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Illinois Tool Works IJ3000 Operation Manual

Integrated valve ink jet system
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Operations
Manual
Integrated Valve
Ink Jet System
5760-107
Revision G
1 Missouri Research Park Drive • St. Charles, MO 63304 • ServiceLine 1-800-526-2531
Illinois Tool Works Inc © 2008

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Summary of Contents for Illinois Tool Works IJ3000

  • Page 1 Operations Manual Integrated Valve Ink Jet System 5760-107 Revision G 1 Missouri Research Park Drive • St. Charles, MO 63304 • ServiceLine 1-800-526-2531 Illinois Tool Works Inc © 2008...
  • Page 3 Diagraph reserves the right to change or alter any information or technical specifications at any time and without notice. ©2008 Illinois Tool Works Inc All rights reserved Printed in the United States of America...
  • Page 5 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.

  • Page 7: Section 1: Introduction

    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.)
  • Page 8 Integrated Valve Section 1: Introduction Page 2 of 106 5760-107 Operations Manual Rev G...

  • Page 9: Section 2: Safety

    Integrated Valve Section 2: Safety 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.
  • Page 10 Integrated Valve Section 2: Safety Page 4 of 106 5760-107 Operations Manual Rev G...

  • Page 11: Section 3: System Components

    Integrated Valve Section 3: System Components Section 3: System Components 1 IJ3000 Controller 2 IDS3000 3 Print Heads 4 Conveyor 5 Product 6 Print Head Bracketry 7 Ink Status Beacon 8 Encoder 9 Ink Supply Container 10 Photosensor 11 Ink Level Detect...
  • Page 12 Integrated Valve Section 3: System Components 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-XLS Controller Assemblies 5760-009SV1D Stainless Enclosure, Single Interface, Domestic 5760-009SV2D Stainless Enclosure, Dual Interface, Domestic...
  • Page 13 Controller/IDS Pedestal Mounting Kit 5760-352 Controller/IDS T-Base Mounting Kit 5760-362 Controller 90° Pivot Bracket Kit 5765-200 IJ3000-ES Conveyor Mounting Kit (Also see page 11) Print Head Cables (when using IDS3000) 5700-245-002 Print Head Cable Assembly, 2’ 5700-245-010 Print Head Cable Assembly, 10’...
  • Page 14 Integrated Valve Section 3: System Components Part Number Description Encoder and Photosensor 5760-820-IJ Encoder Assembly w/Mounting Bracket & 25’ Cable 5760-383 Photosensor, Diffuse Type & 20’ Cable 2464182-010 Encoder or Photosensor Extension Cable, 10’ 2464182-025 Encoder or Photosensor Extension Cable, 25’ Ink Cap Assemblies and Plumbing 5760-307 5 Gallon Ink Cap Assembly...
  • Page 15 A hinged cover provides access to replace- able parts. The IJ3000 Integrated Valve Controller can control any combination of IV9 Dot and IV18 Dot print heads totaling 72 dots per interface board. IDS3000 Ink Delivery System The Ink Delivery System (IDS) provides ink to the print heads.
  • Page 16 Integrated Valve Section 3: System Components IDS3000-ES Ink Delivery System The IDS3000-ES Ink Delivery System provides pres- I NK O UT BEACON surized ink to the integrated valve print heads. The sys- tem contains an ink pump, fluid capacitor and printed circuit board to control ink supply to the print heads.
  • Page 17 Other mounting options for the controller and IDS include the T-stand and pedestal mount, shown below. Assembly instructions are included with parts kits. PEDESTAL MOUNT T-STAND T-STAND IJ3000-ES 5765-200 IDS3000-ES CONVEYOR MOUNT 5760-107 Operations Manual Rev G Page 11 of 106...
  • Page 18 Integrated Valve Section 3: System Components 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 •...
  • Page 19 Integrated Valve Section 3: System Components DOUBLE POLE FLOOR MOUNT MULTI-PANEL FLOOR MOUNT 5760-107 Operations Manual Rev G Page 13 of 106...
  • Page 20 Integrated Valve Section 3: System Components 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.
  • Page 21 Integrated Valve Section 3: System Components Print Head Models The following table lists the eight models of Diagraph I.V. print heads and their characteris- tics. Total Photo- Non- Non- Part Non- cell to Type Characteristics Print Print Number Print First Base Area Dot (C)

  • Page 22: Ink Supply

    Integrated Valve Section 3: System Components Ink Regulator The ink regulator, supplied with the print head, regulates ink pressure to the print head. The regulator is preset at the factory to the correct output pressure. • Porous Ink Regulator 5701-502 •...

