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IJ4000 Impulse Jet

Section 4: Troubleshooting

5765-018 Operations Manual Rev J

Page 35

Section 4: Troubleshooting

The IJ4000 ink jet system incorporates advanced designs, both in hardware and in software. However, if the system ever fails to perform prop-

erly, some built-in indicators will help in troubleshooting. This section will help minimize system downtime and explain some of the diagnostic fea-

tures built into the system.

Print Quality

This section shows examples of various print problems and actions which should be taken to improve the print.

Problem: Minor fractures in print channels.
Possible Cause:

Debris on front plate, air in channel.

Action:

Run Automatic Cleaning System (ACS), using a foam swab to assist in

removal of debris.

Problem: Missing Channels and Channel fractures in print channels.
Possible Cause:

Excessive debris on front plate, air in channel.

Action:

Wipe front plate and run Automatic Cleaning System (ACS), using a foam

swab to assist in removal of debris.

Problem: Missing print channels.
Possible Cause:

Air in channel.

Action:

Run Automatic Cleaning System. If air cannot be removed by running an

ACS cycle, run a Prime Cycle per instructions in “Missing Print” on page 23.

Summary of Contents for IJ4000

Page 1: ...Operations Manual 1 Missouri Research Park Drive St Charles MO 63304 Service Line 1 800 526 2531 Illinois Tool Works Inc 2021 IJ4000 Impulse Jet System 5765 018 Revision J ...

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 2021 Illinois Tool Works Inc All rights reserved ...

Page 3: ...specified carries a limited warranty The inks and conditioners used with the IJ4000 Impulse Jet System carry a limited warranty For all warranty terms and conditions contact Diagraph an ITW Company for a complete copy of the Limited Warranty Statement Warranty IJ4000 System ...

Page 4: ...tosensor and Encoder 24 Step 11 Configure the Print Head via the Controller 25 Step 12 Create a Message 27 Step 13 Print a Message 28 Section 3 Maintenance and Shutdowns 29 System Maintenance 29 Print Head Maintenance 29 ACS Automatic Cleaning System 31 SMART IDS Maintenance 33 Section 4 Troubleshooting 35 Print Quality 35 IJ4000 Impulse Jet System Trouble Shooting 38 Detailed Guide to Determine P...

Page 5: ...ystem 57 SMART IDS Ink and Vacuum Control PCB 64 Appendix C Updating the HMI SMART IDS via USB or Ethernet 71 Appendix D InkJet Demo Software for Windows 71 Appendix E Software Interface 71 Appendix F Part Numbers 72 System 72 Bracketry 73 Fittings and Tubing 74 IJ4000 HMI 74 IJ4000 SMART IDS 75 Cables 76 Print Head Replacement Parts 76 Consumables 77 Service Parts and Optional Equipment 78 ...

Page 6: ...tem contains hazardous voltage 115 230VAC Disconnect from mains power before Performing preventive maintenance Performing any repairs to the unit Servicing the equipment in any manner ESD protection should be worn when servicing internal printed circuit boards After service to the equipment is completed replace all protective devices such as grounding cables and covers before operating the equipme...

Page 7: ...th a controller and a print head Cables and ink lines are not shown System Components Bracketry Kit Item 1 Print Head Item 2 SMART IDS Item 3 IJ4000 HMI Controller Item 4 Power Cord not shown Serial Cable not shown Tubing not shown Software not shown Ink is not included NOTE See limitations in Tubing Limitations Vertical on page 13 TYPICAL INSTALLATION 4 3 1 2 ...

Page 8: ...Manual Rev J Page 8 Step 1 Assemble Bracketry to Conveyor NOTE Mount bracketry as square and as level as possible PRINT HEAD CONVEYOR MOUNT 5765 246 for 384E Print Head 5765 253 for 768E Print Head HMI CONTROLLER SMART IDS MOUNT 5765 250 OPTIONAL T STAND 5765 249 ...

