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Illinois Tool Works IJ300 Operation Manual

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Operations
Manual
Controller
5760-121
Revision B
1 Missouri Research Park Drive • St. Charles, MO 63304 • ServiceLine 1-800-526-2531
Illinois Tool Works Inc © 2005

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  • Page 1 Operations Manual Controller 5760-121 Revision B 1 Missouri Research Park Drive • St. Charles, MO 63304 • ServiceLine 1-800-526-2531 Illinois Tool Works Inc © 2005...
  • Page 3 Diagraph reserves the right to change or alter any information or technical specifications at any time and without notice. ©2005 Illinois Tool Works Inc All rights reserved Printed in the United States of America...
  • Page 5 Controller Warranty: The IJ3000 Controller, including all components unless otherwise specified, carries a limited warranty. For all warranty terms and conditions, contact Diagraph an ITW Company for a complete copy of the Limited Warranty Statement. 5760-121 Controller Operations Manual Rev B...

  • Page 7: Table Of Contents

    Controller Section 1: Introduction ............1 IJ3000 Controller .
  • Page 8 Controller Section 5: Setup Functions ............23 Tasks .
  • Page 9 Controller Section 7: Utility Functions ............63 User Access Control .
  • Page 10 Controller Appendix G: Configuring a PC to Communicate with the IJ3000 ..... . . 101 Windows XP® ............101 Windows 2000®...

  • Page 11: Section 1: Introduction

    Controller Section 1: Introduction Section 1: Introduction This manual describes the operation of the IJ3000 Controller. It includes programming instructions to create and edit print messages for the IJ3000 Controller. The IJ3000 Con- troller is used in conjunction with high resolution Impulse Jet, WaxJet and large character Valve Jet type print heads.
  • Page 12 Controller Section 1: Introduction Page 2 of 115 5760-121 Operations Manual Rev B...

  • Page 13: Section 2: Safety

    Controller Section 2: Safety Section 2: Safety 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 equip- ment.
  • Page 14 Controller Section 2: Safety Page 4 of 115 5760-121 Operations Manual Rev B...

  • Page 15: Section 3: Typical System Components

    Controller Section 3: Typical System Components Section 3: Typical System Components (The following view shows an IJ3000 Impulse Jet System.) 1 IJ3000 Controller 8 Encoder 2 CIDS3000 9 Ink Supply 3 Print Heads 10 Photo Sensor 4 Conveyor 11 Vacuum Waste Collector Bottle 5 Product 12 Encoder Cable 6 Print Head Bracketry...
  • Page 16 Controller Section 3: Typical System Components The Diagraph IJ3000 Controller is available in the following configurations: Part Number Description IJ3000 Controller Assemblies for Impulse Jet Systems 5760-001PJ1D Painted Enclosure, Single Impulse Jet Interface, Domestic 5760-001PJ2D Painted Enclosure, Dual Impulse Jet Interface, Domestic 5760-001SJ1D Stainless Enclosure, Single Impulse Jet Interface, Domestic 5760-001SJ2D...

  • Page 17: Ij3000 Controller

    Controller Section 3: Typical System Components IJ3000 Controller The controller gathers and stores all the informa- tion required for printing a message. This informa- tion can come from the following sources: 1. The user interface, which tells the controller what message to print on the product. 2.
  • Page 18 Controller Section 3: Typical System Components Page 8 of 115 5760-121 Operations Manual Rev B...

  • Page 19: Section 4: Getting Started

    Controller Section 4: Getting Started Section 4: Getting Started IJ3000 Keypad Backspace/ Delete Key BRIGHTNESS KEYS POWER KEYS Lighter Darker Power On Escape & Caps Lock Caps “ Enter ‘ Lock < > Shift Shift Ctrl Arrow Keys Turning the Controller On The power keys are located at the top left corner of the keypad.

  • Page 20: Commands

    Controller Section 4: Getting Started Commands There are three main commands given in this manual: Highlight, Press, and Touch. Highlight Highlight a display control to select it for further action, or to give it input focus. Different types of display controls are highlighted differently. For example, highlighted text is dis- played in inverse video (light characters on a dark background), while highlighted screen buttons and message fields are displayed with a box around them.