  • Page 23: Section 4: Installation

    Integrated Valve Section 4: Installation Section 4: Installation System Overview The figure below illustrates a typical install, with conveyor-mounted controller and print heads. (Cables and ink lines are not shown.) IJ3000-XLS IJ3000-ES 5760-107 Operations Manual Rev G Page 17 of 106...

  • Page 24: Testing The Electrical Outlet

    ATTENTION: On doit installer à côté de l'appareil une prise de courant facilement accessi- ble. Before installing the IJ3000 system, verify the integrity of the 115VAC sourced power, in accordance with the National Electric Code (NEC) and approved local electrical codes. If using a standard AC outlet, use the following procedure to verify the integrity of your outlet.
  • Page 25 Components” on page 5 and following. Corner brackets are attached to aluminum bars as shown. Controller/IDS Mounting Plates ATTACHING CORNER BRACKET Single T-nut 2-Hole Corner Bracket Corner Bracket CONTROLLER/IDS BRACKETRY IJ3000 IDS3000 CONVEYOR-MOUNTED CONTROLLER AND IDS 5760-107 Operations Manual Rev G Page 19 of 106...
  • Page 26 Integrated Valve Section 4: Installation Print Head Bracketry This section shows bracketry for conveyor-mounted print heads. The bracketry can be assembled in two different configurations, as shown below. See “Section 3: System Com- ponents” on page 5 and following for other print head bracketry options. With all conveyor-mounted options, plant maintenance will need to drill holes in the con- veyor for final attachment.

  • Page 27: Mounting The Photosensor

    Integrated Valve Section 4: Installation Mounting the Photosensor 1. Position the photosensor (5760-383) upstream from the first print head. The maximum placement distance is 81 inches from the photocell to the print head. 2. The photosensor depth range can be adjusted. Refer to the photosensor manufac- turer’s instruction sheet for instructions on adjusting the range.

  • Page 28: Controller Connections

    Integrated Valve Section 4: Installation The Encoder The encoder (5760-820-IJ) uses a wheel that rolls against the conveyor belt to track the speed. It sends a signal to the controller, which makes Conveyor adjustments reported changes in the line speed. It is not necessary to install the encoder immediately adja- cent to the print heads.
  • Page 29 All controller cables must be routed through the strain relief cable clamp in the back of the controller (applicable on IJ3000-LS and IJ3000-XLS only). The controller to print head cable must be connected to the highest vertical head. Print head to print head cables...
  • Page 30 NOTE: The optional second Interface Board is available for IJ3000-LS and IJ3000-XLS only. The IJ3000 ships standard with one interface board, capable of printing up to 72 dots on a maximum of eight print heads. A second interface board can be added for capability up to 144 dots.
  • Page 31 Integrated Valve Section 4: Installation Attaching Ink Regulators 1. Attach a single T-nut loosely to the bottom side of the regulator bracket. 2. Slide the regulator bracket and T-nut into the slotted bar and tighten into place. Plumbing the System All ink line connections should be as short as possible.
  • Page 32 Integrated Valve Section 4: Installation POWER CORD BEACON ETHERNET INK LOW LEVEL DETECT INK OUT TO PRINTER FILTERED INK INLET FILTER 2. Insert the female connector end [E] of the ink regulator tubing assembly over the male fitting on the T connector. Attach the male connector end [L] of the ink regulator tubing assembly to the female connector [M] ink inlet port of the first print head.
  • Page 33 Integrated Valve Section 4: Installation Connecting the Ink Supply Wear eye protection and use appropriate safety equipment when working with ink. 1. Place a pail of Diagraph ink within eight feet of the IDS. 2. Unscrew the shipping cap from the pail. Insert the cap assembly and tighten snugly by hand.