Page 9: ...ev J Page 9 Step 2 Assemble Print Head onto Bracketry ROLLER RETRACTING BRACKET MOUNT FOR 384E PRINT HEAD 5765 246 SINGLE POLE FLOOR MOUNT 5760 355 RETRACTING BRACKET CAN BE MOUNTED ON EITHER SIDE OF PRINT HEAD ROLLER RETRACTING BRACKET MOUNT FOR 768E PRINT HEAD 5765 253 ...

Page 10: ...e Tilt 5 NOTE Tilt angles are given when looking at the rear of the print head Front to rear tilt should be less than 1 5 as indicated by the digital level LED readout on the top rear of the print head AB 768E PRINT HEAD 27 2mm 1 07in TO LOWEST ORIFICE 101 6mm 4in SOLID CHARACTER HEIGHT CD 50 8mm 2in SOLID CHARACTER HEIGHT ABC 22 9mm 0 90in TO LOWEST ORIFICE 384E PRINT HEAD 5 MAX 5 MAX ...

Page 11: ...Adjust Print Head to Substrate Use the bracket handle to adjust print head vertically Loosen the adjustment knobs on the Retracting Bracket to slide the print head toward or away from substrate BRACKET HANDLE VERTICAL ADJUSTMENT ADJUSTMENT KNOBS 3mm 1in GAP RECOMMENDED HORIZONTAL ADJUSTMENT ...

Page 12: ...IJ4000 Impulse Jet Section 2 Quick Start 5765 018 Operations Manual Rev J Page 12 Step 4 Install SMART IDS SMART IDS OPTIONAL FLOOR MOUNT ...

Page 13: ...est Practices SMART IDS 1 5m 5ft Consult Factory if longer HMI Alternate Configurations Conveyor SMART IDS 1m 3ft 1m 3ft SMART IDS HMI Conveyor SMART IDS HMI Conveyor Mount Smart IDS below the height of the print heads Do not create service loops or coils of tubing Minimize length of tubing by cutting to length ...

Page 14: ...m Total Tubing Length 1 Print Head 2 Print Heads 6 1m 20ft Maximum Total Tubing Length 768E Print Heads 384E Print Heads 1 Print Head 15 2m 50ft Maximum Total Tubing Length 2 Print Heads 9 1m 30ft Maximum Total Tubing Length 3 or 4 Print Heads 4 6m 15ft Maximum Total Tubing Length SMART IDS SMART IDS SMART IDS SMART IDS SMART IDS ...

Page 15: ...IJ4000 Impulse Jet Section 2 Quick Start 5765 018 Operations Manual Rev J Page 15 Step 5 Install IJ4000 HMI Controller CONTROLLER ...

Page 16: ...the conveyor compo nents print heads encoder photocell 4 Customer system connections are made inside the SMART IDS Refer to the following page NOTE It is recommended that the Task 1 Print Head be closest to the IJ4000 HMI 5 Plug the SMART IDS into the appropriate mains power outlet NOTE Ensure that the Smart IDS is powered off It will be activated as part of the ink line bleeding procedure SMART I...

Page 17: ...R ENCODER CABLE TASK 2 INTERFACE BOARD CONNECTIONS TASK 1 INTERFACE BOARD CONNECTIONS PRINT HEAD CABLES POWER CORD CUSTOMER SYSTEM CONNECTIONS See Appendix A for details COM2 OPTIONAL I O BOARD ENCODER PHOTOSENSOR CABLE NOTE In many applications Photocell and Encoder may be shared from Task 1 to Task 2 USB FILE BACKUP TRANSFER ACCESS ETHERNET HMI COM1 ...

Page 18: ... diagram at right for typical print head plumbing connections NOTE Do not connect lines to print heads at this time 4 6mm 15ft MAX VACUUM INK CONVEYOR PRINT HEAD PRINT HEAD TEE FITTING 2460 120 DO NOT CONNECT TO PRINT HEAD YET DO NOT CONNECT TO PRINT HEAD YET INK FITTING 5361 329 SMART IDS INK VACUUM FILTER REMOVE AND SAVE CAP REMOVE AND SAVE ALL 3 CAPS VACUUM FITTING 5765 721 INK OUTLET VENT VACU...

