Illinois Tool Works ResMark 5000 Operation Manual
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Illinois Tool Works ResMark 5000 Operation Manual

High-resolution inkjet system
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Operations
Manual
ResMark 5000 High-Resolution System
400386
Revision B
1 Missouri Research Park Drive • St. Charles, MO 63304 • Service Line 1-800-526-2531
Illinois Tool Works Inc © 2023

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Summary of Contents for Illinois Tool Works ResMark 5000

  • Page 1 Operations Manual ResMark 5000 High-Resolution System 400386 Revision B 1 Missouri Research Park Drive • St. Charles, MO 63304 • Service Line 1-800-526-2531 Illinois Tool Works Inc © 2023...
  • 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 The ResMark 5000 High-Resolution System, including all components unless otherwise specified, carries a limited warranty. The inks and conditioners used with the ResMark 5000 High-Resolution System carry a limited warranty. For all warranty terms and conditions, contact Diagraph, an ITW Company, for a complete copy of the Limited Warranty...

  • 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

    ResMark 5000 System 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.

  • Page 7: Section 2: Quick Start

    ResMark 5000 System Section 2: Quick Start Section 2: Quick Start The figure at right illustrates a typical installation. System Components: 1. Bracketry Kit (Item 1) 2. Printers (Item 2) 3. HMI (Item 3) 4. Power Supply (Item 4) 5. Photosensor (Item 5) 6.

  • Page 8: Step 1: Assemble Bracketry To Conveyor

    ResMark 5000 System Section 2: Quick Start 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)

  • Page 9: Step 2: Assemble Printer Onto Bracketry

    ResMark 5000 System Section 2: Quick Start Step 2: Assemble Printer onto Bracketry NOTE: The dovetail adapter and mounting bracketry can be mounted on either side of the Printer. DOVETAIL ADAPTER AND RETRACTING BRACKET AND CAN BE MOUNTED ON EITHER SIDE OF...

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

    ResMark 5000 System Section 2: Quick Start 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.

  • Page 11: Step 4: Mount Photosensor And Encoder

    ResMark 5000 System Section 2: Quick Start Step 4: Mount Photosensor and Encoder Photosensor 1. Mount the photosensor (kit 400203) in the roller bracket attached to the Primary Printer Module and route the cable as shown in one of the two shown configurations depending on the application.

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

    ResMark 5000 System Section 2: Quick Start Step 5: Daisy-Chain Printers, HMI, and/or Customer Network OPTIONAL 1. Install secondary Printers as shown in the previous steps. 2. Secondary Printers should be connected between the upstream Printer Ethernet out port to the input port on its Printer as shown as shown in the diagrams below.
  • Page 13 ResMark 5000 System Section 2: Quick Start Networked System with Optional HMI - One Printer PRIMARY PRINTER TO DOWNSTREAM FROM UPSTREAM PRINTER OR HMI PRINTER OR CUSTOMER NETWORK CUSTOMER NETWORK Networked System with Optional HMI - Two or More Printers...

  • Page 14: Step 6: Powering Up The Printers

    ResMark 5000 System Section 2: Quick Start Step 6: Powering up the Printers 5. Install the power cord into the first Printer in the system (from now on called the Primary Printer). The power supply cable or jumper cable can be plugged into either power port.

  • Page 15: Step 7: Adjust Printer To Substrate

    ResMark 5000 System Section 2: Quick Start Step 7: Adjust Printer to Substrate WASTE BOTTLE STATUS LED AT TEMPERATURE LED 1. Tighten bracketry to conveyor such that the Printer is perpendicular to the carton; however, INK CARTRIDGE ALL CHANNEL STATUS LEDs ensuring that the Printer is level from front to back.

  • Page 16: Step 8: Printer Level And Tilt

    ResMark 5000 System Section 2: Quick Start Step 8: Printer Level and Tilt Printer Level 1. Slightly loosen the Slide Bracketry Screws shown in the diagram in "Step 7: Adjust Printer to Substrate" on page 15. 2. When the Printer is perpendicular to the substrate, tighten the Slide Bracketry Screws.

  • Page 17: Step 9: Install Ink Cartridge

    ResMark 5000 System Section 2: Quick Start Step 9: Install Ink Cartridge 1. Remove the shipping plugs from the rear and top of the Ink Supply Module. REMOVE Retain plugs for potential later use. 2. Install the ink cartridge and vent filter as shown.

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

    ResMark 5000 System Section 2: Quick Start Step 10: Priming the Printer and Testing Print Quality 1. Ensure all Printers are at operating temperature. SHIP CAP INSTALLED 2. Ensure that the shipping cap is installed for Recirculation, otherwise ink may overflow.

  • Page 19: Step 11: Cap Unused Ports

    ResMark 5000 System Section 2: Quick Start Step 11: Cap Unused Ports After the installation is complete, it is recommended that all unused ports be capped to prevent accidental electrostatic discharge into a connector. The Primary Printer should have all ports populated with a USB DEVICE OR cable.