  • Page 34: Priming The System

    Integrated Valve Section 4: Installation Priming the System IDS3000 To prime the IDS3000 for the first time after installa- tion, hold the prime button and simultaneously depress the Power button. The pump will automati- Prime cally start, and will run for up to 20 cycles, pushing ink into the lines.
  • Page 35 Integrated Valve Section 4: Installation Checking Ink Pressure Variations in ink pressure produce differ- ent dot sizes; the higher the pressure, the larger the dot. However, over-pressuriz- ing a print head can result in leakage, or cause ink to shoot across the conveyor. Under-pressurizing can cause ink to drip from the front plate while printing;...
  • Page 36 Integrated Valve Section 4: Installation Setting Ink Pressure NOTE: The pressure regulator shipped with the print head is pre-set at the factory and should NOT require adjustment. Bleed all air from regulator before adjusting set pressure. Tools and materials required: •...
  • Page 37 Integrated Valve Section 4: Installation Print Head Operation Initial Startup and Power Save: When the print LED DISPLAY head is connected to the electronic cable, the PRINT HEAD CABLE INLET display shows the center decimal point to signify there is power. This is the Power Save mode. PUSH BUTTON This mode saves energy by not powering all the MEMBRANE SWITCH...
  • Page 38 After the equipment installation is complete (including all ink line and electrical connec- tions), a print head purge should be performed. Power On both the IJ3000 Controller and the IDS3000 Ink Delivery System. Prior to purging the print heads, the Print Station Config- uration needs to be set up on the IJ3000 Controller, per the following instructions.
  • Page 39 Integrated Valve Section 4: Installation Specifying Number of Print Heads Touch the up/down arrows to set the number of print heads on each side of the conveyor. The illustration at the top of the screen will automatically change to reflect your choices. In the example at right, four print heads have been speci- fied on the near side and two on the far side of the conveyor.
  • Page 40 Integrated Valve Section 4: Installation Defining Print Head Properties The final step in print head configuration is defining the properties of the individual print heads. Beginning with print head number one and working in numerical order, you will need to define the following: •...
  • Page 41 Integrated Valve Section 4: Installation Purging Print Heads Purge all heads with ink as follows: 1. On the Home Screen menu, select Print. 2. On the Print menu, select Purge. 3. Touch the head you wish to purge first. 4. Hold a lint-free wipe in front of the print head.
  • Page 42 Integrated Valve Section 4: Installation Page 36 of 106 5760-107 Operations Manual Rev G...

  • Page 43: Section 5: Frequently Asked Questions

    Integrated Valve Section 5: Frequently Asked Questions Section 5: Frequently Asked Questions Q: How do I fine-tune my print so all the message lines are aligned flush left? A: Adjust the Product Sensor Offset. This is the distance in inches between the center of the photosensor and the center of the print head.
  • Page 44 Integrated Valve Section 5: Frequently Asked Questions Page 38 of 106 5760-107 Operations Manual Rev G...

  • Page 45: Section 6: Maintenance

    Integrated Valve Section 6: Maintenance Section 6: Maintenance The following are the recommended maintenance procedures to keep the IJ3000 ink jet system printing cleanly and efficiently. System Maintenance Intermittent (as required): 1. Be sure the photosensor is clean and free of debris.
  • Page 46 Integrated Valve Section 6: Maintenance Shutdowns of Seven Days or Longer For extended shut down periods, it is recommended that the print head(s), regulator(s) and IDS3000 Ink Deliv- ery System be thoroughly flushed with appropriate conditioner. In order to perform this procedure, an ade- INK OR quate supply of conditioner and an BLEED PORT...
  • Page 47 Integrated Valve Section 6: Maintenance IDS Maintenance Changing Ink Containers CAUTION: Porous ink must be used with a porous IDS. Non-porous ink must be used with a non-porous IDS. The IDS can not be flushed to use a different ink type. Beacon Status &...
  • Page 48 Integrated Valve Section 6: Maintenance The following procedure explains how to change ink while the system continues to print. Determine whether the system is using porous (TWP) or non-porous (TSO) ink, and replace with the same type of ink. Changing ink colors is a two step process: first flush the system with the appropriate condi- tioner for your ink type, then change ink colors - making sure to use the same ink type.
  • Page 49 Integrated Valve Section 6: Maintenance Ink Regulator Maintenance The following maintenance procedure can remove obstructions from the valve seat area of the ink regulator, restoring normal operation: 1. Unplug the ink regulator from the print head. (Ink may be used, but conditioner is pre- ferred for this procedure).
  • Page 50 Integrated Valve Section 6: Maintenance Page 44 of 106 5760-107 Operations Manual Rev G...