Page 19: ...gs Wipe off both con nectors 6 Cut off the vacuum line fitting 5765 721 noted in red on the previous page Remove the plug from the print head vacuum line and push the now raw tubing end into the print head vacuum fit ting NOTE It is critical that all air be purged out of the ink lines prior to connection to the rear of the print heads 7 Form a loop for the next closest print head If the vacuum cyc...

Page 20: ...l 384E Print Head is shown WHEN UPPER LED IS RED PRINT HEAD IS POINTED UP TOO FAR WHEN CENTER LED IS GREEN PRINT HEAD IS READY TO PRINT WHEN LOWER LED IS RED PRINT HEAD IS POINTED DOWN TOO FAR BRACKETRY KITS COME WITH TIE WRAP MOUNTS INSERT TIE WRAP MOUNT IN BAR AND TURN 90 INSERT TIE WRAPS INTO MOUNTS FORM AN 8 MINIMUM SERVICE LOOP FOR TUBING AND CABLE ...

Page 21: ...t this step once more 6 Remove the ship cap see diagram and store on the side of the 768E print head or on the top of the 384E print head NOTE Do not use lint free wipes in the print channel use foam swabs instead 7 Use a foam swab to lightly wipe the orifice plate in a vertical downward motion 8 Prime the print head by pressing the button once quickly ACS 9 Print can be tested by slowly passing a...

Page 22: ...IJ4000 Impulse Jet Section 2 Quick Start 5765 018 Operations Manual Rev J Page 22 SNAP SHIPPING CAP ON TOP OF PRINT HEAD TABS THUMB SCREWS SHIPPING COVER STORAGE ...

Page 23: ...ir bubbles flowing out of the top of the print head and down the face If bubbles are evident repeat steps 1 to 3 three times 4 Perform an ACS cycle then slowly swipe a sheet of paper in front of the print head while pressing the All Channel Print button on the rear of the print head 5 If any print is still missing after all air bubbles are purged recap the print head perform several Prime cycles d...

Page 24: ... sends a signal to the controller which makes adjustments for reported changes in the line speed It is not necessary to install the encoder immediately adjacent to the print heads It is more important to place it where it will accurately measure the speed of the con veyor Install it in contact with the conveyor or with a wheel or roller moving the same speed as the conveyor The encoder s mounting ...

Page 25: ...sents the direction the product will move on the conveyor as seen while standing in front of the IJ4000 HMI or Task 1 Print Head 4 Touch the up down arrows to set the number of print heads on each side of the conveyor 5 Touch the Next button 6 Touch the first print head in the daisy chain If there is only one print head this step is bypassed NOTES The first print head in the daisy chain should be ...

Page 26: ...ffset is 53 3mm 2 1in 9 Select the Encoder tab and touch the External Encoder icon 10 If Internal Encoder is selected type in the speed 11 Select the Print Heads tab then touch the next head to highlight it and continue setup 12 Touch the OK button Print Head setup is now com plete Touch any print head on the display to review or change the properties for that head Touch the Setup Wizard button to...

Page 27: ...he Home Screen select the Messages but ton then select the New button Create and save the message then exit the message editor Message Display Area Product Side Quick Save Product Setup Menu Cursor Field Coordinates On screen Keyboard Bar Codes Text Time Code Count Code Logo Zoom Field Properties Font Selection Carton Ruler Variable Field Delete Button Message Info Line Field Cursor Next Field But...

Page 28: ...8 Step 13 Print a Message 1 From the Home Screen press the Print button 2 Select the desired message to print and press the Print button 3 The message will print on the next photosensor trigger PRINT BUTTON RED PLAY INDICATOR NOT READY TO PRINT GREEN PAUSE INDICATOR READY TO PRINT ...

Page 29: ...reen Print Head Maintenance Daily Shift Startup Periodic Wear safety goggles when working with industrial inks or solutions The majority of print quality degradation is due to excessive debris deposits on the print head orifice plate that disrupt the ink droplet path For best preventative maintenance practices do the following 1 Remove excessive debris build up corrugate dust glue strands and the ...

