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Integrated Valve

Appendix B: Theory of Operation

5760-107 Operations Manual Rev C 

Page 57 of 86

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). It exe-
cutes the system program from flash and SRAM. The other microcontroller (U21) controls
the keyboard and touch screen, decoding user inputs and sending appropriate commands
to the CPU.

The LCD controller (U22) contains the display RAM, as well as all circuitry needed to read
the display RAM, format its data and send it to the LCD with the necessary control signals
so that what you see on the display is of some use. The CPU writes display data into the
display RAM.

The real time clock and calendar (U2) keeps system time.

The 3V battery (BT1) preserves system data and keeps the clock running during power
outages or when the IJ3000 is not plugged into a power outlet.

Test Points:

TP1:

12VDC

TP2:

GND

TP3:

5VDC

TP4:

3.3VDC

LEDs:

D2:

Green. 5VDC present indicator

D3:

Yellow. Flashes when the CPU is running.

D21:

Ethernet connector, Green. Flashes to indicate network traffic.

D22:

Ethernet connector, Red. Indicates valid network connection. 

Jumpers:

J3:

Flash Lock; used during CPU board manufacture. There
should be no jumper during normal operation.

J8:

Used during CPU board manufacture. There should be no jumper

during normal operation.

JP3:

Used during CPU board manufacture. There should be no jumper

during normal operation.

YELLOW

LED

GREEN

LED

D22

D21

P2

P1

J5

D2

D3

J3

TP1

JP1

J2

J1

J4

TP4

BT1

P3

GREEN LED, VISIBLE

ON THE CONNECTOR

VIA  A LIGHT PIPE

RED LED, VISIBLE

ON THE CONNECTOR

VIA  A LIGHT PIPE

CPU BOARD

U22

U21

U13

U2

Summary of Contents for Diagraph IJ3000

Page 1: ...1 Missouri Research Park Drive St Charles MO 63304 ServiceLine 1 800 526 2531 Illinois Tool Works Inc 2004 5760 107 Revision C Integrated Valve Ink Jet System Operations Manual ...

Page 2: ......

Page 3: ... time and without notice 2004 Illinois Tool Works Inc All rights reserved Printed in the United States of America IJ3000 Integrated Valve Ink Jet System Operations Manual 5760 107 Revision C Multiple Translations This manual has been translated into other languages If there is an inconsistency or ambiguity as to the meaning of any word or phrase in a translation the English text will prevail ...

Page 4: ...nents unless otherwise specified carries a limited warranty The inks and conditioners used with the IJ3000 system carry a limited warranty For all warranty terms and conditions contact Diagraph an ITW Company for a complete copy of the Limited Warranty Statement Warranty ...

Page 5: ...stalling Controller IDS Bracketry 17 Print Head Bracketry 18 Mounting the Print Heads 18 Mounting the Photosensor 19 Photosensor Operation 19 The Encoder 20 Controller Connections 20 CPU Connections 21 Using the Optional Second Interface Board 21 Sharing an Encoder and or Photosensor 21 Configuring the IDS 22 Attaching Ink Regulators 22 Plumbing the System 23 Connecting the Ink Supply 25 Priming t...

Page 6: ...sts 39 Purge Test 39 Print Test 39 Photosensor Test 40 Print Head Ink Pressure Test 40 Ink Regulator Input Pressure Test 40 Encoder Functional Testing 41 Print Quality Troubleshooting 43 Diagnosis 43 Setting Ink Pressure 46 Ink Regulator Maintenance Procedure 47 Print Head Pulse Width Adjustment 48 Cleaning the Front Plate of a Clogged Print Head 49 Broaching the Orifice 49 Print Head Pre Load Adj...

Page 7: ... Line Override Feature 61 Overheating Protection 61 IDS Board Test Points 62 IDS Wiring Diagrams 63 Appendix C Parts and Supplies 65 Consumables 65 Parts in Modular Kits 66 IDS Assembly Kits 67 Appendix D Maximum dpi Calculation for a Given Line Speed 69 Appendix G Font Samples 71 Appendix F Setting the IP Address of an IDS3000 79 Equipment Needed 79 Procedure 79 Appendix G Testing an Electrical O...