  • Page 21: Radio Buttons

    Controller Section 4: Getting Started Radio Buttons Touch a radio button or its text description to make a selection. A black dot indicates the current selection. Check Boxes Touch a check box or its text description to toggle an option or feature on and off. The fea- ture or option is enabled when a checkmark appears in the box.

  • Page 22: Text Entry Box

    Controller Section 4: Getting Started Text Entry Box Touch a text entry box to highlight it, type in the desired text, and press Enter. Press ESC any time prior to pressing Enter to restore the original text. Touching another screen control or pressing the up or down arrow keys after entering new text, but before pressing Enter, sets the new text just as if Enter had been pressed.

  • Page 23: Message Selection Box

    Controller Section 4: Getting Started Message Selection Box Use the message selection box to select a print message for printing, editing, deleting, etc. Select a print message by touching its name, by using the arrow keys on the keypad to move through the message names until the desired one is highlighted, or by typing the name in the box provided.

  • Page 24: Keypad Controls

    Controller Section 4: Getting Started Keypad Controls Enter Backspace/Delete Escape & Caps “ Enter ‘ Lock < > Shift Shift Control Ctrl Alternate Arrow Keys The following keypad keys can be used to navigate through a screen: ESC (Escape): Press ESC to close the current window, dialog box, or menu. Any changes made in the window or dialog box that have not been saved will be discarded.

  • Page 25: Enter

    Controller Section 4: Getting Started Enter: Enter key behavior is determined by the screen control that has input focus. • Press Enter to actuate a Text button, Bitmap button, or Decorated button. • Press Enter to choose a Radio button selection. •...

  • Page 26: Home Screen

    Controller Section 4: Getting Started Home Screen Task 2 Print/Pause Button Message Window Task 1 Select Show Menu / Button Hide Menu Button Task 1 Print/Pause Button Task 2 Select Button The Home Screen is usually the first screen displayed at power on. The major parts of the Home Screen are the Message Window, the Task 1 and Task 2 control buttons, the Show Menu / Hide Menu button, and the system controls and access buttons.

  • Page 27: Print/Pause Buttons

    Controller Section 4: Getting Started Print/Pause Buttons Touch a task's Print/Pause button to toggle the task between printing and not printing (paused). The icon on the button indicates what action will be taken when the button is touched. That is, if blue double bars are shown, touch the button to pause print. If a green arrow is shown, touch the button to resume printing.

  • Page 28: Moving Around The Edit Screen

    Controller Section 4: Getting Started Moving Around the Edit Screen Crosshairs Pointer Side 1 / Side 2 Buttons Edit Window Next Field Button Current Position Indicator Edit Window: Print messages are created and edited in the Edit Window. Unlike all other IJ3000 screens and dialog boxes, input focus on the Edit Screen remains in one place - the Edit Window.

  • Page 29: Crosshairs Pointer

    Controller Section 4: Getting Started Crosshairs Pointer: The crosshairs pointer indicates where a new data field is placed when added to a print message. Use the keypad keys listed below to move the crosshairs pointer around the Edit Window. Touching the screen inside the Edit Window can also move the crosshairs pointer. The pointer moves to where the screen is touched.
  • Page 30 Controller Section 4: Getting Started Integrated Valve: Direction Distance Press keypad key up/down 1 dot row up/down arrow up/down 9 dot rows Shift + up/down arrow down 9 dot rows Enter (when no fields are highlighted and the crosshairs pointer is black) left/right 1 print column left/right arrow...

  • Page 31: Next Field Button

    Controller Section 4: Getting Started Next Field Button: Touch the Next Field button to highlight or select the data fields in the order in which they were added to the print message. A selected field's color changes from dark blue to red and a box surrounds the field.
  • Page 32 Controller Section 4: Getting Started Page 22 of 115 5760-121 Operations Manual Rev B...

  • Page 33: Section 5: Setup Functions

    Controller Section 5: Setup Functions Section 5: Setup Functions Tasks A task consists of all operations associated with a single interface board. (All print heads connected in a daisy chain are part of one task.) If only one interface board is connected, Task 2 will not be applicable and Task 2 buttons will not be displayed.

  • Page 34: Specifying Product Direction

    Controller Section 5: Setup Functions Specifying Product Direction Touch the box that represents the direction the product will move on the conveyor. The next screen will appear automatically. 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 the choices.