Page 30: ...o not swab this time 4 Wipe the front plate with a clean lint free cloth to remove any excess ink Shutdowns of 1 Week to 3 Months Shutdown 1 Disconnect SMART IDS from mains power 2 Spray the appropriate cleaning solvent on a lint free cloth and before installing ship cap lightly wipe the front of the print head to remove for eign debris 3 Install shipping cap onto the front of the print head and i...

Page 31: ...ring the storage period See Consumables on page 77 for part numbers Follow instructions in document 5760891N Flush Solution can remain in the print head for one year from the date of flushing ACS Automatic Cleaning System NOTE If the beacon on the SMART IDS is in any way illuminated or flashing the ACS will not activate Make sure all ink faults are corrected before attempting an ACS The ACS is an ...

Page 32: ... clean the selected print head Once a print head has been cleaned verify that all channels are printing properly by touching the All Channel Print button located on the back of the print head Swipe a sheet of paper or other material across the front of the print head as the head purges The print head purges for three seconds each time the All Chan nel Print button is touched 3 Automatically from t...

Page 33: ...will flash slowly Shutdowns of 1 Week to 3 Months During planned shutdown periods of 1 week to 3 months as well as when storing spare print heads 1 Remove the ink bottle close the reservoir vent cap and install the reservoir ship cap Shutdowns of 3 Months or More 1 Follow the recommendations of Shutdowns of 1 Week to 3 Months 2 It is recommended that the print head system be flushed with ScanTrue ...

Page 34: ...elative humidity with no condensation Temperatures above or below the recommended storage temperature for a period greater than one week will reduce the storage life of the ink NOTE Do not shake the bottle of ink before use Agitating the ink may introduce air into the Print Head If shaken the bottle must sit for at least two hours before use Use Life of an OPENED Bottle of Ink ScanTrue II 3 months...

Page 35: ...ems and actions which should be taken to improve the print Problem Minor fractures in print channels Possible Cause Debris on front plate air in channel Action Run Automatic Cleaning System ACS using a foam swab to assist in removal of debris Problem Missing Channels and Channel fractures in print channels Possible Cause Excessive debris on front plate air in channel Action Wipe front plate and ru...

Page 36: ...h sponge swab 5760 832 and run Automatic Cleaning System Problem Fuzzy Print Possible Cause Print head too far away from substrate Action Move print head to within 1 8 from product Problem Occasional checkerboard print pattern Possible Cause Encoder slipping or bouncing on belt Action Tighten encoder on belt replace encoder o rings if required replace con veyor belt with smooth seamless type belt ...

Page 37: ...ncoder Action Check for correct encoder must use part 5760 820 IJ Problem Short image dark print checkerboard pattern Possible Cause Incorrect encoder or wheel size or incorrect line speed set too high if using internal encoder Action Check for correct encoder must use part 5760 820 IJ Problem Backwards print Possible Cause Incorrect print direction specified in set up Action Re do print head set ...

Page 38: ...n Check for power LED on Internal Power Supply Board If LED is illuminated check power supply output on P2 It should be 12VDC PC Board Check the LED indicators and connector voltages on the board LED3 Green indicates a print head is signaling for the Vacuum Pump to turn on LED5 Red indicates the Waste Bottle is full LED6 Red turns on off and flashes with the beacon Off indicates ink is OK On indic...

Page 39: ...h is turned on Check for power LED on Internal Power Supply Board If LED is illuminated check power supply output on P2 It should be 12VDC PC Board Check the LED indicators and connector voltages on the board LED5 Red indicates the Waste Bottle is full LED6 Red turns on off and flashes with the Beacon Off indicates ink is OK On indicates ink is low Slow Flash 1Hz indicates ink is out and Fast Flas...

Page 40: ...ll not heat At Tem perature LED never turns on Print Engine or PC Board Return print head to manufacturer Missing print Air in Print Head Air in the Print Head is the most likely cause of missing channels Refer to Missing Print on page 23 for bleeding procedures Ink Reservoir in Print Head does not refill or no ink pumps out during an ACS or Prime Cycle 384E Solenoids or PC Board Return print head...