  • Page 20: Section 3: Maintenance And Shutdowns

    ResMark 5000 System Section 3: Maintenance and Shutdowns Section 3: Maintenance and Shutdowns Following are the recommended maintenance procedures to keep the Printer printing cleanly and efficiently. System Maintenance SHIPPING CAP STORAGE Intermittent (as required): 1. Be sure the photosensor is clean and free of debris.

  • Page 21: Ink Supply Module Maintenance

    ResMark 5000 System Section 3: Maintenance and Shutdowns Ink Supply Module Maintenance Daily / Shift Startup / Periodic 1. Do not remove the ink cartridge. Use a low pressure air nozzle (5psi) and / or maintenance spray and a lint free cloth to remove debris buildup on and around the Ink Supply Module.

  • Page 22: Cleaning Maintenance System

    ResMark 5000 System Section 3: Maintenance and Shutdowns Cleaning Maintenance System The cleaning system is an invaluable maintenance tool for routine cleaning of loose debris from the print engine orifice plate. The images below demonstrate print before and after the cleaning.

  • Page 23: Printer Module Replacement

    ResMark 5000 System Section 3: Maintenance and Shutdowns Printer Module Replacement The normal life of a high-resolution piezoelectric Printer is dictated by the amount of debris the orifice plate encounters during the coding application. Fine corrugate will fly into the orifice holes and clog / disrupt printing. The Printer Module can be returned to the factory and disassembled, cleaned (down to the engine level), and returned to normal service making it more economical and green for the environment.

  • Page 24: Section 4: Troubleshooting

    ResMark 5000 System Section 4: Troubleshooting Section 4: Troubleshooting Print Quality This section shows examples of various print problems and actions which should be taken to improve the print. Minor Fractures in Print Possible Cause Action Step 1: Run Cleaning cycle.
  • Page 25 ResMark 5000 System Section 4: Troubleshooting Missing Channels Possible Cause Action Step 1: Run Prime feature for 5 seconds. Excessive debris on front Step 2: Use a foam swab to clean debris on orifice plate in a vertical downward motion while ink is flowing.
  • Page 26 ResMark 5000 System Section 4: Troubleshooting Top-Down Dropout Possible Cause Action Step 1: Remove vent cap and install filter. Step 2: Install orifice plate ship cap and recirculate for 15 minutes. Vent Cap installed on vent Step 3: Remove ship cap, swab orifice plate, and run Prime feature for 5 seconds.
  • Page 27 ResMark 5000 System Section 4: Troubleshooting Occasional Checkerboard Print Pattern Possible Cause Action Encoder slipping or bouncing Step 1: Tighten encoder spring mechanism to ensure constant contact with the conveyor belt. on belt Conveyor is not smooth or Step 1: Relocate encoder to a smooth representative surface or a new conveyor will be needed.
  • Page 28 ResMark 5000 System Section 4: Troubleshooting Short Image, Dark Print, Checkerboard Pattern Possible Cause Action Incorrect encoder or wheel Step 1: Check for correct encoder (must use part number 400206 or equal). size Step 1: Measure actual conveyor speed with a tachometer.

  • Page 29: System

    ResMark 5000 System Section 4: Troubleshooting System System Possible Review Observation Action Symptom Cause Check for Power LED to the Ink Supply Module. If No power from power Power Supply LED is not illuminated, check power supply LED and /...
  • Page 30 ResMark 5000 System Section 4: Troubleshooting System Possible Review Observation Action Symptom Cause Replace Ink Supply Module LED8: Green; indicates a Printer is signaling for the PC Board Vacuum Pump to turn on. Replace PCB Green Empty waste bottle Waste LED is red.
  • Page 31 ResMark 5000 System Section 4: Troubleshooting Photosensor Normal operation: • Photosensor plugged into the Primary Printer. • The photosensor green power on LED is illuminated. • The photosensor yellow detect LED illuminates when an object is held between 5 mm - 100 mm (0.2 in - 4 in) from the face of the sensor.

  • Page 32: Appendix A: System Specifications

    ResMark 5000 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] 400386 Operations Manual Rev B Page 32...

  • Page 33: Controller Hmi

    ResMark 5000 System Appendix A: System Specifications Controller HMI 2X M8 X 32mm 308.0mm [12.13in] 154.0mm [6.06in] [2X M8 X 1.25in] 38.1mm [1.50in] 225.0mm [8.86in] 93.4mm [3.68in] Size Fonts Electrical Weight: 2,18kg [5.5lb] True Type Input: 12VDC, 3A Height: 196,1mm [7.72in] Display Width: 330,7mm [13.02in]...

  • Page 34: 2" Printer

    ResMark 5000 System Appendix A: System Specifications 2" Printer Size - 2" Head 167mm L: 447mm [17.6in] [6.6in] W: 66mm [2.6in] 104mm H: 117mm [4.6in] 117mm [4.1in] [4.6in] Weight: 2,7kg [6lbs] IP Rating IP65 (estimated) 121mm 231mm 216mm Enclosure [4.8in] [9.1in]...

