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Illinois Tool Works 400386UB Operation Manual

Piezo inkjet system
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Operations
Manual
Piezo InkJet System
400386UB
Revision A

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Summary of Contents for Illinois Tool Works 400386UB

  • Page 1 Operations Manual Piezo InkJet System 400386UB Revision A...
  • Page 2 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. ©2023 Illinois Tool Works Inc. All rights reserved...
  • Page 3 Piezo InkJet System Warranty: This Piezo InkJet system, including all components unless otherwise specified, carries a limited warranty. The inks and conditioners used with this system carry a limited warranty. For all warranty terms and conditions, contact your reseller for a complete copy of the Limited Warranty Statement.

  • Page 4: Table Of Contents

    Section 1: Safety and Ink Usage ..................................6 Section 2: Quick Start ......................................7 Step 1: Assemble Bracketry to Conveyor ..............................8 Step 2: Assemble Printer onto Bracketry ..............................9 Step 3: Mount and Connect Power Supply ...............................10 Step 4: Mount Photosensor and Encoder ..............................11 Step 5: Daisy-Chain Printers, HMI, and/or Customer Network .......................12 Step 6: Powering up the Printers ................................14 Step 7: Adjust Printer to Substrate ................................15...
  • Page 5 Appendix B: Theory of Operation ..................................38 Functional Description ....................................38 2" and 4" Printer ......................................38 ISM Features ......................................39 Ink States ........................................40 Printer Daisy Chain ....................................41 Print Trigger Photosensor ..................................41 Encoder ........................................41 Appendix C: Diagrams .......................................42 ISM Main CPU PCB Assembly ................................42 ISM Internal Wiring Diagram ...................................43 Appendix D: Ink ........................................44 Storage Life of a FACTORY SEALED Cartridge of Ink .........................44...

  • Page 6: Section 1: Safety And Ink Usage

    CAUTION: The Ink Supply Module contains hazardous voltage (90VDC). Disconnect from mains power before: • Performing preventive maintenance. • Performing any repairs to the unit. • Servicing the equipment in any manner. Caution: Denotes possible personal injury due to sharp object. 400386UB Operations Manual Rev A Page 6...

  • Page 7: Section 2: Quick Start

    4. Power Supply (Item 4) 5. Photosensor (Item 5) 6. Encoder (Item 6) 7. Power Cord (not shown) 8. Ethernet Cable (not shown) 9. Software (not shown) 10. Ink (not included) TYPICAL INSTALLATION 400386UB Operations Manual Rev A Page 7...

  • Page 8: Step 1: Assemble Bracketry To Conveyor

    Step 1: Assemble Bracketry to Conveyor 1. Firmly tighten all fasteners. NOTE: Ensure bracketry is square and level. OPTIONAL HMI CONTROLLER / MOUNT (5765250) PRINTER CONVEYOR MOUNT (400201 FOR 2" PRINTER) (400204 FOR 4" PRINTER) 400386UB Operations Manual Rev A Page 8...

  • Page 9: Step 2: Assemble Printer Onto Bracketry

    Printer. DOVETAIL ADAPTER AND RETRACTING BRACKET AND CAN BE MOUNTED ON EITHER SIDE OF PRINTER ROLLER / RETRACTING BRACKET MOUNT (for 2" Printer) (400201) ROLLER / RETRACTING BRACKET MOUNT (for 4" Printer) (400204) 400386UB Operations Manual Rev A Page 9...

  • Page 10: Step 3: Mount And Connect Power Supply

    1. Install power supply with power cord mains facing the conveyor and DC output facing out towards the rear of the Printer. 2. Firmly tighten fasteners to bracketry or convenient location. NOTE: One power supply pack can power up to two Printers in any combination of 2" or 4". 400386UB Operations Manual Rev A Page 10...

  • Page 11: Step 4: Mount Photosensor And Encoder

    CAUTION: Do not excessively pre-load the encoder wheel. A radial force of over 18,14 kg [40lbs] will reduce the life of the bearings. Photosensor Input Encoder Input Conveyor Encoder Wheel Encoder Spring 400386UB Operations Manual Rev A Page 11...