Page 41: ...nstructions NOTE If the red LED on the photosensor fails to illuminate when an object is placed in front of but not touching the photosensor it indicates that the photosensor is disconnected or the power supply or photosensor has failed System Symptom Possible Cause Operational Test Method Ink Reservoir in Print Head does not refill or no ink pumps out during an ACS or Prime cycle 768E Continued P...

Page 42: ... Ink Flow Proper ink flow through the Impulse Jet ink circuit is critical not only to being able to print but also to maintain the IJ Print Heads in proper con dition without introducing air into the print engine Most often issues with ink flow through the Impulse Jet System will be indicated by the following error message The following procedure should be used to identify the proper issue and res...

Page 43: ...h should drop and clear error by removing the bottle 2 Make sure Ink Bottle is properly installed has adequate ink and is not expired 3 Check and correct all vent ports on Smart IDS and Print Head s to make sure they are not capped and filters are not obstructed 4 Check and correct Ink supply tubing for any obvious signs of damage or interference bends kinks loops equipment placed on top of lines ...

Page 44: ...IJ4000 Impulse Jet Section 4 Troubleshooting 5765 018 Operations Manual Rev J Page 44 Print Head Ink Supply Tubing IDS Diagnosis ...

Page 45: ...IJ4000 Impulse Jet Section 4 Troubleshooting 5765 018 Operations Manual Rev J Page 45 ...

Page 46: ... all print heads 3 Disconnect the Ink supply tubing from each print head 4 Go to the first print head reconnect the print head cable a Make sure that the print head cable connects directly to the Smart IDS Interface Card Task Board b 384 print heads that were daisy chained may require switching cables to make a direct connection 5 Connect the Ink supply tubing 6 Power on the Smart IDS and observe ...

Page 47: ...on 4 Troubleshooting 5765 018 Operations Manual Rev J Page 47 Impulse Jet Ink Components and Ink Circuit The Impulse Jet Ink Circuit is gravity fed from the ink supply tubing to the 5760335 pump and then out to the print heads ...

Page 48: ...A System Specifications 5765 018 Operations Manual Rev J Page 48 Appendix A System Specifications System 207mm 8 1in 247 5mm 9 7in 475mm 18 7in 845 2mm 33 3in 520 7mm 20 5in 371 3mm 14 6in 116 8mm 4 6in 114 7mm 4 5in 669 5mm 26in ...

Page 49: ...0 psi approximately pump output when operating Ports 2 RS 232 Ports 1 USB Port 1 100 base T Ethernet Port Factory set IP Address 10 1 2 3 Environment Ambient operating temperature 5 C to 40 C 40 F to 104 F Operating humidity 10 90 non condensing Tubing Limitations Maximum vertical tube length bottom of SMART IDS to bottom of highest print head 6 1m 20ft ink pump limitation Maximum height of SMART ...

Page 50: ...m 6 51in Size Weight 2 18kg 4 6lb Height 196 1mm 7 72in Width 330 7mm 13 02in Depth 41 3mm 1 62in IP Rating IP34 estimated Enclosure Stainless Steel User Interface Graphical User Interface with on screen keyboard Fonts Unicode Display 259 08mm 10 2in LCD with touch screen 800 x 480 pixels Storage 512 MB flash memory Ports 2 RS 232 ports 1 USB port 1 100 Base T Ethernet port Electrical Input 15VDC ...

Page 51: ... min ute 200 dpi 38 1 meters per minute 125 feet per minute 300 dpi Barcode Up to 45 72 meters per minute 150 feet per minute Higher line speeds achievable with reduction of dpi Print Resolution 384 128 Head 128 addressable channels 50 8mm 2in solid print height Throw Distance Up to 6mm 1 4in for alphanumeric 1 6mm 1 16in recommended for best barcode quality 66 5mm 2 62in 116 8mm 4 60in 22 9mm 0 9...

Page 52: ...in ute 200 dpi 38 1 meters per minute 125 feet per minute 300 dpi Barcode Up to 45 72 meters per minute 150 feet per minute Higher line speeds achievable with reduction of dpi Print Resolution 768E 256 Head 256 addressable channels 101 6mm 4in solid print height Throw Distance Up to 6mm 1 4in for alphanumeric 1 6mm 1 16in recommended for best barcode quality 151 9mm 5 98in 27 1mm 1 07in TO LOWEST ...