Page 8: ...Integrated Valve Page iv of iv 5760 107 Operations Manual Rev C ...

Page 9: ...gned to work with Diagraph I V Integrated Valve print heads and the IDS3000 Ink Delivery System See the IJ3000 Controller Manual part number 5760 121 I V Print Heads Print Heads designed for high speed printing applications in harsh environments using Diagraph porous and non porous inks IDS3000 An ink delivery system capable of supplying porous and non porous ink to a maximum of eight 18 dot or si...

Page 10: ...Integrated Valve Section 1 Introduction Page 2 of 86 5760 107 Operations Manual Rev C ...

Page 11: ...ment s main 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 ground ing cables and covers before operating equipment WARNING This equipment contains ink under pressure B...

Page 12: ...Integrated Valve Section 2 Safety Page 4 of 86 5760 107 Operations Manual Rev C ...

Page 13: ...ble 19 Photosensor Cable 20 Controller to Print Head Cable 21 Print Head to Print Head Cable 22 Ink Filter 5700 026 23 Throw Distance 24 Ink T Fitting 5700 509 25 Male Quick Disconnect 5700 508 26 Ink Supply Cap Assembly 27 Ethernet Cable 5760 240 1 1 IJ3000 Controller 2 IDS3000 3 Print Heads 4 Conveyor 5 Product 6 Print Head Bracketry 7 Ink Status Beacon 8 Encoder 5700 731 9 Ink Supply Container ...

Page 14: ...PEV2N Painted Controller IDS Dual Interface Non Porous IDS European 5760 SEV1P Stainless Controller IDS Single Interface Porous IDS European 5760 SEV1N Stainless Controller IDS Single Interface Non Porous IDS European 5760 SEV2P Stainless Controller IDS Dual Interface Porous IDS European 5760 SEV2N Stainless Controller IDS Dual Interface Non Porous IDS European IJ3000 Controller Assemblies Include...

Page 15: ...quires Single Print Head Kits 5760 357 Multi Print Head Floor Mounting Kit w 44 Bar Requires Single Print Head Kits 5760 360 Print Head Angle Bracket w T Nuts Controller IDS Bracketry 5760 350 Controller IDS Conveyor Mounting Kit 5760 351 Controller IDS Pedestal Mounting Kit 5760 352 Controller IDS T Base Mounting Kit 5760 014 Controller IDS Floor Cart 5760 362 Controller 90 Pivot Bracket Kit Prin...

Page 16: ...e print head and at what rate of speed The controller comes in a stainless steel or painted metal case that makes it splash proof and resistant to electromagnetic interference A hinged cover provides access to replace able parts The IJ3000 Impulse Jet Controller can control up to two 32 channel print heads or one 256 channel print head per interface board With the optional second interface board t...

Page 17: ...ds and other accessories This manual details instructions for mounting all system components to a conveyor Other mounting options for the controller and IDS include the T stand pedestal and cart mount shown below Assembly instructions are included with parts kits CART WITH CONTROLLER IDS 5760 014 T STAND WITH CONTROLLER IDS 5760 352 PEDESTAL WITH CONTROLLER IDS 5760 351 ...

Page 18: ...or mounting print heads Diagraph bracketry is modular and can assume several configurations Single pole conveyor mount Double pole conveyor mount Single pole floor mount Double pole floor mount Multi panel floor mount SINGLE POLE CONVEYOR MOUNT DOUBLE POLE CONVEYOR MOUNT SINGLE POLE FLOOR MOUNT MULTI PANEL FLOOR MOUNT DOUBLE POLE FLOOR MOUNT ...

Page 19: ... produce highly legible to 2 tall alphanumerics special characters barcodes and logos Each type of I V print head has specific distances above and below the orifices spaces in which the print head cannot print These non printing zones are critical when designing print head layout in multi head applications The figure at right shows the print and non print areas obtained when two 9 dot print heads ...