  • Page 12: Step 5: Daisy-Chain Printers, Hmi, And/Or Customer Network

    (400463). Standalone System with HMI - One Printer PRIMARY PRINTER TO DOWNSTREAM FROM UPSTREAM PRINTER OR HMI PRINTER Standalone System with HMI - Two or More Printers SECONDARY PRINTER SECONDARY PRINTER PRIMARY PRINTER 400386UB Operations Manual Rev A Page 12...
  • Page 13 PRIMARY PRINTER TO DOWNSTREAM FROM UPSTREAM PRINTER OR HMI PRINTER OR CUSTOMER NETWORK CUSTOMER NETWORK Networked System with Optional HMI - Two or More Printers SECONDARY PRINTER SECONDARY PRINTER PRIMARY PRINTER CUSTOMER NETWORK 400386UB Operations Manual Rev A Page 13...

  • Page 14: Step 6: Powering Up The Printers

    TYPICAL INSTALLATION Best practices are to plug power PRIMARY PRINTER SECONDARY PRINTER into the Printers first before the A/C mains. POWER LED POWER LED POWER JUMPER CABLE P/N 400490 POWER SUPPLY P/N 400380 400386UB Operations Manual Rev A Page 14...

  • Page 15: Step 7: Adjust Printer To Substrate

    NOTE: Printer print gap can be adjusted to be larger in heavy debris environment but must be balanced with print quality. 1 mm - 2 mm (.04in - .08in) PRINT GAP RECOMMENDED CARTON HORIZONTAL ADJUSTMENT SLIDE BRACKETRY SCREWS DOVETAIL TOOL-LESS CONVEYOR HANDLE VERTICAL ADJUSTMENT TOOL-LESS HANDLES 400386UB Operations Manual Rev A Page 15...

  • Page 16: Step 8: Printer Level And Tilt

    Rear of the Printer: • Clockwise Tilt: 85° (Printer Module disengages from the Ink Supply Module at 90°) • Counterclockwise Tilt: 90° Cleaning and priming features are effective up to ±15° Tool-less Locking Handle 400386UB Operations Manual Rev A Page 16...

  • Page 17: Step 9: Install Ink Cartridge

    For a full description of the LED / Button panel on the top of the of Ink Supply Module see "Ink States" on page 40. Vent Plug INSTALL Solid Flashing Ink Cartridge Filter Vent 400386UB Operations Manual Rev A Page 17...

  • Page 18: Step 10: Priming The Printer And Testing Print Quality

    4. If any print is still missing after all air bubbles are purged, repeat steps 7. - 9., in "Step 10: Priming the Printer and Testing Print Quality" on page 18, up to three more times as necessary. 400386UB Operations Manual Rev A Page 18...

  • Page 19: Step 11: Cap Unused Ports

    See "Service Parts and Optional Equipment" on page 49 for plug and cap kits. ETHERNET FROM UPSTREAM PRINTER OR 24VDC CUSTOMER NETWORK POWER Step 12: Create a Message and Control the Printer Reference manual Create & Control 400463. 400386UB Operations Manual Rev A Page 19...

  • Page 20: Section 3: Maintenance And Shutdowns

    3. Press the Clean / Prime button one more time (Clean) to ensure channel priming, but do not swab this time. 4. Wipe the front plate with a clean lint-free cloth to remove any excess ink. 400386UB Operations Manual Rev A Page 20...

  • Page 21: Ink Supply Module Maintenance

    Follow instructions in “Step 10: Priming the Printer and Ink Cartridge Testing Print Quality” on page 18. Shipping Plug Shipping Cap - Shipping Cap - Ensure Tabs Are Ensure Tabs Are Fully Seated In Slots Fully Seated In Slots Vent Plug 400386UB Operations Manual Rev A Page 21...

  • Page 22: Cleaning Maintenance System

    3. Automatically, from the controller Clean menu: The system can also be programmed to automatically clean the Printers during regular down times in the production schedule in increments of 30 minutes, or on a weekly schedule. 400386UB Operations Manual Rev A Page 22...

  • Page 23: Printer Module Replacement

    (down to the engine level), and returned to normal service making it more economical and green for the environment. Printer Module swap is easy. Installation is the reverse of the below removal steps. Unlock Printer Module Install Ship Cap Remove Printer Rotate Printer Module Module 90° 400386UB Operations Manual Rev A Page 23...