Page 53: ...ct Diagram 1 IJ4000 HMI Controller 2 SMART IDS 3 Print Head 4 Conveyor 5 Product 6 Print Head Bracketry 7 Ink Status Beacon 8 Encoder 9 Ink Supply 10 Photosensor 11 Vacuum Waste Collector Bottle 12 Encoder Cable 13 Print Head Cable 14 Throw Distance 3mm 1 8in Recommended 3 1 13 6 4 10 8 2 5 7 11 6 13 12 14 3 9 ...

Page 54: ...ge Lookup INTEGRATED SCANNER WEIGHT SCALE IV12 VALVEJET PRINTER THERMAL TRANSFER PRINTER PLC TJ HP PRINTER External Input I O CABLE FROM SMART IDS PHOTOSENSOR ENCODER CABLE TASK 2 INTERFACE BOARD CONNECTIONS TASK 1 INTERFACE BOARD CONNECTIONS PRINT HEAD CABLES POWER CORD CUSTOMER SYSTEM CONNECTIONS COM2 OPTIONAL I O BOARD ENCODER PHOTOSENSOR CABLE USB FILE BACKUP TRANSFER ACCESS ETHERNET HMI COM1 ...

Page 55: ...a signal to the SMART IDS to turn on off the ink pump The reservoir is vented allowing atmospheric pressure to be maintained inside the reservoir The vent is located on the back of the print head and is filtered to ensure debris can not enter the ink reservoir Ink is fed from the print head ink reservoir to the print engine via gravity Capillary action is then utilized to supply the orifices in th...

Page 56: ...lug Print Trigger Photosensor The photosensor detects when a product is about to pass by the print heads and signals the IJ4000 HMI Controller to start a print cycle The pho tosensor signal is active low and it must remain low for at least one encoder pulse Once a print cycle starts it continues to completion regard less of what the photosensor signal does The IJ4000 is compatible with through bea...

Page 57: ...rint will be disabled on all print heads and a signal will be sent to the SMART IDS that will cause a slow flashing of the beacon 4 SMART IDS vacuum and ink waste collector Like the ink vacuum is supplied to all the print heads via a single tubing line that is subsequently teed The SMART IDS is equipped standard with a heavy duty vacuum pump to assist in the Automatic Cleaning System ACS Additiona...

Page 58: ...tubing line is required from the SMART IDS A pressur ized can of solvent is the main source of solvent The solvent flows through a regulator into the SMART IDS This supply line has a pressure sensor to detect when the pressurized solvent can is empty When the can is empty the beacon light will illumi nate steady One must determine the state of the beacon lamp by determining whether the ink supply ...

Page 59: ...isabling the pumps overflow is not only prevented at the separator bottle but also at the print head by disabling the ACS feature Additionally the vacuum pump is prevented from pulling the ink into itself Once the ink separator bottle has been replaced or emptied the SMART IDS power switch must be toggled off then on to reset Ink Fault Detection If an ink line is not plugged into a port or is brok...

Page 60: ... Also supplies the input voltage to the 1 8V regulator TP4 1 8VDC power for the CPU core LEDs D1 Ethernet connector Green Flashes to indicate network traffic D2 Ethernet connector Green Indicates valid network connection D1 Yellow flashes when the CPU is running On CPU module D4 Green indicates 3 3V is present D2 Green indicates 3 3V is present On CPU module GREEN LED GREEN LED VISIBLE ON THE CONN...

Page 61: ...IJ4000 Impulse Jet Appendix B Theory of Operation 5765 018 Operations Manual Rev J Page 61 IJ4000 SMART IDS Main CPU PCB continued ...

Page 62: ...DS ink low signal active low TP11 Print head pump signal active high TP12 SMART IDS ink out signal active low TP13 Print head at temperature signal active low TP14 SMART IDS vacuum signal active low TP15 Print head ink out signal active high TP16 SMART IDS pump signal active low TP17 DC power in 24V TP18 Print head CLOCK signal TP19 Print head DATA2 signal TP20 Print head DATA signal TP21 Print he...

