
200
11
200
200
181
12
200
200
166
13
200
200
153
14
200
190
142
15
200
177
133
16
200
166
125
17
200
156
117
18
200
148
111
19
200
140
105
20
200
133
100
The Impulse Jet Print head operational through-put (the maximum print speed) is determined by the density and resolution of the printed message. The print density is defined as the amount of printed dots in a given area, with a solid black image having a density of 100%. The higher the
density, the higher the ink flow demand is in the print head. A typical alpha-numeric message has a print density of about 20%, while a 100%
magnification I- 2 of 5 bar code, has a print density of about 40%. A full-scale logo with a heavy background can have a density of up to 70%. The
following tables identify the image rate versus print speed for various densities. The data shown is based on a 152,4mm [6in] message printing at
200 dpi horizontal resolution.
Line Speed
(meters per minute)
Line Speed
(feet per minute)
20% - 40% Density
# of Images per Sec.
Above 70% Density
# of Images per Sec.
15,24
50
2
2
30,48
100
2
2
45,72
150
2
1
60,96
200
2
1
5765-016 Operations Manual Rev A
Page 55
IJ4000 Impulse Jet
Appendix B: Theory of Operation
Centralized-IDS Board
LEDs:
Connectors:
LED1:
NOT DEFINED.
LED2:
Red; indicates a print head is signalling that the print
head reservoir is low and the ink out timer has expired.
LED3:
Green; indicates a print head is signalling for the vacuum
pump to turn on.
LED4:
Green; indicates a print head is signalling for the liquid
pump to turn on.
LED5:
Red; indicates that the waste bottle is full.
LED6:
Red; turns on, off, and flashes with the beacon. Off
indicates ink is OK, on indicates ink is low, slow flash
(1 Hz) indicates ink is out, and fast flash (6 Hz) indicates
that the waste bottle is full or the pump was turned on for
more than 10 seconds.
LED7:
Yellow; indicates ink is low in the Centralized-IDS reservoir.
SW1:
NOT DEFINED.
P1:
Centralized-IDS I/O connector.
J1:
Beacon.
J2:
External beacon.
J3:
Liquid pump.
J4:
Vacuum pump.
J5:
Power (12V).
J6:
Reservoir float switch.
J7:
Waste bottle float switch.
J8:
Programming port, for programming U1 via a PC.
J10:
Pressure sensor for flushing solvent
J11:
RFID communication
5765-016 Operations Manual Rev A
Page 56
IJ4000 Impulse Jet
Appendix B: Theory of Operation
Centralized-IDS Interconnect Diagram
P1: VAC INPUT
POWER SUPLY
CABLE, POWER SUPPLY
TO ON/OFF SWITCH
SEPARATOR
BEACON
P2: VDC OUTPUT
CABLE, POWER SUPPLY TO
PCB AND ON/OFF SWITCH LED
WASTE
BOTTLE
VACUUM
PUMP
INK DELIVERY
SYSTEM PCB
J5
J1
J10
J4
J11
CABLE, INTELLIGENT
INK SYSTEM
J7
CHASSIS
GROUND
RESERVOIR AND
INTELLIGENT INK
SYSTEM (RFID)
J6
WHITE
J3
P1
CABLE, INK RESERVOIR
J2
BLUE
BROWN
WHITE
CABLE, PCB TO LIQUID PUMP
CABLE, GROUND
GREEN/YELLOW
CABLE, IEC
CONNECTOR
TO SWITCH
BROWN
CROSSOVER CABLE
BLACK
RED
RED DOT
REAR VIEW OF
POWER ENTRY
IEC320-14
TO AC POWER
TO CONTROLLER
5765-016 Operations Manual Rev A
LIQUID PUMP
TO OPTIONAL
EXTERNAL BEACON
Page 57
IJ4000 Impulse Jet
Appendix B: Theory of Operation
IJ768 Print Head
REAR VIEW
OUTPUT TO
PRINT HEAD
INPUT FROM
CONTROLLER
INK INLET
PURGE
AT
TEMPERATURE
HEATER ON
VACUUM /
RETURN
PRINT HEAD INK INLET FILTER
INTAKE ENGINE
PRINT ENGINE
VENT
RESERVOIR
ACCESS
RETURN SOLENOID
INK/VACUUM RETURN
INK INLET
COMBO CHECK VALVE/
FILTER/ORIFICE FITTING
FILTERED VENT
PURGE SOLENOID
CHECK VALVE
5765-016 Operations Manual Rev A
INK RESERVOIR W/LEVEL DETECT
Page 58
IJ4000 Impulse Jet
Appendix B: Theory of Operation
IJ768 Print Head
Test Points:
TP1:
TP2:
TP3:
LEDs:
LED1:
LED2:
LED3:
LED4:
LED5:
LED6:
LED7:
LED8:
LED9:
LED10:
LED11:
LATCH; 5 volt logic signal. The
column is printed on the rising edge
of the LATCH signal.