  • Page 24: Section 4: Troubleshooting

    Use a foam swab to clean debris on orifice plate in a vertical downward motion while ink is flowing. Debris on front plate Step 3: Run Prime feature for 5 seconds. Fuzzy Print Possible Cause Action Printer too far away from Step 1: Move Printer to within 1/8” from product. substrate 400386UB Operations Manual Rev A Page 24...
  • Page 25 Printer not level Step 1: Install ship cap and recirculate for 15 minutes. Lack of recirculation during Step 2: Remove ship cap, swab orifice plate, and run Prime feature for 5 seconds. startup 400386UB Operations Manual Rev A Page 25...
  • Page 26 Remove ship cap, swab orifice plate, and run Prime feature for 5 seconds. Step 1: Install ship cap and recirculate for 15 minutes. Lack of Recirculation during Step 2: Remove ship cap, swab orifice plate, and run Prime feature for 5 seconds. startup 400386UB Operations Manual Rev A Page 26...
  • Page 27 Check for correct encoder (must use part number 400206 or equal). size Step 1: Measure actual conveyor speed with a tachometer. Speed set too low for internal Step 2: Adjust internal line speed to match actual line speed. encoder 400386UB Operations Manual Rev A Page 27...
  • Page 28 Speed set too high for Step 2: Adjust internal line speed to match actual line speed. internal encoder Backwards Print Possible Cause Action Incorrect print direction Step 1: Correct print direction in Control software. specified in setup 400386UB Operations Manual Rev A Page 28...

  • Page 29: System

    Empty waste bottle Waste LED is red. Check internal connections to of LED Waste Full Remove waste bottle; LED should change to green. array / membrane switch and re-seat J12 connector or replace PCB 400386UB Operations Manual Rev A Page 29...
  • Page 30 All Channel Print button on No audible or visible PC Board Replace PCB clean white paper. channel firing Printer will not print at all Replacing PCB does Printer Module Replace Printer Module not fix the issue 400386UB Operations Manual Rev A Page 30...
  • Page 31 Navigate to the Control 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 PCB. Refer to Create & Control manual 400463. 400386UB Operations Manual Rev A Page 31...

  • Page 32: Appendix A: System Specifications

    Piezo InkJet System Appendix A: System Specifications Appendix A: System Specifications System 546mm 156mm [21.5in] [6.1in] 290mm [11.4in] 830mm 141mm [32.7in] [5.6in] 433mm [17.0in] 615mm [24.2in] 400386UB Operations Manual Rev A Page 32...

  • Page 33: Controller Hmi

    IP Rating Storage & Memory densing IP34 (estimated) 64GB SSD 4GB RAM Enclosure HDPE Plastic Ports (2) USB-A 3.0 port User Interface (1) Gigabit Ethernet port Graphical User Interface with on screen keyboard 400386UB Operations Manual Rev A Page 33...

  • Page 34: 2" Printer

    Pigmented Ink for porous substrates, black 50.7mm [2.00in] Environment CHARACTER Ambient operating temperature: 4°C to 40°C (40°F to HEIGHT 104°F) Operating humidity: 5% - 90% non-condensing Cleaning System Consumable Usage 19.9mm [0.78in] TO LOWEST ORIFICE Ink: 0.6ml 400386UB Operations Manual Rev A Page 34...

  • Page 35: 4" Printer

    Pigmented Ink for porous substrates, black Environment Ambient operating temperature: 4°C to 40°C (40°F to 104°F) Operating humidity: 5% - 90% non-condensing Cleaning System Consumable Usage 19.0mm [0.75in] TO LOWEST ORIFICE Ink: 0.7ml 400386UB Operations Manual Rev A Page 35...

  • Page 36: System Interconnect Diagram

    7. Ink Status / Communications LED 8. Encoder 9. Photosensor 10. Encoder Cable 11. Photosensor Cable 12. Ethernet Cable, HMI to Printer 13. Ethernet Cable, Printer to Printer 14. Throw Distance (1mm - 2mm [.04in - .08in] Recommended) 400386UB Operations Manual Rev A Page 36...

  • Page 37: Customer System Connection

    Piezo InkJet System Appendix A: System Specifications Customer System Connection USB DEVICE OR FIRMWARE UPGRADE PHOTOSENSOR ENCODER ETHERNET FROM UPSTREAM PRINTER OR CUSTOMER NETWORK ETHERNET TO DOWNSTREAM PRINTER OR HMI 24VDC POWER 400386UB Operations Manual Rev A Page 37...