Page 63: ...IJ4000 Impulse Jet Appendix B Theory of Operation 5765 018 Operations Manual Rev J Page 63 IJ4000 Print Head Interface Interconnect Diagram HIGH RESOLUTION INTERFACE BOARD 400479 ...

Page 64: ...icates that the waste bottle is full LED6 Red turns on off and flashes with the beacon Off indicates ink is OK on indicates ink is low slow flash 1 Hz indicates ink is out and fast flash 6 Hz indicates that the waste bottle is full or the pump was turned on for more than 10 seconds LED7 Yellow indicates ink is low in the SMART IDS reservoir Connectors SW1 NOT DEFINED P1 SMART IDS I O connector J1 ...

Page 65: ...60 515 5760 514 5765 365 5765 370 5765 370 BOTTOM FIRST POWER SUPPLY BROWN BLUE RED DOT RED BLACK WHITE BROWN BLUE POWER OUT TO IJ4000 HMI POWER OUT TO IJ4000 HMI BROWN BLUE BROWN BROWN BROWN BLUE BLUE BEACON RESERVOIR VACUUM PUMP SEPARATOR 12V POWER SUPPLY SMART IDS BOARD POWER SWITCH POWER INLET TOP SECOND POWER SUPPLY TIE WRAP TO IJ4000 HMI NETWORK HUB NETWORK LIQUID PUMP OPTIONAL REMOTE BEACON...

Page 66: ...ation 5765 018 Operations Manual Rev J Page 66 IJ384E Print Head PRINT ENGINE PURGE SOLENOID REAR VIEW CHECK VALVE PRINT HEAD INK INLET FILTER INTAKE SOLENOID INK VACUUM RETURN FILTERED VENT RETURN SOLENOID INK RESERVOIR W LEVEL DETECT INK INLET ...

Page 67: ...ation 5765 018 Operations Manual Rev J Page 67 IJ768E Print Head INTAKE SOLENOID PRINT ENGINE REAR VIEW CHECK VALVE PRINT HEAD INK INLET FILTER PURGE SOLENOID INK VACUUM RETURN FILTERED VENT RETURN SOLENOID INK RESERVOIR W LEVEL DETECT INK INLET ...

Page 68: ...IJ4000 Impulse Jet Appendix B Theory of Operation 5765 018 Operations Manual Rev J Page 68 Print Head Control PCB 5765 543 PRINT HEAD PCB FRONT VIEW 5765 543 PRINT HEAD PCB BACK VIEW ...

Page 69: ...as expired LED4 Green indicates high voltage is low LED5 Green indicates print head has reached its operating temperature The operating temperature is set via a resistor in the print engine LED6 Green indicates print head is in stand by mode Heater and high voltage are turned off LED7 Green indicates print head reservoir is full LED8 Green indicates intake valve is open LED9 Yellow indicates heate...

Page 70: ... 15 N C 2 PUMP 14 VACUUM 1 DATA4 J3 ON IJ INTERFACE BOARD J1 PRINT HEAD BOARD N C 1 VACUUM 14 PUMP 2 N C 15 INKLOW 3 I O 16 INKOUT 4 GND 17 GND 5 24V 18 24V 6 N C 19 N C 7 XPRINT 20 XPRINT 8 SCS PHOTO 21 N C 9 DATA4 22 DATA4 10 DATA3 23 DATA3 11 CLOCK 24 CLOCK 12 N C 25 N C 13 1 DATA 4 14 VACUUM 2 PUMP 15 N C 3 INKLOW 16 I O 4 INKOUT 17 GND 5 GND 18 24V 6 24V 19 DATA3 7 DATA3 20 XPRINT 8 XPRINT 21...

Page 71: ...nd ink delivery system please refer to document 5765 390N Updating the Controller and Ink Delivery System via USB or Ethernet Appendix D InkJet Demo Software for Windows For information on the InkJet Demo software please refer to document 5765 388N InkJet Demo Software for Windows Appendix E Software Interface For information on interfacing with the software please refer to document 5760 113 Softw...