  • Page 51: Section 7: Troubleshooting

    Section 7: Troubleshooting Section 7: Troubleshooting The IJ3000 ink jet system incorporates advanced designs, both in hardware and in soft- ware. 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.
  • Page 52 Integrated Valve Section 7: Troubleshooting Print Test This test will determine if the print heads are printing. 1. Place cloth in front of print head front plate. 2. Initiate print cycle by tripping photocell. 3. Encoder must be spinning if using an external device. 4.
  • Page 53 17 to 30 psig. Normal operation of the P.I.C. IDS is 15 psig. Encoder Navigate the IJ3000 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 IJ3000 PCB.

  • Page 54: Print Quality Troubleshooting

    Integrated Valve Section 7: Troubleshooting Print Quality Troubleshooting Diagnosis HOW TO USE THIS SECTION: 1. Look at the problem characters on your substrate and compare them with the figure below to diagnose the exact name for the problem. 2. Look at the next segment entitled "Print Quality Definitions" to verify that you classified the problem correctly.
  • Page 55 Integrated Valve Section 7: Troubleshooting Print Quality Definitions [1] Internal Dot Size Variation The system prints dots that are different in size. [2] Extra Dots The system continues to print dots outside the designated dot columns. [3] Tails The system prints dots with small trails of ink. [4] Splatter The system prints shapeless dots surrounded by tiny "aerosol"...
  • Page 56 Integrated Valve Section 7: Troubleshooting PRINT QUALITY POSSIBLE CAUSE PROBLEM Internal Dot Size Variation • Low ink pressure Extra Dots • High ink pressure • Pulse width set too high • Incorrect pre-load Tails • Print head too far from the target •...
  • Page 57 Integrated Valve Section 7: Troubleshooting Ink Regulator If print dot size is fluctuating, check the print head pressure. If the dot size fluctuations can be correlated to changes in ink pressure, the ink regulator may be in need of service. Dot diameters will decrease if the regulator input pressure is less than 10 PSIG.
  • Page 58 Integrated Valve Section 7: Troubleshooting Cleaning the Front Plate of a Clogged Print Head If dots are missing from the print, the print head front plate may have dried ink or debris covering the orifices. To clean the front plate: 1.
  • Page 59 Integrated Valve Section 7: Troubleshooting Print Head Pre-Load Adjustment Pre-load adjustment is sometimes required, as print head components wear over time. Pre-load adjustment may be required under the following conditions: • Excessive or constant ink leakage. • Poor print quality in the form of tails, extra dots, splattering, or a stuck open valve. •...
  • Page 60 Integrated Valve Section 7: Troubleshooting 6. Identify the orifice that is leaking from the diagrams at right and below. 7. Use the diagrams at right and below to locate the adjustment nut that controls the leaking orifice. 8. Using the solenoid adjustment tool, SLOWLY AND CAREFULLY turn the adjustment nut counterclockwise VIEW OF FRONT PLATE approximately 1/8 turn to add additional pressure to the...