  • Page 35: Setting Daisy Chain Order

    Controller Section 5: Setup Functions Setting Daisy Chain Order Both print heads are displayed, and the user is prompted to indicate the first print head in the daisy chain by touching it. (If there is only one print head, this step is bypassed.) Once this is done, the Print Head Proper- ties screen appears.
  • Page 36 Controller Section 5: Setup Functions • Product sensor offset: Enter the distance between the photosensor and the print head, in inches. This may need to be fine-tuned after print setup. For Impulse Jet: The maximum sensor offset is 52" for IJ96, IJ192, IJ352 and WJ192 Print Heads.

  • Page 37: Encoder Setup

    Controller Section 5: Setup Functions Encoder Setup Touch the Encoder tab at the bottom of the System Setup screen to access encoder options. Touch either the External encoder, at left, or the Internal timer, at right. The choice will be indicated by a gray box on the screen.

  • Page 38: Group Setup

    Controller Section 5: Setup Functions Group Setup The IJ3000 can be setup to create and manage messages for both Task 1 and Task 2 as a single "group" message. This allows for single message editing for a two task controller with multiple heads on each task.

  • Page 39: Setting Up A Second Cids3000

    Controller Section 5: Setup Functions Setting Up a Second CIDS3000 To set up the application to use a second CIDS3000, go to the Home Screen, touch Task 2, Show Menu, Control Panels, System Setup, then Task Options. The default setting for Task 2 print heads is set to use the CIDS3000 connected to Task 1.

  • Page 40: Serial Port Setup

    Controller Section 5: Setup Functions Serial Port Setup To set the COM1 and COM2 serial port device type and baud rate: 1. On the Home screen, touch the Control Panels button to open the Control Panels Menu. 2. Touch the System Setup button on the Control Panels Menu to open the System Setup screen.

  • Page 41: Using A Bar Code Scanner

    Controller Section 5: Setup Functions Using a Bar Code Scanner A bar code scanner attached to a serial port can be used for message lookup, that is, load- ing a message for printing, or to insert variable field data into a printing message. •...

  • Page 42: Message List Access

    Controller Section 5: Setup Functions Message List Access The Message list access controls determine whether the print messages listed in the Print...Message Selection box are local (stored in the IJ3000’s internal memory) or on the network. Touch the radio button appropriate to the application. If Network is chosen, the Network message list URL text entry box becomes active.

  • Page 43: Defining User Codes

    Controller Section 5: Setup Functions Touch the OK button to save the changes and return to the Home Screen. If any of the IP addresses have changed, the system will need to be rebooted for those changes to take effect; a dialog box appears with that option. To discard any changes made and return to the Home Screen, touch the Cancel button or press ESC on the keypad.

  • Page 44: Time & Date Screens

    Controller Section 5: Setup Functions Touch the Restore Defaults button to restore the default codes for the selected compo- nent. The default codes are: • Hours: 24 single letter codes A through Z, except the letters I and O, which may be con- fused with the numbers 1 and 0, respectively.

  • Page 45: The Date Screen

    Controller Section 5: Setup Functions The Date Screen Date Screen displays IJ3000's current month and year set- tings and the days for that month and year. The selected date is the current date setting. To change the date within the current month, touch the desired date.

  • Page 46: The Rollover Time Screen

    Controller Section 5: Setup Functions The Rollover Time Screen Touch the hour or minute display to highlight the hour or minute and activate the up/down arrows. Touch the up/down arrows to adjust the hour or minute. Touch Apply to save the new time, or OK to save and return to the Home Screen.

  • Page 47: Auto Clean Setup (For Impulse Jet Heads W/Acs Only)

    Controller Section 5: Setup Functions Auto Clean Setup (for Impulse Jet Heads w/ACS only) Use the Auto Clean Setup screen to turn automatic print head cleaning on and off, select the auto clean timing method, and program cleaning times. The Auto Clean Setup screen is available only on IJ3000 systems that have at least one Impulse Jet print head interface board.

  • Page 48: Set Times Operation

    Controller Section 5: Setup Functions Set Times Operation Touch the Set times radio button to automatically clean the print heads on specific days and times, and to display the controls for setting those times. To program an auto clean time: 1.