CLOCK; 5 volt logic signal. Data is
shifted into the shift register on the
falling edge of the CLOCK signal.
DATA; 5 volt logic signal. Serial data
input signal to shift register.
Green; indicates print head is
requesting Centralized-IDS to turn
liquid pump on.
Green; indicates print head is
requesting Centralized-IDS to turn
vacuum pump on.
Green; indicates print head
reservoir is low and the ink out timer
has expired.
Green; indicates high voltage is low.
Green; indicates print head has reached its
operating temperature. The operating
temperature is set via a resistor in the print
engine.
Green; indicates print head is in stand-by
mode. Heater and high voltage are turned off.
Green; indicates print head reservoir is full.
Green; indicates intake valve is open.
Yellow; indicates heater is on.
Green; indicates return valve is open.
Green; indicates purge valve is open
5765-016 Operations Manual Rev A
Connectors:
SW1:
J1:
J2:
J4:
J5:
J6:
J7:
J8:
Purge switch.
Print head I/O connector.
Print engine connector.
Programming port, for programming
microcontroller via a PC.
Reservoir float switch connector.
Solenoid valve assembly connector.
(Not used.)
Flush Valve connector.
Page 59
IJ4000 Impulse Jet
Appendix B: Theory of Operation
IJ768 Print Head Interconnect Diagram
5765-016 Operations Manual Rev A
Page 60
IJ4000 Impulse Jet
Appendix C: Part Numbers
Appendix C: Part Numbers
System
Item
1
2
3
4
5
Part No.
5765-004J
5765-013384S2
5765-013384S2FL
5765-017768S2
5765-017768S2FL
5765-014DJ1
5765-014DJ2
5765-014DJ1-S
5765-014DJ2-S
5765-014EJ1
5765-014EJ2
5765-014EJ1-S
5765-014EJ2-S
5765-011S2
5765-011ES2
1
5
3
2
5765-016 Operations Manual Rev A
Description
IJ4000-HMI Controller, Stainless Enclosure, 10.2 inch Touchscreen
IJ4000 384E Print Head, Scantrue II®
IJ4000 384E Print Head, Scantrue II®, Flushed
IJ3000 768Jet Print Head, Scantrue II®
IJ3000 768Jet Print Head, Scantrue II®, Flushed
IJ4000 Connection HUB, Domestic, 1 Interface Board, Domestic
IJ4000 Connection HUB, Domestic, 2 Interface Boards, Domestic
IJ4000 Connection HUB, Domestic, 1 Interface Board, I/O Card, Domestic
IJ4000 Connection HUB, Domestic, 2 Interface Boards, I/O Card, Domestic
IJ4000 Connection HUB, Domestic, 1 Interface Board, European
IJ4000 Connection HUB, Domestic, 2 Interface Boards, European
IJ4000 Connection HUB, Domestic, 1 Interface Board, I/O Card, European
IJ4000 Connection HUB, Domestic, 2 Interface Boards, I/O Card, European
Centralized-IDS, Stainless Enclosure, Domestic, Scantrue II®
Centralized-IDS, Stainless Enclosure, European, Scantrue II®
4
Page 61
IJ4000 Impulse Jet
Appendix C: Part Numbers
Bracketry
Item
1
2
3
1
Description
IJ4000 Retracting Bracket Kit, 384E Print Head
IJ3000 Retracting Bracket Kit, 768 Print Head
IJ4000 Print Head Roller/Retractor Mounting Bracket Kit,
384E Print Head
4
5760-388
IJ3000 Print Head Roller Mounting Bracket Kit, 768 Print
Head
5
5765-249
IJ4000 T-Base Stand Kit
6
5765-250
IJ4000 Conveyor Mounting Bracket Kit
7
5760-354
Multi Print Head Conveyor Mounting Kit *
8
5760-355
Print Head Floor Mounting Kit *
9
5760-356
Multi Print Head Floor Mounting Kit w/24" Bar *
5760-357
Multi Print Head Floor Mounting Kit w/44" Bar *
* Requires Single Print Head Kits
22
Part No.