  • Page 61: Appendix A: System Specifications

    Integrated Valve Appendix A: System Specifications Appendix A: System Specifications IV9 Dot Print Head .05" [1.3mm] 3.60" [91.4mm] .25" [6.4mm] 4.40" [111.7mm] 45° 15.5° .25" [6.3mm] .90" [22.9mm] 3.50" [88.9mm] 8.38" [212.8mm] 11.38" [289.0mm] 1.50" [38.1mm] .40" [10.2mm] Ø.32" [Ø8.2mm] 4.45"...
  • Page 62 Integrated Valve Appendix A: System Specifications IV18 Dot Print Head 4.00" [101.6mm] .18" [4.6mm] 55° 4.78" [121.4mm] .64" [16.3mm] 15° .89" [22.7mm] 3.28" [83.4mm] 8.93" [226.9mm] 11.35" [288.2mm] 9.45" [239.9mm] 1.50" [38.1mm] Ø.33" [Ø8.3mm] 4.92" [124.9mm] .30" [7.6mm] 7.75" [196.8mm] 1.50"...
  • Page 63 Integrated Valve Appendix A: System Specifications IDS3000 Ink Delivery System Size Height: 5.7" (144mm) Width: 12.0" (304.8mm) Depth: 10.0" (255mm) Weight: 14 lb. (6.4kg) Cable Clearance: 3" from the rear of the 10.0” TOP VIEW [255mm] Enclosure Stainless steel Ink Filtration 100 micron absolute (5760-319 Ink Filter Assembly) 12.0”...
  • Page 64 Integrated Valve Appendix A: System Specifications IDS3000-ES Ink Delivery System Size Height: 10.8" (274mm) Width: 10.4": (263mm) Depth: 3.7" (93mm) Weight: 10.7 lb (4.9 kg) Cable and Plumbing Clear- 10.8 [274mm] ance: 3" from the bottom of the IDS Enclosure 8.0 [203mm] Powder-coat painted steel Mounting...

  • Page 65: Appendix B: Pressurized Ink Can Ink Delivery System

    Integrated Valve Appendix B: Pressurized Ink Can Ink Delivery System Appendix B: Pressurized Ink Can Ink Delivery System WARNING: Do not install a can of ink until all plumbing connections have been made. Wear eye protection and use appropriate safety equipment when working with ink. CAUTION: Porous ink must be used with a porous IDS.

  • Page 66: Installation

    Integrated Valve Appendix B: Pressurized Ink Can Ink Delivery System Consumables Product Part Number Package Porous (Water-based) Conditioner, TWP, Can 5750-242 2/case Ink, TWP-101 Black, Can 5750-243 6/case Ink, TWP-3 Green, Can 5750-246 6/case Ink, TWP-2 Red, Can 5750-244 6/case Maintenance Spray, TWP, Can 5750-249 2/case...

  • Page 67: Controller Setup

    Integrated Valve Appendix B: Pressurized Ink Can Ink Delivery System DIAGRAM A PRINT HEAD INK INLET PORT (1900-758) PRESSURIZED CAN IDS VALVE, STRAIGHT, 1/8" BARB, 1/8" FLOW (1900-757) INK OUTLET BLEED PORT PRINTHEAD SUPPLY LINE (1900-401) 1/8 ID TUBING 1301-468) REGULATOR REGULATOR VALVE, STRAIGHT, 1/4"...

  • Page 68: Specifications

    Integrated Valve Appendix B: Pressurized Ink Can Ink Delivery System Replacing the Ink Can As the ink can empties, ink pressure will drop below normal operating pressure. The con- troller will display an "Ink Low" warning when pressure at the print head drops below 5.8 PSI and an "Ink Out"...