  • Page 49: Sleep Mode (For Waxjet Tasks Only)

    Controller Section 5: Setup Functions Sleep Mode (for WaxJet Tasks only) Sleep Mode lowers the temperature of the WaxJet 192 Print Heads and the Wax Delivery System from their operating temperatures to 90°C (194°F). Use Sleep Mode to maintain the viability of the wax when the system is left on during long periods of printer inactivity (eight to sixteen hours, or longer).

  • Page 50: Auto Sleep

    Controller Section 5: Setup Functions To awaken a sleeping task, select the task by touching its corresponding Task button, then touch the Wake Up button on the Print Menu. Print is re-enabled when the task’s Print Heads and Wax Delivery System reach operating temperature.
  • Page 51 Controller Section 5: Setup Functions The Sleep Cycle Setup screen is displayed: On the right side of the screen are controls for entering and deleting sleep events, and for turning Auto Sleep on and off. The left side of the screen has a chart that gives an at-a- glance look at all sleep events entered.
  • Page 52 Controller Section 5: Setup Functions 3. Touch the Enter key. That part of the chart that covers the period between the From and To times is shown in blue-gray. The illustration below shows the screen after a sleep event of 23:30 (11:30 PM) Friday to 22:30 (10:30 PM) Sunday is entered. 4.

  • Page 53: Section 6: Message Functions

    Controller Section 6: Message Functions Section 6: Message Functions Creating a Print Message A print message has one or more data fields containing a text or graphic element. Text fields may contain fixed text, variable text, a date code, a time code, or a product count. Graphic fields contain either a logo or a bar code.
  • Page 54 Controller Section 6: Message Functions Edit Screen controls and features: Title Bar: The Title Bar shows the task for which the message is being created (in this case Task 1) and the name of the message. All new messages have the name "New" until they are saved.
  • Page 55 Controller Section 6: Message Functions Fonts Button: Touch the Fonts button to select the font for the next field to be added to the print message, or to change the font of an existing field. The name of the current font selection is displayed on the button.
  • Page 56 Controller Section 6: Message Functions Step 3: Set up your product. Touch the Product Setup button to display the Product Setup dialog box: Enter the product's length, and the left margin for side one and two, if applicable. Touch the Print Properties tab. Use the up/down arrows to select the desired print resolution: 100, 150, or 200 dots per inch (dpi) for Impulse Jet, or 4 to 25 dpi...
  • Page 57 Controller Section 6: Message Functions Step 4: Select the desired font for the first field. Touch the Font button to display the list of available fonts, highlight the selection, and touch the OK but- ton. Step 5 Add data fields to the print message, changing the font (as needed) before the addition of each new field.
  • Page 58 Controller Section 6: Message Functions If the date code is not exactly where it should be, use the arrow keys to reposition it. Press Enter when the date code is at the desired location. Message with date code Adding a time code: To add a time code to the print message, move the crosshairs pointer to the desired location and touch the Time Code button;...
  • Page 59 Controller Section 6: Message Functions Pallet count: Touch the Pallet count radio button and enter the number of items per pallet. A pallet count is incremented or decremented every n items, where n is the number of items per pallet. Normally, a product count is increased or decreased by 1 after every print cycle.
  • Page 60 Controller Section 6: Message Functions • Touch the OK button to close the dialog box and insert the variable field into the print message. Vari- able fields are represented on the Edit Screen by a string of Xs. If the field is not exactly where it should be, use the arrow keys to adjust its position.
  • Page 61 Controller Section 6: Message Functions • Touch the Print human readable check box to remove the check- mark if human readable data is not to be printed with the bar code. (Printing human readable is the default setting.) • Touch the OK button to close the dialog box and insert the bar code into the print message.
  • Page 62 Controller Section 6: Message Functions When the measurement has been determined, it can be set in all bar code fields printed on the substrate. The measurement is set by selecting a bar code field, then the field type button fol- lowed by the properties button.

  • Page 63: Editing A Message

    Controller Section 6: Message Functions Step 6 Save the print message. Touch the Save button to display the Save dia- log box. Enter a unique name for the message and touch the Save button. Editing a Message From the Home Screen: 1.

  • Page 64: Editing Fields

    Controller Section 6: Message Functions Editing Fields A field must be selected before it can be edited. A selected field is displayed in red and has a black box around it. You can select a field by touching the Next Field button, by pressing the Tab key, or by touching the field directly.