5765-245
5780-253
5765-246
8
6
4
3
5
9
7
5765-016 Operations Manual Rev A
Page 62
IJ4000 Impulse Jet
Appendix C: Part Numbers
Fittings and Tubing
Part No.
Description
Contents
Where Used
1301-468
Tubing, 1/8" ID x 1/4" OD
50 foot roll
External plumbing of impulse jet
products
5770-224
Fitting 1301-699, 1/8 Barb x 1/8 Barb
In-Line Shutoff Valve
5 fittings per kit
Effluent bottle
5765-207
Fitting 5361-338, 1/8 Barb x 1/8 Flow
Bulk-Head Male Valve
5 fittings per kit
Vacuum port on rear of print head
and bottom of Centralized-IDS
5765-208
Fitting 5361-329, 1/8 Barb x 1/8 Flow
In-Line Male
5 fittings per kit
Connects to print head ink port and
Centralized-IDS ink port, or any
female fitting
5770-226
Fitting 1900-405, 1/8 Barb x 1/8 Flow
In-Line Female Valve
5 fittings per kit
Connects to print head vacuum
port and Centralized-IDS vacuum
port, or any male fitting
5765-209
Fitting 2460-120, 1/8 Barbed Tee
5 fittings per kit
Ink and vacuum supply lines
5765-210
Fitting 2460-143, Luer Cap, Male
5 fittings per kit
Cap for vent ports on the print
head and Centralized-IDS
5765-241
Fitting 5765-562, Luer, 74 Micron,
Male
5 fittings per kit
Filter for vent port on back of print
head and top of Centralized-IDS
5765-016 Operations Manual Rev A
Page 63
IJ4000 Impulse Jet
Appendix C: Part Numbers
Centralized-IDS Assembly Kits
Item
Part No.
Description
1
5760-335
Liquid Pump Replacement
2
5760-336
Vacuum Pump Replacement
3
5760-337
PCB Replacement
4
5760-338
Power Supply Replacement
5
5760-339
Reservoir Replacement, ScanTrue® II
6
5760-340
Separator Replacement
7
5760-342
Waste Bottle Replacement, ScanTrue® II
8
5760-343
Internal Tubing & Fitting Replacement,
Non-Flushing
5760-870
Internal Tubing & Fitting Replacement, Flushing
5760-372
Beacon Replacement
9
See next page for kit contents and drawings
5765-016 Operations Manual Rev A
8
9
1
5
4
2
6
3
7
Page 64
IJ4000 Impulse Jet
Appendix C: Part Numbers
Item list for Centralized-IDS Assembly on previous page:
Item
Part No.
Description
Contents
1
5760-335
Liquid Pump
Replacement
Liquid pump 2460-230 - 1;
Hose clamp 5760-519 - 2
2
5760-336
Vacuum Pump
Replacement
Vacuum pump 5760-516 - 1
3
5760-337
PCB
Replacement
PCB 5765-520 - 1
1
2
3
LED2
LED3
J9
LED4
P1
LED6
4
5760-338
Power Supply
Replacement
LED1
Power supply 5760-507 - 1
J8
J2
LED7
5760-339
Reservoir Replacement, ScanTrue® II
Reservoir 5760-524 - 1
6
5760-340
Separator
Replacement
Separator 5760-526 - 1;
Screw 5151-001 - 2
7
5760-342
Waste Bottle
Replacement,
ScanTrue® II
Waste Bottle 5760-523 - 2
8
5760-343
(NonFlushing)
Internal Tubing &
Fitting Replacement
Tubing, 1/8 ID, 1301-468; Tubing, 3/16 ID, 1301-871;
Tubing, 3/8 ID, 1303-559; Fitting 5361-338 - 1;
Fitting 1900-758 - 1; Fitting 2460-141 - 2; Fitting 2460-144 - 2;
Fitting 2460-145 - 2; Fitting 5361-307 - 1; Fitting 5361-310 - 1;
Fitting 5361316 - 4; Fitting 5361-318 - 1; Fitting 5361-317 - 2;
Fitting 5361-320 - 1; Filter 2460-159 - 2;
Check valve 2460-165 - 1; Check valve X40081-001 - 1;
Hose clamp 5760-519 - 2
(see
previous
page)
or
5760-870
(Flushing)
9
5760-372
Beacon
Replacement
Beacon 5760-511 - 1
(shown at
right)
5760-344
External
Fitting Kit
Fitting 1900-405 - 1;
Fitting 5361-329 - 1;
Fitting 2460-120 - 2
(not shown)
5760-345
Optional
Remote Beacon
Beacon 5760-520 - 1;
Strain relief 5760-222 - 1;
Mounting bracket.