  • Page 69: Appendix C: Theory Of Operation

    A daisy chain can be up to 72 dots long (eight IV9 Dot heads, four IV18 Dot heads, or a combination of IV9 Dot and IV18 Dot heads totaling no more than 72 dots), and an IJ3000 can have one or two daisy chains (one for each Print Head Inter- face Board).
  • Page 70 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 IJ3000 has two encoder options, external and internal. Use the external encoder where the conveyor speed fluctuates. You can use the internal encoder when the conveyor speed is constant.
  • Page 71 Integrated Valve Appendix C: Theory of Operation IV Print Head Theory of Operation Integrated Valve inkjet technol- ogy utilizes electronically con- trolled solenoid valves to open and close the flow of pressurized ink through a series of holes, channels, and small orifices. Regulated ink pressure is sup- plied to the rear of the print head.
  • Page 72 IDS3000 when the container is almost empty. The IDS3000 then alerts the operator by turning on the beacon light, and by sending a sig- nal via ethernet to the IJ3000 controller. 3. Ink supply "out" detection. After the ink container float has dropped low and the...
  • Page 73 IDS3000. This conditional information is then passed on to the user via a fixed "on" beacon light to the IJ3000 control- ler via ethernet. Note that the low ink condition has no operational effect on the system. It is merely a notification to the user that a new ink supply should be at the ready.
  • Page 74 Integrated Valve Appendix C: Theory of Operation Temporary Broken Line Override Feature During first-time priming after installation, or other instances when it is necessary to purge air out of downstream ink lines, the broken line detection feature can be temporarily over- ridden by holding the prime button and simultaneously toggling the power button.
  • Page 75 Integrated Valve Appendix C: Theory of Operation IDS3000 Board Test Points LED2 LED1 IDS BOARD TP11 TP10 LED3 LED4 TP12 TRANS PUMP Test Points: TP4, TP5: (TP4 - TP5) = 1.2mV/PSI at the pressure sensor TP6: 0.1V/PSI of pressure TP7: Toggles at the end of a pressure sampling period TP8: TP9:...
  • Page 76 Integrated Valve Appendix C: Theory of Operation IDS3000-ES Ink Delivery System Features The IDS3000-ES Ink Delivery System provides ink to the print heads. In addition to pump- ing ink from the supply container, the IDS3000-ES is programmed with the following fea- tures: 1.
  • Page 77 Integrated Valve Appendix C: Theory of Operation Operation After the appropriate fluid lines are plumbed to the inlet and outlet ports and all electrical connections are made, the IDS3000-ES can be turned ON. Depressing the ON/OFF switch starts the process of automatically flushing the IDS3000-ES with the supply fluid. Ink is sucked from the supply tube in the tank, through the filter, and into the IDS3000-ES pump.
  • Page 78 Integrated Valve Appendix C: Theory of Operation IDS3000-ES Board Test Points Test Points: TP1, TP4: (TP4 - TP5) = 1.2mV/PSI at the pressure sensor TP2: 0.1V/PSI of pressure TP3: Toggles at the end of a pressure sampling period TP5: 24VDC TP6: 50VDC (approx.) unregulated from IDS power supply TP7:...

  • Page 79: Appendix D: Interconnect Diagrams

    Integrated Valve Appendix D: Interconnect Diagrams Appendix D: Interconnect Diagrams IDS3000 Wiring Diagram For Non-European Countries (115V) 5760-107 Operations Manual Rev G Page 73 of 106...
  • Page 80 Integrated Valve Appendix D: Interconnect Diagrams IDS3000-ES Wiring Diagram for Non-European Countries (115V) Page 74 of 106 5760-107 Operations Manual Rev G...
  • Page 81 Integrated Valve Appendix D: Interconnect Diagrams IV9 Dot or IV18 Dot 5760-107 Operations Manual Rev G Page 75 of 106...
  • Page 82 Integrated Valve Appendix D: Interconnect Diagrams Page 76 of 106 5760-107 Operations Manual Rev G...