Page 72: ...E Print Head ScanTrue II Flushed Domestic or European 3 5765 015768S2 IJ3000 768E Print Head ScanTrue II Domestic or European 4 5765017DJ1 IJ4000 SMART IDS 1 Card Domestic 5765017DJ2 IJ4000 SMART IDS 2 Cards Domestic 5765017DJ1 S IJ4000 SMART IDS 1 Card I O Domestic 5765017DJ2 S IJ4000 SMART IDS 2 Cards I O Domestic 5765017EJ1 IJ4000 SMART IDS 1 Card European 5765017EJ2 IJ4000 SMART IDS 2 Cards Eu...

Page 73: ...tracting Bracket Kit 384E or 768E Print Head Domestic or European 4 5765 253 IJ4000 Print Head Roller Mounting Bracket Kit 768E Print Head Domestic or European 5 5765 249 IJ4000 T Base Stand Kit 6 5765 250 IJ4000 Conveyor Mounting Bracket Kit 7 5760 354 Multi Print Head Conveyor Mounting Kit 8 5760 355 Print Head Floor Mounting Kit 9 5760 356 Multi Print Head Floor Mounting Kit w 24 Bar 5760 357 M...

Page 74: ...9 1 8 Barb x 1 8 Flow In Line Male 5 fittings per kit Connects to print head ink port and SMART IDS ink port or any female fitting 5770 263 Fitting 5765 721 3 16 Barb x 1 8 Flow Female 5 fittings per kit Connects to print head vacuum port and SMART IDS vacuum port 5765 209 Fitting 2460 120 1 8 Barbed Tee 5 fittings per kit Ink supply lines 5765 210 Fitting 2460 143 Luer Cap Male 5 fittings per kit...

Page 75: ...Replacement 14 5765 256 Kit Interface Board Upgrade IJ Additional Task includes Power Supply Interface Board and Cables 5 5765 381 Kit Replacement CPU SMART IDS 15 5760 342 Kit Waste Bottle Replacement 2 Pack 6 5760 335 Kit Liquid Pump Replacement 16 5760 341 Kit 12V Bulb Replacement 2 Pack 7 5765 255 Kit Internal Tubing Fitting Replacement 17 5760 344 Kit External Fittings 8 5760 339 Kit Reservoi...

Page 76: ...T IDS to Print Head 10 5760 614 025 Cable IJ4000 SMART IDS To Print Head 25 Item Part No Print Head Description 1 5765 238 384E IJ384E Roller Bracket Kit 2 5765 254 768E IJ768E Roller Bracket Kit 3 5760 835 384E 768E Roller Replacement Kit 5 Rollers 4 5765 242 384E Orifice Cover Plate 5 5760 813 768E Orifice Cover Plate 6 5765 272 384E 768E Kit Print Head PCB 384E 768E 384E PRINT HEAD 768E PRINT H...

Page 77: ...1 0961 01D ScanTrue II PLUS Pigmented Oil Based for Porous Media Black 1 Bottle 500mL 001 0988 01D ScanTrue II PLUS Pigmented Oil Based for Porous Media Black 1 Bottle 1L 001 0899 01 ScanTrue II Flush Storage Solution 1 Bottle 500mL 5760 695 Impulse Jet Maintenance Spray for ScanTrue II 2 Pack Spray Can 5760 800 Start Up Cleaning Kit Gloves Lint Free Wipes and Foam Swabs 5760 832 Sponge Swabs 100 ...

Page 78: ...ot shown 2464 182 010 Extension Cable 10 for Encoder or Photosensor 2464 182 025 Extension Cable 25 for Encoder or Photosensor 4 5760 614 002 Print Head Cable Assembly 2 5760 614 006 Print Head Cable Assembly 6 5760 614 010 Print Head Cable Assembly 10 5760 614 015 Print Head Cable Assembly 15 5760 614 025 Print Head Cable Assembly 25 5 5765 206 Encoder O Ring Replacement Kit contains O ring 2 7 8...

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