Page 20: ...substrate 800 1 14 1 94 5700 407 1 2 9 Dot Non Porous Prints 1 4 5 16 and 1 2 tall characters on non porous substrate 800 1 14 1 94 5700 404 7 8 9 Dot Porous Prints 7 16 5 8 and 7 8 tall characters on porous substrate 610 93 1 54 5700 405 7 8 9 Dot Non Porous Prints 7 16 5 8 and 7 8 tall characters on non porous substrate 610 93 1 54 5700 402 1 18 Dot Porous Prints 1 4 3 8 1 2 and 1 tall character...

Page 21: ...ive object is detected Encoder The variable speed encoder assembly 5700 731 provides conveyor line speed information to the controller In addition to providing line speed information an encoder also allows automatic disabling of printing when the line stops Ink Supply Ink is supplied via 5 gallon or 30 gallon plastic containers The ink cap assembly contains a float mechanism that detects a low ink...

Page 22: ...Integrated Valve Section 3 System Components Page 14 of 86 5760 107 Operations Manual Rev C ...

Page 23: ...tallation 5760 107 Operations Manual Rev C Page 15 of 86 Section 4 Installation System Overview The figure below illustrates a typical install with conveyor mounted controller and four print heads Cables and ink lines are not shown ...

Page 24: ... poor grounding or interference Symptoms of power related problems can be unexplained loss of controller memory loss of message garbled print and unexplained hardware resets The best way to eliminate these types of problems is to install the controller on a dedicated line with a line conditioner A dedicated line refers to an AC line that only the system com ponents are plugged in to This is most e...

Page 25: ...lted directly to the conveyor Detailed assembly instructions are included with parts kit 5760 350 Other mounting options including parts kit numbers are illustrated in Section 3 System Components Corner brackets are attached to aluminum bars as shown 2 Hole Corner Bracket 4 Hole Corner Bracket Mounts to Conveyor Controller IDS Mounting Plates CONTROLLER IDS BRACKETRY ATTACHING CORNER BRACKET Singl...

Page 26: ...efore mount ing on the bracketry Attach the print head to the bracketry with a print head mounting bracket as shown You may need to vertically adjust each bracket s horizontal bar later to fine tune message placement This is especially true when using multiple print heads as message lines will need to be synchro nized with each other NOTE When adjusting the horizontal bar or print head mounting br...

Page 27: ...tandard with the 5760 383 photosensor kit The mounting bracket is included Photosensor Operation 1 Ensure the photosensor is secured and positioned perpendicular to the product 2 Place the product in front of the photosen sor as in normal operation 3 Press and hold the white teach button on the rear of the photosensor for approx imately 1 2 seconds 4 The rear LED will change state and stay on afte...

Page 28: ...with the conveyor or with a wheel or roller moving the same speed as the conveyor The encoder s mounting bracket is spring loaded Adjust the spring collar to ensure that the encoder main tains stable contact with the conveyor CAUTION Do not jam the encoder wheel against the surface of the conveyor A radial force of over 40 lbs will reduce the life of the bearings Controller Connections Spring Moun...

Page 29: ...intstation which will be referred to as Task 2 on the controller s user interface Sharing an Encoder and or Photosensor In many cases it is possible to use the same encoder and or photosensor to control both printstations This is done by connecting the cables to the first interface board and directing Task 2 to share these components with Task 1 Refer to Setup Functions Encoder Setup in the IJ3000...

Page 30: ...ram in Appendix B Theory of Operation Connect the ethernet cable to the appropriate recep tacle 4 Tighten bulkhead fit tings by hand then turn with a wrench and replace the IDS cover 5 Place the Ink Status Beacon where it can be seen by plant personnel and attach it to bracketry with a T nut Attaching Ink Regulators 1 Attach a single T nut loosely to the bottom side of the regulator bracket 2 Slid...

Page 31: ...w connector H Attach the elbow connector to the Ink Out To Printer quick disconnect F on the IDS G Cut line to the length desired and insert over the barbed end of a T connector J 2 Insert the female end of the ink regulator E tubing assembly over the male fitting on the T connector and attach the male end to the first print head NOTE Listen for a click as you push the quick disconnects together A...

Page 32: ...int head Repeat with all remaining print heads 4 Cut another line of tubing B to connect to the last T connector on the line C Attach a male quick disconnect to the other end of the tubing 5 Attach the effluent bottle assembly K with its female quick disconnect A at the end of the line NOTE Be sure the effluent shutoff valve is off at this time To close the shutoff valve depress the metal tab on t...