  • Page 38: Appendix B: Theory Of Operation

    LEDs located on the rear of the ISM. They show when the heater is ON (irregular modulation) and when the print engine is at the appropriate temperature (steady ON light). NOTE: Since ink is fed to the print engine via gravity, it is important to maintain the Printer at a level position during operation. 400386UB Operations Manual Rev A Page 38...

  • Page 39: Ism Features

    Ink volume in any given cartridge is tracked down to the milliliter. Status is both read and written to the cartridge. If the cartridge is moved to another Printer, then the correct ink volume is maintained with the cartridge. In addition, there are five LED divisions on the rear of the ISM. Each division representing 20% ink volume. 400386UB Operations Manual Rev A Page 39...

  • Page 40: Ink States

    3. If an incorrect cartridge type is inserted, then print will immediately be disabled and all LEDs will flash on the ISM interface. NOTE: Never mix ink types because they are not miscible. Irreversible internal damage will occur. 400386UB Operations Manual Rev A Page 40...

  • Page 41: Printer Daisy Chain

    The external encoder plugs into the Printer CPU (J4), and its signal is used to time the sending of column data to the Printer. The internal encoder signal is a constant frequency pulse stream generated on the Printer CPU. This pulse stream is divided down in the CPU to generate the desired speed / timing. 400386UB Operations Manual Rev A Page 41...

  • Page 42: Appendix C: Diagrams

    Ethernet Output: M12 LED9 Encoder: Indicates ON / moving Reservoir Float Switch: 2-pin LED11 Ink Pump: Indicates ON Membrane Switch & LED: 8-pin ZIF LED14 Heartbeat: Indicates program is active PM Primary LED: 4-pin 400386UB Operations Manual Rev A Page 42...

  • Page 43: Ism Internal Wiring Diagram

    Appendix C: Diagrams ISM Internal Wiring Diagram MEMBRANE SWITCH & LED ARRAY SMART CHIP COUPLING INK WASTE PRINT ENGINE FLOAT SWITCH PRINTER MODULE PRIMARY LED INK RESERVOIR 24VDC FLOAT SWITCH VACUUM PUMP INK PUMP 400386UB Operations Manual Rev A Page 43...

  • Page 44: Appendix D: Ink

    Appendix E: Updating the ISM Firmware via USB For instructions on updating the ISM, refer to Create & Control manual, 400463. Appendix F: Software Interface For information on interfacing with the software, refer to Create & Control manual, 400463. 400386UB Operations Manual Rev A Page 44...

  • Page 45: Appendix G: Part Numbers

    Appendix G: Part Numbers Appendix G: Part Numbers System Item Part No. Description 404050 HMI / Controller 400001PUB 2" Printer, Porous Ink (Domestic or European) 400004PUB 4" Printer, Porous Ink (Domestic or European) 400386UB Operations Manual Rev A Page 45...

  • Page 46: Printer Replacement Parts

    PCB, Rear Plate, & Vacuum Module Assembly 400214 Roller with Mounting Bracketry, 2" Printer 400215 Roller with Mounting Bracketry, 4" Printer 5760835 Roller Replacement Kit (5 Rollers) 400209 Orifice Ship Cap, 2" Printer 400210 Orifice Ship Cap, 4" Printer 400386UB Operations Manual Rev A Page 46...

  • Page 47: Bracketry

    5760355 Printer Floor Mounting Kit * 5760356 Multi Printer Floor Mounting Kit w/24" Bar * 5760357 Multi Printer Floor Mounting Kit w/44" Bar * * Requires Single Printer Kits (400200, 400201, or 400204) 400386UB Operations Manual Rev A Page 47...

  • Page 48: Fittings

    High-Resolution Maintenance Spray for Porous Ink 2 Pack, Spray Can 5760800 Start Up / Cleaning Kit Gloves, Lint-Free Wipes and Foam Swabs 5760832 Sponge Swabs 100 Sponge Swabs 6600171 Lint-Free Wiping Cloths 300 Cloths 400386UB Operations Manual Rev A Page 48...

  • Page 49: Service Parts And Optional Equipment

    Shipping Plug, Printer Module 400221 Wheel Replacement, Encoder 400222 Power Supply and Mounting Bracket Hardware 400225 Waste Bottle, pack of 6 400235 Shipping Cap, Ink Supply Module Coupler 400236 Replacement Cable, Encoder (not Shown) 400386UB Operations Manual Rev A Page 49...

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