  • Page 65: Deleting A Field

    Controller Section 6: Message Functions Editing All Other Field Types: 1. Select the field; its color changes from dark blue to red. 2. Touch the corresponding field type button (the button with the dark gray background); the field's Edit dialog box is displayed. 3.

  • Page 66: Edit Screen Keyboard Shortcuts

    Controller Section 6: Message Functions Character Width Trait will adjust the width of all characters in the selected text field. The factory default character width settings will produce characters and logos that are propor- tional to each print head type: Default Character Width Print Head Type Fonts...

  • Page 67: Creating And Editing A Group Message

    Controller Section 6: Message Functions Creating and Editing a Group Message When the system has been set up in group mode, group messages can be created. The edit screen can be entered from either Task 1 or Task 2. Touch Side 1, under Task 1, and create the desired message.

  • Page 68: Estimating Ink Consumption

    Controller Section 6: Message Functions Estimating Ink Consumption A utility available on the Edit Screen estimates a print message’s ink con- sumption. To display the estimated ink consumption for the message being created or edited, select Ink Usage from the Messages Menu. Ink consumption is reported as the estimated number of times the entire message will print per five gallons of...

  • Page 69: Printing A Message

    Controller Section 6: Message Functions Printing a Message 1. Touch the decorated Print button at the top of the Home Screen to access print options, then touch the Print … button. Or, touch the Print … button at the bottom of the screen.

  • Page 70: Making Adjustments During Printing

    Controller Section 6: Message Functions Making Adjustments During Printing Product count and variable field data can be changed during printing, as long as the con- troller has not been set up for Message Look Up, Network Mode, Network Notification or Command and Control.

  • Page 71: Changing Variable Field Data

    Controller Section 6: Message Functions When the Adjust Print Counts... button is touched, and the current print message con- tains one or more counts, the Product Count Input dialog box is displayed: To change the product count, touch the Next box, type in the new count, and press Enter on the keypad.
  • Page 72 Controller Section 6: Message Functions Page 62 of 115 5760-121 Operations Manual Rev B...

  • Page 73: Section 7: Utility Functions

    Controller Section 7: Utility Functions Section 7: Utility Functions User Access Control On the Home Screen, touch Control Panels, then User Access. Open Access vs. Passwords Touch the Open access radio button to allow all users unrestricted access to all IJ3000 functions.

  • Page 74: Status Screen (For Impulse Jet Or Integrated Valve)

    Controller Section 7: Utility Functions Status Screen (for Impulse Jet or Integrated Valve) To display the Status Screen, touch the Status button on the Home Screen. Integrated Valve Impulse Jet Head Status Head Status Print Task status indicators: All indicators are updated once per second. Indicates the task photocell is not blocked.
  • Page 75 Controller Section 7: Utility Functions Indicates one or more print heads in that task’s daisy chain are not at operating tempera- ture. Look at the "At Temperature" LED on the back of the individual print heads to identify which print head is not "at temp." Indicates the ink supply is OK.

  • Page 76: Status Screen (For Waxjet)

    Controller Section 7: Utility Functions Status Screen (for WaxJet) The WaxJet Print Task status indicators for Product detect, Printing, Line speed, Task 1 and Task 2 are the same as those for Impulse Jet and Integrated Valve. The remaining sta- tus indicators differ slightly, as noted below.
  • Page 77 Controller Section 7: Utility Functions Indicates the Wax Delivery System is not at operating temperature. Indicates the wax supply for all print heads and Wax Delivery Systems in the daisy chain is Indicates a Low Wax condition: wax pellets need to be added to the melt tank on one or more of the Wax Delivery Systems in the daisy chain.
  • Page 78 Controller Section 7: Utility Functions Ink Systems Status (Integrated Valve) displays the ink levels (OK, LOW, or OUT), the pressure and vacuum read- ings, and the ink line status (OK or FAULT) for one or two IDS3000s. Ink System Status information is refreshed every two seconds.

  • Page 79: System Test

    Controller Section 7: Utility Functions System Test Touch Screen Calibration is completed at the factory. This calibration can be performed any time there are problems with the touch screen. From the Home Screen, select Show Menu, Control Panels, then Utilities. Choose Calibrate Touch Screen and touch Do Function.