Page 33: ...rt the cap assembly and tighten snugly by hand 3 Connect the 1 8 ink supply line from the Filtered Ink Inlet quick disconnect on the IDS to the female coupling on the ink cap assembly CAUTION Porous ink must be used with a porous IDS Non porous ink must be used with a non porous IDS The IDS can not be flushed to use a different ink type 5 Gallon Ink Pail Low Ink Beacon To IDS Ink Cap Assembly Leve...

Page 34: ...ump will turn off automatically after 20 cycles 2 It will still be necessary to bleed the air from the lines Open the shutoff valve on the efflu ent bottle assembly by pushing together until the connections snap into place this will allow air to flow out of the main line As soon as ink begins flowing into the effluent bottle close the shutoff valve and disconnect the assembly Keep a clean wipe han...

Page 35: ...essure for your print head CAUTION Observe the following precautions while using and cleaning the ink pressure gauge 1 Do not probe into the pressure gauge with objects when cleaning Use the appropriate conditioner and brush 2 Pressure measurements are relative to the height from which they are measured When measuring print head pressure the gauge must be at the same height as the print head 3 Do ...

Page 36: ...turning the knob counter clockwise until it stops 2 Purge the print head until the pressure decreases to 1 0 PSIG 3 Open the ink regulator by slowly turning the knob clockwise until the optimum pressure is reached 4 When the pressure holds steady snap down the red lock ring on the regulator to hold the knob in place 5 Re check this pressure periodically for the first few days of operation and week...

Page 37: ... the step by step print head setup procedure Once begun the procedure may be aborted by pressing Cancel or the Escape key at any time without changing the current print head setup To begin the print head setup procedure touch the Redo Print Head Setup but ton The next screen prompts you to specify product direction NOTE The Print Head Setup cannot be redone unless the print buffer is empty that is...

Page 38: ... by touching it The grayed out heads are not eligible as they are in the middle of the chain If there is only a single print head this step is bypassed NOTE The first print head in the daisy chain should be the top print head in your system as this one will be printing the top line of data and will be the first one for which you are prompted to enter data In the example at right you have chosen th...

Page 39: ...e print head in inches This may need to be fine tuned after print setup The max imum sensor offset is 81 After a print head s properties are defined touch the Next Head button to move to the next one or just touch a print head on the display to highlight it Repeat this pro cess for each print head in your daisy chain until all heads have been defined After the last print head is defined touch the ...

Page 40: ... symbol Ink should eject for a few seconds from the print head orifices 6 To check for proper purging swipe a sheet of cardboard or other material across the front of the print head at about the normal printing distance as the print head purges If all orifices are purging the result should be a solid band of ink across the material It is not uncommon for the first purge to show streaks where some ...

Page 41: ...Q Will changing the print resolution change the positioning of the print on the product A Yes An increase in resolution moves the dots and thus the characters closer together increasing the rate at which the message downloads to the print head and thus starting the print cycle earlier A decrease in resolution has the opposite effect In addition the point at which the print head begins printing can...

Page 42: ...Integrated Valve Section 5 Frequently Asked Questions Page 34 of 86 5760 107 Operations Manual Rev C ...

Page 43: ...ur ink system Spray conditioner on a lint free wipe and wipe the faceplate in a circular motion to remove ink from the orifices Inspect lines and connections for leaks Make repairs if needed Purge all heads with ink as follows 1 On the Home Screen menu select Print 2 On the Print menu select Purge 3 Touch the head you wish to purge first 4 Hold a lint free wipe in front of the print head 5 Touch t...

Page 44: ...fitting on the back of the print head and open the shutoff valve 5 Squeeze the flush bottle to force conditioner through the print head Note the color of the liquid in the waste line and continue flushing until it runs clear 6 Close the shutoff valve and disconnect the effluent bottle and flush bottle assemblies 7 Re attach the ink line to the print head and purge the print head until ink is again...