Mounting hardware
(not shown)
5760-341
Replacement Bulb
Kit, 12 VDC
Bulb 2470-142 - 2
5765-016 Operations Manual Rev A
4
SW1
J5
LED5
J3
5
J1
J6
J7
J4
5
6
7
9
Page 65
IJ4000 Impulse Jet
Appendix C: Part Numbers
Print Head Replacement Parts
768 PRINT HEAD
384E PRINT HEAD
ITEM
PART NO.
PRINT HEAD
DESCRIPTION
1
5765-238
384E
IJ4000 Roller Bracket Kit
2
5760-823
768
IJ768 Roller Bracket Kit
3
5760-835
384E & 768
Roller Replacement Kit (5 Rollers)
4
5765-242
384E
Orifice Cover Plate
5
5760-813
768
Orifice Cover Plate
6
5765-239
384E
Combo Fitting/Filter
7
5760-220
768
Combo Fitting/Filter
1
4
6
5
2
7
3
5765-016 Operations Manual Rev A
ROLLER
Page 66
IJ4000 Impulse Jet
Appendix C: Part Numbers
Consumables
Inks, Conditioners, Maintenance Sprays and Print Head Cleaning
Part No.
Description
Contents
001-0598-01D
ScanTrue® II, Pigmented Oil Based for Porous Media, Black
1 Bottle, 500mL
001-0813-01D
ScanTrue® II, Pigmented Oil Based for Porous Media, Black
1 Bottle, 1L
001-0899-01
ScanTrue® II, Flush/Storage Solution
1 Bottle, 500mL
5760-876
Impulse Jet Cleaning Solution for ScanTrue© II
2 Pack, Spray Can
5760-695
Impulse Jet Maintenance Spray for ScanTrue© II
2 Pack, Spray Can
5760-800
Start Up / Cleaning Kit
Gloves, Lint-Free Wipes and Foam Swabs
5760-832
Sponge Swabs
100 Sponge Swabs
5760-891
ScanTrue© II Flushing / Re-inking Kit
2 Bottles Flush Solution,
1 Waste Bottle, 1 Syringe and
1 Reservoir Ship Cap
6000-171
Lint-Free Wiping Cloths
300 Cloths
NOTE: Use only the same type of ink that shipped with the system. Never mix ink types.
5765-016 Operations Manual Rev A
Page 67
IJ4000 Impulse Jet
Appendix C: Part Numbers
Service Parts and Optional Equipment
Item
Part No.
Description
1
5760-820-IJ
Encoder Assembly w/Mounting Bracket & 25’ Cable
2
5760-383
Photosensor, Diffuse Type w/ 20’ Cable
3
5760-345
Beacon, Remote and Centralized-IDS
(not
shown)
2464-182-010
Extension Cable, 10’ - for Encoder or Photosensor
2464-182-025
Extension Cable, 25’ - for Encoder or Photosensor
5760-614-002
Print Head Cable Assembly, 2’
5760-614-006
Print Head Cable Assembly, 6’
5760-614-010
Print Head Cable Assembly, 10’
5760-614-015
Print Head Cable Assembly, 15’
5760-614-025
Print Head Cable Assembly, 25’
5765-206
Encoder O-Ring Replacement Kit, contains:
O-ring, 2-7/8 ID x 3-1/8 OD x 1/8 W - 3;
O-ring, 4-7/8 ID x 1/8 W - 3;
O-ring, 2.175 ID x .103 W - 2
4
5
1
2
3
4
5
5765-016 Operations Manual Rev A
O-RINGS
Page 68
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