  • Page 80: Regional Settings

    Controller Section 7: Utility Functions Regional Settings On the Home Screen, touch Control Panels, then Regional Settings. Touch either the U.S. customary or Metric radio button to select the desired units to be shown for the items in the following table: Line Print Head Margins, X Coordinate,...

  • Page 81: System Reboot

    Controller Section 7: Utility Functions System Reboot Should the system ever become unresponsive or display an "Out of memory" message, a "system reboot" must be performed. Press and hold CTRL and ALT, then press the ON but- ton. CAUTION: Any message that was printing when the system locked up will automatically resume printing when the system reboots.
  • Page 82 Controller Section 7: Utility Functions Page 72 of 115 5760-121 Operations Manual Rev B...

  • Page 83: Section 8: Troubleshooting

    Controller Section 8: Troubleshooting Section 8: 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 84: Ij/3000 Controller

    Controller Section 8: Troubleshooting IJ/3000 Controller: System Symptom Possible Cause Operational Test Method No Controller power, Power Supply Check Power Supply light indicator. no Green LED indi- Check for 24V output for Impulse Jet, or cator light on CPU, 15V output for Integrated Valve. no voltage on CPU Check connector between CPU &...

  • Page 85: Appendix A: System Specifications

    Controller Appendix A: System Specifications Appendix A: System Specifications Controller Size Height: 7.7" [195.6mm] Width: 12.8" [325.1mm] Depth: 14.4" [365.8mm] Weight: 13.6 lbs (6.2kg) Cable Clearance: 3" from the rear of the con- CONTROLLER 14.4” troller TOP VIEW [365.8mm] User Interface Type: Graphical User Interface Keyboard: 70-key, QWERTY style, elasto- meric keyboard...
  • Page 86 Controller Appendix A: System Specifications (2) RS-232 ports, (1) 10Base-T Ethernet port Enclosure Sealed industrial enclosure, available in cold rolled steel (painted black) or stainless steel Print Performance Impulse Jet - Up to 10 lines of print at 200 fpm (See Appendix D) Integrated Valve - Up to 28 lines of print at 650 fpm (See Appendix C) Electrical 90-260 VAC, 50/60 Hz, 3.0A max.

  • Page 87: Appendix B: Theory Of Operation

    Controller Appendix B: Theory of Operation Appendix B: Theory of Operation Functional Description The IJ3000 ink jet system prints text, autocodes (such as product counts or time and date stamps), bar codes, and/or graphics onto products as they travel by conveyor past station- ary print heads.

  • Page 88: Cpu Board

    Controller Appendix B: Theory of Operation CPU Board The CPU Board has two microcontrollers, an LCD controller, flash memory, SRAM, a real time clock/calendar, an Ethernet port, two serial ports, 12V, 5V and 3.3V regulators, a 3V battery, and PC/104 bus connectors. Of the two microcontrollers, one (U13) is the IJ3000's central processing unit (CPU).

  • Page 89: Impulse Jet Print Head Interface Board

    Controller Appendix B: Theory of Operation Impulse Jet Print Head Interface Board The Impulse Jet Print Head Interface Board controls the print head daisy chain, and it is the power entry point for the print heads and the rest of the system (See the previous section on Power.) The Print Head Interface Board also contains the photosensor, external encoder, and CIDS connections.

  • Page 90: Integrated Valve Print Head Interface Board

    Controller Appendix B: Theory of Operation Integrated Valve Print Head Interface Board The IV Print Head Interface Board controls the print head daisy chain, and it is the power entry point for the print heads and the rest of the system (See the Power section above.) The Print Head Interface Board also contains the photosensor and external encoder con- nectors.

  • Page 91: Interconnect Diagrams

    Controller Appendix B: Theory of Operation Interconnect Diagrams IJ3000 Controller CPU Diagram 5760-121 Operations Manual Rev B Page 81 of 115...

  • Page 92: Impulse Jet Controller Interface Board Diagram

    Controller Appendix B: Theory of Operation Impulse Jet Controller Interface Board Diagram 1 GND CLOCK+ CLOCK+ CLOCK- CLOCK- DATA+ DATA+ DATA- DATA- DATA2+ DATA2- DATA4+ IDS_ERROR* IDS_ERROR* LATCH+ LATCH+ LATCH- LATCH- DATA3+ DATA3- +24V +24V +24V +24V INKOUT* INKOUT* ATEMP ATEMP INKLOW* INKLOW*...