Page 45: ...nough ink for a few more minutes of operation The amount of print time remain ing is dependent on the number of print heads and the message being printed so the oper ator may have anywhere from five to 30 minutes to change the ink container If timely action is not taken printed dots will begin to diminish in size until they disappear altogether NOTE Allowing the system to run longer with the beaco...

Page 46: ...pail in place and remove the cap 3 Remove the cap assembly from the empty pail and insert it into the new pail Tighten snugly by hand 4 Connect the 1 8 ink supply line from the IDS to the female quick disconnect on the ink cap Make sure the couplings snap into place 5 Press the Prime button on the IDS momentarily to prime the system The beacon should turn off Daily Startup Be sure all ink lines ar...

Page 47: ...lly open the print head fuse which will open the 15VDC line to the driver board and the daisy chain output connector Mechanical prob lems generally show up as leakage or print quality issues but distance from the substrate and solenoid pulse width will also effect overall print quality Troubleshooting Tests Purge Test This test will determine if the print heads are functional 1 Place cloth in fron...

Page 48: ...nate when an object is placed in front of but not touching it then it indicates that the photosensor is disconnected or the power supply or photosensor have failed Print Head Ink Pressure Test This test will determine if the print head pressure is correct 1 Connect the ink pressure gauge 5700 743 to the ink out port on the rear of the print head 2 While printing not purging check the pressure refe...

Page 49: ...c x 12 9 09 inches per second Remember this number Now you ll need to get out your oscilloscope and make some mea surements on the system you wish to test Set the vertical resolution of the scope to 5 volts per division and set the horizontal resolution to 1 millisecond MEASUREMENTS Connect the scope ground to TP11 on the interface board Connect the voltage probe to TP10 The 5700 731 encoder has a...

Page 50: ...oder accuracy Determine the line speed in inches per second accomplished by dividing speed in feet per minute by 5 or multiplying feet per second by 12 Determine encoder resolution 100 dpi for the 5700 731 encoder Multiply the encoder resolution by the line speed in inches per second to determine what the frequency should be Measure the actual frequency with a scope and compare it to the expected ...

Page 51: ...m 2 Look at the next segment entitled Print Quality Definitions to verify that you classified the problem correctly 3 Look at the table on the following page to identify possible causes for your printing problem 4 See subsequent pages for solutions to various print quality problems Splatter Dragging type dot size var Internal dot size var Tails Extra Dots Undersized Dot Stuck Open Valve No Print O...

Page 52: ...ed Dot The system prints dots that are smaller than nor mal 7 Stuck Open Valve The system prints a solid row of ink ejecting from an orifice 8 Oversized Dot The system prints dots that are larger than nor mal 9 Off Target Printing The individual dots do not line up exactly 10 No Print The system prints nothing 11 Dot Columns Out of Alignment The dot columns do not exactly line up 12 Smearing Print...

Page 53: ...re Pulse width set too high Incorrect pre load Oversized Dot High ink pressure Off Target Printing Print head too far from target Low ink pressure No Print Low ink pressure Pulse width set too low Print head failure Controller or cabling failure Dot Columns Out of Alignment Internal line speed turned on Incorrect direction selected in software Smearing Print Print head too close to target Incorrec...

Page 54: ...ng Note that the pressure drops by as much as 0 75 PSIG usually less during the print cycle Nominal pressure should be centered within the deflection range while printing 3 If pressure is low lift red locking ring and rotate knob clockwise until the nominal print head pressure is centered within the deflection of the gauge while printing 4 If the pressure is high or was adjusted above the specs in...

Page 55: ...procedure can remove obstructions from the valve seat area of the ink regulator restoring normal operation 1 Unplug the ink regulator from the print head Ink may be used but conditioner is pre ferred for this procedure 2 Plug the ink regulator output into the effluent bottle 3 Rotate the pressure adjustment clockwise until it stops then counter clockwise until it stops Repeat six to twelve times N...

Page 56: ...e width Counter clockwise Decrease pulse width NOTE On an 18 dot print head the directions are opposite 4 Check print quality repeat step 3 as required If dot size cannot be adjusted for accept able print quality a pre load adjustment may be required The arrangement of orifices in the front plate controls character size Dot sizes can be adjusted individually for each print head with potentiometers...