  • Page 83: Appendix E: Part Numbers - Consumables And Service Parts

    Integrated Valve Appendix E: Part Numbers - Consumables and Service Parts Appendix E: Part Numbers - Consumables and Service Parts Consumables Inks, Conditioners and Maintenance Sprays The following is a partial list of inks offered by Diagraph. Your sales representative can advise you on the proper ink for your application.
  • Page 84 Integrated Valve Appendix E: Part Numbers - Consumables and Service Parts Service Parts BEACON ETHERNET POWER CORD INK LOW LEVEL DETECT PRINT HEAD FITTING, VALVE, PRINT HEAD INK INLET PORT (1900-758) FITTING, VALVE, 1/8" TUBING, IN-LINE (1900-757) FITTING, VALVE, PRINT HEAD BLEED PORT TUBING, 1/8"...
  • Page 85 Integrated Valve Appendix E: Part Numbers - Consumables and Service Parts Fittings and Tubing KIT NO. DESCRIPTION CON- WHERE USED TENTS 1301-468 Tubing, 1/8" ID x 1/4" 50 foot Plumbing line roll between trunk line and print head 1301-875 Tubing, 1/4" ID x 3/8" 50 foot Plumbing trunk line roll...
  • Page 86 Integrated Valve Appendix E: Part Numbers - Consumables and Service Parts IDS3000 Assembly Kits See item list on next page. Filter Assembly Only Filter Ink Out To IDS Filter Assembly with Tubing and Fittings Ink Cap Assembly Level Detect (To IDS) Low Ink Beacon (To IDS) 5-Gallon...
  • Page 87 Integrated Valve Appendix E: Part Numbers - Consumables and Service Parts IDS3000-ES Assembly Kits See item list on next page. Filter Assembly Only Filter Ink Out To IDS Filter Assembly with Tubing and Fittings Ink Cap Assembly Level Detect (To IDS) Low Ink Beacon (To IDS) 5-Gallon...
  • Page 88 Integrated Valve Appendix E: Part Numbers - Consumables and Service Parts ITEM KIT NO. DESCRIPTION CONTENTS - QUANTITY 5760-300 Spare Parts Kit Bulb - 1; shown Power Fuse - 2; Light Fuse - 2 5770-235 PCB Replacement Kit PCB - 1 5760-314 Transformer Replacement Kit Transformer - 1...
  • Page 89 Integrated Valve Appendix E: Part Numbers - Consumables and Service Parts IV9 Dot Print Head Replacement Part Kits Regulator adjustment locking screw Connect to the ink supply trunk line Pull adjustment Adjustment knob knob to unlock Ink input line Ink output line Direction of ink flow INK REGULATOR...
  • Page 90 Integrated Valve Appendix E: Part Numbers - Consumables and Service Parts IV18 Dot Print Head Replacement Part Kits Regulator adjustment locking screw Connect to the ink supply trunk line Pull adjustment Adjustment knob knob to unlock Ink input line Ink output line Direction of ink flow INK REGULATOR...
  • Page 91 Integrated Valve Appendix E: Part Numbers - Consumables and Service Parts Encoder Replacement Part Kit O-RINGS KIT NO. DESCRIPTION CONTENTS - QUANTITY 5765-206 Encoder O-Ring Replacement Kit O-Ring, 2-7/8 ID x 3-1/8 OD x 1/8 - 3; O-Ring, 4-7/8 ID x 1/8 W - 3; O-Ring, 2.175 ID x .103 W - 2 5760-107 Operations Manual Rev G Page 85 of 106...
  • Page 92 Integrated Valve Appendix E: Part Numbers - Consumables and Service Parts Page 86 of 106 5760-107 Operations Manual Rev G...

  • Page 93: Appendix F: Maximum Dpi Calculation For A Given Line Speed

    Integrated Valve Appendix F: Maximum dpi Calculation for a Given Line Appendix F: Maximum dpi Calculation for a Given Line Speed The maximum line speed of an I.V. print head is limited by the maximum frequency of the solenoid, which is 1000 Hz. The following steps will determine the operating frequency of the solenoids in the application.
  • Page 94 Integrated Valve Appendix F: Maximum dpi Calculation for a Given Line Page 88 of 106 5760-107 Operations Manual Rev G...

  • Page 95: Appendix G: Font Samples

    Integrated Valve Appendix G: Font Samples Appendix G: Font Samples Character appearance is affected by weight and dots per inch (dpi). Character weights available are single dot and bold (double dot). The term "fixed" means the space allotted per character is the same regardless of the character. (An "I" occupies the same space as a "W".) PRINT SAMPLES FOR A ½"...
  • Page 96 Integrated Valve Appendix G: Font Samples 9-dot (single dot) 12.5 9-dot bold (double dot) fixed 12.5 PRINT SAMPLES FOR A 1" IV18 DOT PRINT HEAD 18-dot bold (double dot) Page 90 of 106 5760-107 Operations Manual Rev G...
  • Page 97 Integrated Valve Appendix G: Font Samples 3 x 5-dot (single dot) 16.67 9-dot (single dot), 9-dot bold (double dot) 16.67 5-dot (single dot), 9-dot (single dot) 16.67 5760-107 Operations Manual Rev G Page 91 of 106...
  • Page 98 Integrated Valve Appendix G: Font Samples PRINT SAMPLES FOR A 7/8" IV9 DOT PRINT HEAD (CAN ALSO BE PRINTED WITH A 2" IV18 DOT PRINT HEAD) 5-dot (single dot) 12.5 16.67 7-dot (single dot) fixed 12.5 Page 92 of 106 5760-107 Operations Manual Rev G...
  • Page 99 Integrated Valve Appendix G: Font Samples 7-dot bold (double dot) 12.5 9-dot (single dot) 12.5 5760-107 Operations Manual Rev G Page 93 of 106...
  • Page 100 Integrated Valve Appendix G: Font Samples 9-dot bold (double dot) 12.5 PRINT SAMPLES FOR A 2" IV18 DOT PRINT HEAD 18-dot bold (double dot) Page 94 of 106 5760-107 Operations Manual Rev G...
  • Page 101 Integrated Valve Appendix G: Font Samples 18-dot bold (double dot) 16.67 9-dot (single dot), 9-dot bold (double dot) 16.67 5760-107 Operations Manual Rev G Page 95 of 106...
  • Page 102 Integrated Valve Appendix G: Font Samples 5-dot (single dot), 9-dot (single dot) 16.67 Page 96 of 106 5760-107 Operations Manual Rev G...