  • Page 93: Integrated Valve Controller Interface Board Diagram

    Controller Appendix B: Theory of Operation Integrated Valve Controller Interface Board Diagram 1 GND +15V +15V +15V +15V +15V +15V CLOCK- CLOCK- CLOCK+ CLOCK+ DATA- DATA- DATA+ DATA+ LATCH- LATCH- LATCH+ LATCH+ PHOTO +15V +5VDC ENCODER 5760-121 Operations Manual Rev B Page 83 of 115...
  • Page 94 Controller Appendix B: Theory of Operation Page 84 of 115 5760-121 Operations Manual Rev B...

  • Page 95: Appendix C: Parts And Supplies

    Controller Appendix C: Parts and Supplies Appendix C: Parts and Supplies Controller Battery Type: CR2032, 3V (Diagraph part number 5760-122) (Also available at department and electronics stores.) NOTE: Disconnect power from Controller by unplugging power from CPU Board before replacing battery. CAUTION: Danger of explosion if battery is incorrectly replaced.
  • Page 96 Controller Appendix C: Parts and Supplies Page 86 of 115 5760-121 Operations Manual Rev B...

  • Page 97: Appendix D: Performance Parameters

    Controller Appendix D: Performance Parameters Appendix D: Performance Parameters 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.
  • Page 98 Controller Appendix D: Performance Parameters The Impulse Jet Print head operational through-put (the maximum print speed) is deter- mined 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%.

  • Page 99: Performance Parameters Of An Integrated Valve Controller

    Controller Appendix D: Performance Parameters Performance Parameters of an Integrated Valve Control- 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 100 Controller Appendix D: Performance Parameters Page 90 of 115 5760-121 Operations Manual Rev B...

  • Page 101: Appendix E: Creating & Transferring Logo Files

    Controller Appendix E: Creating & Transferring Logo Files Appendix E: Creating & Transferring Logo Files Creating a Logo Open Paint from a PC by selecting Start, Programs, Accessories, and then Paint. Bring up the Attributes dialog box by selecting Image and then Attributes. 5760-121 Operations Manual Rev B Page 91 of 115...
  • Page 102 Controller Appendix E: Creating & Transferring Logo Files Enter the Width and Height of the logo in Pixels, then select Black and white. Choose Yes at the screen prompt to convert to black and white. Zoom in by selecting View, Zoom, then Large Size. This will make defining the pixels eas- ier.
  • Page 103 Controller Appendix E: Creating & Transferring Logo Files Define the pixels of the logo by using the pencil tool. Bring up the Flip and Rotate dialog by selecting Image, Flip/Rotate. Select Rotate by angle, then 270°. From the File Menu, select Save As... 5760-121 Operations Manual Rev B Page 93 of 115...
  • Page 104 Controller Appendix E: Creating & Transferring Logo Files Name the logo and save it as a Monochrome Bitmap file in the desired folder. Page 94 of 115 5760-121 Operations Manual Rev B...

  • Page 105: Transferring A File From A Pc To An Ij3000

    Controller Appendix E: Creating & Transferring Logo Files Transferring a File from a PC to an IJ3000 Use this procedure to transfer a font file, logo file, message file, or any other IJ3000 type file from a PC to a controller. If the controller already has a file with the same name as the one being transferred, the existing file will be replaced with the new file.
  • Page 106 Controller Appendix E: Creating & Transferring Logo Files 5. Click the Browse… button to locate and select the file to be sent to the controller. 6. Click Upload to send the file to the controller. If the file transfer is successful, the web page shown below will be displayed.

  • Page 107: Transferring A File From An Ij3000 To A Pc

    Controller Appendix E: Creating & Transferring Logo Files Transferring a File from an IJ3000 to a PC Use this procedure to transfer a font file, logo file, message file, or any other IJ3000 type file from an IJ3000 controller to a PC. These instructions assume the IJ3000 is already connected, via Ethernet, to a PC.
  • Page 108 Controller Appendix E: Creating & Transferring Logo Files 5. Scroll through the list to locate the file to be transferred to the IJ3000. Click on the file name to display the Windows® "File Download" dialog box. 6. Click OK. A standard Windows® "Save As" dialog box is displayed. 7.