Page 57: ...he print head 1 Wipe the front plate with a conditioner wetted towel 2 Make sure the broach pin does not extend out of the handle more than 0 10 inch This will ensure that the broach pin will not poke a hole in the membrane and cause internal leak ing Internal leaking will show up as a no print failure several weeks later 3 Identify the clogged orifice by identifying the missing dot s from a print...

Page 58: ...re for adjusting I V print head pre load with the 1902 855 Solenoid Adjustment Tool This procedure is easiest to perform on a bench away from the line When replacing a print head always install the new regulator supplied with the print head and adjust pressure to the correct value CAUTION Failure to follow these instructions can result in damage to the print head 1 Make sure ink pressure is correc...

Page 59: ...ockwise from this position 9 Rotate the bushing clockwise until ink seepage completely stops 10 Wipe the front plate with a clean conditioner wetted cloth Purge the print head and wipe again Observe print head for 15 minutes if ink seeps from the orifice follow step 8 11 Rotate the bushing 1 8 of a turn repeat step 7 until seepage stops or one full turn limit is reached 12 Replace print head cover...

Page 60: ...Integrated Valve Section 7 Troubleshooting Page 52 of 86 5760 107 Operations Manual Rev C ...

Page 61: ...perating Pressure Range 20 psi to 25 psi approximately Cable Ports Ink low level Ethernet Power cord Ink status beacon Environment Ambient operating temperature 40 F to 104 F Operating humidity 10 90 non con densing Tubing Limitations Maximum horizontal tube length 100 ft Maximum vertical tube length bottom of IDS to bottom of highest print head 20 ft Ink Supply Limitations Maximum height above ID...

Page 62: ...Integrated Valve Appendix A System Specifications Page 54 of 86 5760 107 Operations Manual Rev C ...

Page 63: ...n the line The bit that occupied the first spot in line steps to the second the second steps to the third the third to the fourth and so on until the last bit in line steps off the end of the line and is lost Repeat the process enough times and all of the information in the shift register is replaced Repeat the process 72 times and you ve output a column of print data A latch print signal sent aft...

Page 64: ... enters the IJ3000 through J3 on the Print Head Interface Board s A system with a single interface board has one power supply two interface boards require two power supplies On each Print Head Interface Board 15V is routed to the photosensor connector P2 and the print head connector P1 through normally energized relay K1 An over voltage detec tion circuit de energizes K1 and removes power from the...

Page 65: ...some use The CPU writes display data into the display RAM The real time clock and calendar U2 keeps system time The 3V battery BT1 preserves system data and keeps the clock running during power outages or when the IJ3000 is not plugged into a power outlet Test Points TP1 12VDC TP2 GND TP3 5VDC TP4 3 3VDC LEDs D2 Green 5VDC present indicator D3 Yellow Flashes when the CPU is running D21 Ethernet co...

Page 66: ...the photosensor and encoder Test Points TP1 5VDC TP2 3 3VDC TP3 FPGA DONE LOW when the FPGA is being programmed High when FPGA programming is complete TP4 Print head CLOCK signal TP5 Print head DATA signal TP6 Print head LATCH signal TP8 PHOTOSENSOR signal TP9 DC power in 15V TP10 External ENCODER signal TP11 GND TP12 FPGA INIT goes LOW to indicate an FPGA programming error TP13 FPGA PROGRAM pulse...

Page 67: ...di tional 10 pump cycles 4 Broken line detection Any break in the ink line downstream from the IDS causes the accumulator to quickly empty its supply through the break When the IDS senses this precipitous drop in pressure it shuts down the pump and alerts the operator via a rapid flashing of the beacon and an ethernet signal to the controller Startup Operation After the appropriate fluid lines are...

Page 68: ...n has no operational effect on the system It is merely a notification to the user that a new ink supply should be at the ready Ink Supply Replenishment After the ink supply container is replaced the operator depresses the prime button on the IDS3000 front panel This re primes the system via a 10 second flush of ink through the diverting solenoid valve see Startup Operation and the IDS returns to n...