  • Page 103: Appendix H: Setting The Ip Address Of An Ids3000

    Integrated Valve Appendix H: Setting the IP Address of an IDS3000 Appendix H: Setting the IP Address of an IDS3000 Equipment Needed • IDS3000 • PC with an Ethernet port • Ethernet crossover cable (Diagraph part number 5760-240, shipped with the IDS3000) •...
  • Page 104 Integrated Valve Appendix H: Setting the IP Address of an IDS3000 5. Plug one end of the Ethernet crossover cable into P1 on the circuit board. Plug the other end into the Ethernet connector on your PC. 6. Plug in the IDS3000 and turn it on. 7.

  • Page 105: Appendix I: Testing An Electrical Outlet

    Integrated Valve Appendix I: Testing an Electrical Outlet Appendix I: Testing an Electrical Outlet An outlet tester is the preferred method of checking an electrical outlet, although a voltme- ter can also be used. 115VAC 115VAC 115VAC 115VAC 115VAC 115VAC CORRECTLY WIRED INCORRECTLY WIRED INCORRECTLY WIRED...
  • Page 106 Integrated Valve Appendix I: Testing an Electrical Outlet Page 100 of 106 5760-107 Operations Manual Rev G...

  • Page 107: Appendix J: Electrostatic Discharge (Esd)

    Integrated Valve Appendix J: Electrostatic Discharge (ESD) Appendix J: Electrostatic Discharge (ESD) What is ESD? Electrostatic Discharge (ESD) is a triboelectric charge generated by separating or rubbing together two non-conductive materials. What causes ESD? Friction can cause ESD. Friction can be generated by walking across a floor, removing tape from a tape dispenser, pulling a work order from a plastic work order holder, rolling the wheels of a push-cart across the floor, sitting on a foam cushion such as a stool or blowing air across a nonconductive surface.
  • Page 108 Integrated Valve Appendix J: Electrostatic Discharge (ESD) Page 102 of 106 5760-107 Operations Manual Rev G...

  • Page 109: Appendix K: Encoder Functional Testing

    Appendix K: Encoder Functional Testing Appendix K: Encoder Functional Testing In the event of print quality problems that point to variations in encoder performance or location with an IJ3000 Ink Jet System, this procedure will help to verify proper encoder function. Tools: •...
  • Page 110 Integrated Valve Appendix K: Encoder Functional Testing When you're satisfied that the encoder is tracking normally, you can calculate the encoder frequency as follows: Measure the time from the leading edge of one of the 5-volt square waves to the leading edge of the one next to it.

  • Page 111: Appendix L: Glossary Of Terms

    Internal Dot Size Variation - Dots are dif- ing up to 72 dots, connected to one inter- ferent in size at the intersection of a dot col- face board. The IJ3000 can control one or umn and a dot row. two daisy chains.
  • Page 112 Integrated Valve Appendix L: Glossary of Terms Print Indentation -The sum of two mea- Print Station - One or more print heads set surements: The distance from the photo- up to mark a given product in a specified sensor to the center of the print head, plus location.

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