  • Page 109: Appendix F: Setting The Ip Address Of An Ids3000

    Controller Appendix F: Setting the IP Address of an IDS3000 Appendix F: 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 110 Controller Appendix F: 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 111: Appendix G: Configuring A Pc To Communicate With The Ij3000

    Controller Appendix G: Configuring a PC to Communicate with the IJ3000 Appendix G: Configuring a PC to Communicate with the IJ3000 This appendix has instructions for setting the IP address and subnet mask of the PC so it can communicate with the IJ3000 Controller. Included are instructions for Windows XP®, Windows 2000®, Windows 98®, and Windows 95®.
  • Page 112 Controller Appendix G: Configuring a PC to Communicate with the IJ3000 3. Select Internet Protocol (TCP/IP) then click Properties button. 4. Click the Use the following IP address radio button. Enter an IP address of 10.1.2.4, a subnet mask of 255.255.255.0, click the OK button.

  • Page 113: Windows 2000

    Controller Appendix G: Configuring a PC to Communicate with the IJ3000 Windows 2000® 1. Open the Start menu; select Settings, then Network and Dial-up Connections. 2. Click the desired connection, then open the File menu and select Properties. 5760-121 Operations Manual Rev B Page 103 of 115...
  • Page 114 Controller Appendix G: Configuring a PC to Communicate with the IJ3000 3. Select Internet Protocol (TCIP/IP) then click Properties button. 4. Click the Use the following IP address radio button. Enter an IP address of 10.1.2.4, a subnet mask of 255.255.255.0, and click the OK button.

  • Page 115: Windows 98

    Controller Appendix G: Configuring a PC to Communicate with the IJ3000 Windows 98® 1. Open the Start menu; select Set- tings, then Control Panel. 2. Double-click the Network icon (bottom row, second from the right in the illustration below.) 5760-121 Operations Manual Rev B Page 105 of 115...
  • Page 116 Controller Appendix G: Configuring a PC to Communicate with the IJ3000 3. Select TCP/IP and click the Properties button. 4. On the IP Address page, click the Specify an IP address radio button. Enter an IP address of 10.1.2.4, a subnet mask of 255.255.255.0, and click the OK button.

  • Page 117: Windows 95

    Controller Appendix G: Configuring a PC to Communicate with the IJ3000 Windows 95® 1. Open the Start menu; select Set- tings, then Control Panel. 2. Double click the Network icon (lower right in the illustration below). 5760-121 Operations Manual Rev B Page 107 of 115...
  • Page 118 Controller Appendix G: Configuring a PC to Communicate with the IJ3000 3. Select TCP/IP, then click the Properties button. 4. On the IP Address page, click the Specify an IP address radio button. Enter an IP address of 10.1.2.4, a subnet mask of 255.255.255.0, and click the OK button.

  • Page 119: Appendix H: Network Box

    Controller Appendix H: Network Box Appendix H: Network Box IJ3000 Network Box Menu Map General Use the Up/Down Arrows to select the desired function or sub-menu. A single or double arrow in the left-most column of the display indicates the current selection. The Main Menu and System Info Menu always display a single arrow.

  • Page 120: Task Menu

    Controller Appendix H: Network Box Task Menu Pause/Resume Printing is a toggle function. When Pause Printing is displayed, the task is currently printing. Press Enter to pause print (the display changes to Resume Printing). When Resume Printing is displayed the task is currently paused or no message is print- ing.

  • Page 121: Appendix I: Testing An Electrical Outlet

    Controller 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 OUTLET...
  • Page 122 Controller Appendix I: Testing an Electrical Outlet Page 112 of 115 5760-121 Operations Manual Rev B...

  • Page 123: Appendix J: Electrostatic Discharge (Esd)

    Controller 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 124 Controller Appendix J: Electrostatic Discharge (ESD) Page 114 of 115 5760-121 Operations Manual Rev B...

  • Page 125: Appendix K: Glossary Of Terms

    Controller Appendix K: Glossary of Terms Appendix K: Glossary of Terms Autocode - A field entered into a message to print a variable such as date, time, pallet count, or plant location. COM - Abbreviation for a serial communications port on a computer. Usually expressed as "COM port"...

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