Page 69: ... be temporarily over ridden by holding the prime button and simultaneously depressing the power button This will allow the pump to cycle up to 20 times without shutting down The beacon will flash with each cycle The IDS will automatically end this process after 20 pump cycles If more override cycles are desired simply repeat the process If immediate use of the broken line feature is desired then s...

Page 70: ... GND TP9 50VDC approx unregulated from IDS power supply TP10 24VDC TP11 12VDC TP12 5VDC TP13 Toggles at the end of a vacuum sampling period LEDs LED1 Not defined LED2 Green indicates traffic on the network LED3 Green indicates the solenoid is energized diverting ink back to the ink container LED4 Yellow indicates the pump is running Fuses F1 Power fuse 250V 315mA F2 Beacon fuse 125V 1A Connectors ...

Page 71: ...Integrated Valve Appendix B Theory of Operation 5760 107 Operations Manual Rev C Page 63 of 86 IDS Wiring Diagrams ...

Page 72: ...Integrated Valve Appendix B Theory of Operation Page 64 of 86 5760 107 Operations Manual Rev C ...

Page 73: ...cation Check availability of ink colors Red Yellow Blue Green Brown Purple Orange Porous Inks Description Type Available Colors TWP 101 Water Based Value Ink Black Only TWP 1 Water Based Premium Ink Black Colors TWP Conditioner Water Based Conditioner Non Porous Inks Description Type Available Colors TSO 1 Alcohol Based Value Ink Black Colors TSO 3100 Alcohol Based Premium Ink Black Only TSO 4400 ...

Page 74: ...I V Interface Board Replacement Kit 1 I V Interface Board 5760 305 Color Display Replacement Kit 1 display assembly display touch screen display PCB etc 5760 306D I V Interface Board Upgrade Kit Domes tic 1 interface board with plate power supply power sup ply clamp power cord 5760 310 IDS Inlet Outlet Tubing and Filter Kit 5760 311 IDS PCB Replacement Kit 5760 314 IDS Transformer Replacement Kit ...

Page 75: ...bly Kits ITEM PART NO DESCRIPTION 1 5760 311 PCB REPLACEMENT KIT 2 5760 314 TRANSFORMER REPLACEMENT KIT 3 5760 315 5760 318 PUMP REPLACEMENT KIT 115VAC PUMP REPLACEMENT KIT 230VAC 4 5760 317 INTERNAL TUBING AND FITTINGS KIT 5 5760 389 THERMAL CUTOFF KIT 6 5760 394 ACCUMULATOR REPLACEMENT KIT 1 3 4 2 5 6 ...

Page 76: ...Integrated Valve Appendix C Parts and Supplies Page 68 of 86 5760 107 Operations Manual Rev C ...

Page 77: ...software This setting is measured in dots per inch a setting of 4 denotes 4 dots or print col umns per inch Resolution can be set from 4 to 25 dpi 2 The operating frequency of the solenoids can be determined with these two parameters by following the next two steps Determine the line speed in inches per second Divide the line speed in feet per minute by 5 to get inches per second A line speed of 2...

Page 78: ...Integrated Valve Appendix D Maximum dpi Calculation for a Given Line Page 70 of 86 5760 107 Operations Manual Rev C ...

Page 79: ...ghts available are single dot and bold double dot The term fixed means the space allotted per character is the same regardless of the character An I occupies the same space as a W PRINT SAMPLES FOR A 9 DOT PRINT HEAD CAN ALSO BE PRINTED WITH A 1 18 DOT PRINT HEAD 5 dot single dot 1 2 3 4 5 16 67 25 DPI 7 dot single dot fixed DPI 1 2 3 4 5 12 5 25 DPI 1 2 3 4 5 7 dot bold double dot 12 5 25 ...

Page 80: ...ont Samples Page 72 of 86 5760 107 Operations Manual Rev C PRINT SAMPLES FOR A 1 18 DOT PRINT HEAD DPI 1 2 3 4 5 9 dot single dot 25 12 5 1 2 3 4 5 9 dot bold double dot fixed 12 5 25 DPI 1 2 3 4 5 18 dot bold double dot 25 10 DPI ...