  • Page 35: 4" Printer

    ResMark 5000 System Appendix A: System Specifications 4" Printer Size - 4" Head L: 338,1mm [13.31in] 146mm [5.8in] W: 71,1mm [2.80in] 167mm [6.6in] H: 160,8mm [6.33in] 159mm [6.3in] Weight: 4,3kg [9.5lbs] IP Rating IP65 (estimated) 121mm 244mm 231mm [4.8in] Enclosure [9.1in]...

  • Page 36: System Interconnect Diagram

    ResMark 5000 System Appendix A: System Specifications System Interconnect Diagram 1. 4" Printer (Primary) 2. 2" Printer (Secondary) 3. HMI 4. Conveyor 5. Product and Print Direction 6. Printer Bracketry 7. Ink Status / Communications LED 8. Encoder 9. Photosensor 10.

  • Page 37: Customer System Connection

    ResMark 5000 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 400386 Operations Manual Rev B Page 37...

  • Page 38: Appendix B: Theory Of Operation

    ResMark 5000 System Appendix B: Theory of Operation Appendix B: Theory of Operation Functional Description This high-resolution inkjet Printer 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 Printers. Print can be placed 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.

  • Page 39: Ism Features

    ResMark 5000 System Appendix B: Theory of Operation ISM Features Recirculation WASTE BOTTLE AT TEMPERATURE LED STATUS LED This feature can only be controlled locally at the Printer as the orifice shipping cap must be INK CARTRIDGE ALL CHANNEL STATUS LEDs aligned properly and securely mounted in place.

  • Page 40: Ink States

    ResMark 5000 System Appendix B: Theory of Operation Waste Bottle Status During normal operation the waste bottle status light will be green; indicating the waste bottle is not full. When the ink waste level rises to a point where it lifts the float UP in the waste module, this LED will turn red. The waste ink will then need to be removed and emptied according to local laws and regulations.

  • Page 41: Printer Daisy Chain

    ResMark 5000 System Appendix B: Theory of Operation Ink Waste Collector Full Upon filling the ink waste collector bottle, a float level detect raises inside the separator assembly. The feature disables pumps inside the ISM until the waste bottle is emptied. By disabling the pumps, overflow is prevented at the waste bottle.

  • Page 42: Appendix C: Diagrams

    ResMark 5000 System Appendix C: Diagrams Appendix C: Diagrams ISM Main CPU PCB Assembly Description Connector Description Connector Description LED1 Ethernet: ON = 100 Mbps; OFF = 10Mbps WIFI Dongle: USB Ink and Vacuum Pumps: 6-pin LED2 Ethernet: ON = 100 Mbps; OFF = 10Mbps...

  • Page 43: Ism Internal Wiring Diagram

    ResMark 5000 System 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 400386 Operations Manual Rev B...

  • Page 44: Appendix D: Ink

    ResMark 5000 System Appendix D: Ink Appendix D: Ink Storage Life of a FACTORY SEALED Cartridge of Ink • 24 months from date of manufacture. • Store in a cool dry environment between 10°C - 32°C (50°F - 90°F). Temperatures above or below the recommended storage temperature for a period greater than one week will reduce the storage life of the ink.

  • Page 45: Appendix G: Part Numbers

    ResMark 5000 System Appendix G: Part Numbers Appendix G: Part Numbers System Item Part No. Description 404050 HMI / Controller 400001PDG 2" Printer, Porous Ink (Domestic or European) 400004PDG 4" Printer, Porous Ink (Domestic or European) 400386 Operations Manual Rev B...

  • Page 46: Printer Replacement Parts

    ResMark 5000 System Appendix G: Part Numbers Printer Replacement Parts Item Part No. Description 400002PDG Ink Supply Module, Porous Ink 400003PDG Printer Module, 2", Porous Ink (Domestic or European) 400005PDG Printer Module, 4", Porous Ink (Domestic or European) 400205 PCB, Rear Plate, & Vacuum Module Assembly 400214 Roller with Mounting Bracketry, 2"...

  • Page 47: Bracketry

    ResMark 5000 System Appendix G: Part Numbers Bracketry Item Part No. Description 400200 Mounting Bracket Kit with Retractor for 2" or 4" Printer (Domestic or European) 400201 Mounting Bracket Kit with Retractor and Rollers for 2" Printer (Domestic or European)

  • Page 48: Fittings

    ResMark 5000 System Appendix G: Part Numbers Fittings Part No. Description Contents Where Used 400223 Fitting, 400522, Luer Cap, Male 5 fittings per kit ISM vent port - storage 400224 Fitting, 400521, Luer, 90 degree 5 fittings per kit ISM vent port - while printing...

  • Page 49: Service Parts And Optional Equipment

    ResMark 5000 System Appendix G: Part Numbers Service Parts and Optional Equipment Item Part No. Description 400203 Photosensor, Diffuse Type w/ 2ft Cable Encoder Assembly w/ Mounting Bracket & 20ft 400206 Cable 400208 Photosensor/Encoder Adapter (not shown) 400211 Beacon, Remote...

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