Page 81: ...endix E Font Samples 5760 107 Operations Manual Rev C Page 73 of 86 1 2 3 4 5 3 x 5 dot single dot 16 67 DPI 16 67 1 2 3 4 5 9 dot single dot DPI 9 dot bold double dot 16 67 1 2 3 4 5 5 dot single dot DPI 9 dot single dot ...

Page 82: ...nt Samples Page 74 of 86 5760 107 Operations Manual Rev C PRINT SAMPLES FOR A 7 8 9 DOT PRINT HEAD CAN ALSO BE PRINTED WITH A 2 18 DOT PRINT HEAD 5 dot single dot 1 2 3 4 5 16 67 DPI 12 5 7 dot single dot fixed DPI 1 2 3 4 5 12 5 20 ...

Page 83: ...Integrated Valve Appendix E Font Samples 5760 107 Operations Manual Rev C Page 75 of 86 7 dot bold double dot DPI 1 2 3 4 5 12 5 20 12 5 1 2 3 4 5 9 dot single dot DPI 20 ...

Page 84: ...rated Valve Appendix E Font Samples Page 76 of 86 5760 107 Operations Manual Rev C PRINT SAMPLES FOR A 2 18 DOT PRINT HEAD 12 5 1 2 3 4 5 9 dot bold double dot DPI 20 10 1 2 3 4 5 DPI 18 dot bold double dot ...

Page 85: ...Integrated Valve Appendix E Font Samples 5760 107 Operations Manual Rev C Page 77 of 86 16 67 1 2 3 4 5 DPI 18 dot bold double dot 16 67 1 2 3 4 5 9 dot single dot DPI 9 dot bold double dot ...

Page 86: ...Integrated Valve Appendix E Font Samples Page 78 of 86 5760 107 Operations Manual Rev C 16 67 1 2 3 4 5 5 dot single dot DPI 9 dot single dot ...

Page 87: ...part number 5760 240 shipped with the IDS3000 The setip exe program Available from Diagraph Customer Service Phillips head screwdriver Procedure 1 Install the setip exe program on your PC 2 Unplug the IDS3000 3 Remove the IDS3000 cover 4 Locate the integrated circuit with the label at the center back of the circuit board See photos below The label will look similar to this Record the bottom two li...

Page 88: ...lled setip exe 8 Type setip followed by a space followed by the IDS3000 MAC address recorded in step 4 followed by a space followed by the IP address for the IDS3000 then press Enter For example type setip 00 06 0B 00 00 13 10 1 2 2 9 To verify that the IDS3000 was set to the desired address type ping followed by a space followed by the address For example ping 10 1 2 2 If successful the response ...

Page 89: ... the entire installation but not the branch circuits individu ally At the service equipment a single ground wire connects both the neutral and ground to earth The NEC calls this wire the ground electrode conductor WIRE DESCRIPTION FUNCTION LINE Usually black Cannot be white or green Carries the live voltage and current to the equipment NEUTRAL White or natural gray Grounded at the service equipmen...

Page 90: ...Integrated Valve Appendix G Testing an Electrical Outlet Page 82 of 86 5760 107 Operations Manual Rev C ...

Page 91: ...scharged to an electronic circuit components or printed circuit boards permanent damage may also occur This damage may be in the form of reduced functionality reduced life or complete non function ality The static charge does not have to be noticeable to the human touch in order to cause problems in an electronic system A human being does not start to feel the effects of static electricity until t...

Page 92: ...Integrated Valve Appendix H Electrostatic Discharge ESD Page 84 of 86 5760 107 Operations Manual Rev C ...

Page 93: ...connection at a baud rate of 230 Kbps Extra Dots Dots printed outside the des ignated dot columns Font A complete set of characters alphabetic numeric and punctuation in one typeface The font used in this glossary is Arial IDS The Ink Delivery System consists of a number of components working together to transfer ink from the ink pail to the printed product Ink Filter A 100 micron filter located i...

Page 94: ...tance from the leading edge of the product to the start of printing Print Head A solenoid activated mecha nism that propels ink droplets onto a mov ing surface Printstation One or more print heads set up to mark a given product in a specified location psi Pounds per Square Inch a measure of air pressure Pulse Width The amount of time a print head solenoid is on one of the factors con trolling the ...

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