Integrated Valvejet 9 Dot Print Head What am I getting? What are the improvements? Diagraph is proud to release the new IV9 Dot print head. New features include: Environmentally Sealed housing for harsh environments LED Display Channel purge button built into the head First dot correction Electronic dot size Correction on the print head Ability to read pressure on the display Compatible with IJ3000 and Series 1 Systems See page 5 for more details. What does the new print head replace? New Print head 5770002P500 - ASSY,IV9DOT PRNT HD,1/2",POR 5770002N500 - ASSY,IV9DOT PRNT HD,1/2",NP 5770002P875 - ASSY,IV9DOT PRNT HD,7/8",POR 5770002N875 - ASSY,IV9DOT PRNT HD,7/8",NP Replaces. 5700406 - PH,IV 1/2",POR 5701201 - PH,IV,1/2" POR,ENVIRONMENTAL 5700407 - PH,IV 1/2",NP 5701202 - PH,IV,1/2" NP,ENVIRONMENTAL 5700404 - PH,IV,7/8" POR 5700475 - PH ASSY,7/8" 9-DOT POR SP 5700405 - PH,IV,7/8" NP 5700476 - PH,7/8" 9-DOT,NP,SP Can I get the old style print head? Previous designs are available in our remanufactured program. The remanufactured program will have a price increase that will go into effect on 12/1/06. The old print head design will no longer be available after 1/31/07. Will the new print head fit onto my existing production line that already has old style print heads? The dimensions between the old style print head and new style print head are different. Less correction may be needed if heads are replaced from downstream (last print head to print on the product) to upstream (first print head to print on the product) on your production line. See page 7 and 8 for drawing. How can I tell if I need an adapter for the new head to fit my brackets? If your brackets are round in shape you will need an adapter for the new style print head. Round brackets are typical for a Series 1 system, which should be five years or older. The part number for the adapter bracket is 5770-219 $55. Print heads used with an IJ3000 should not need an adapter, these systems have shipped with 80/20 brackets and are compatible with the new print heads. See page 9 for drawing. - 1 -
Can I use my current ink? Yes, your current Series 1 and IJ3000 IV System ink will work with the new IV 9 Dot print head. What are the dimensions of the new print head vs. the old print head? Dimensions can be found on our website www.diagraph.com See included dimensional drawing page 7 and 8. What will I need to change when I get the new print head? Because the new print head does not have the same dimensions as the old style print head it may be necessary to adjust the distance from the photocell to the print head on an IJ3000 system (refer to IJ3000 Manual P# 5760-121 Rev D page 26 for instruction). Adjustments to the position of the new IV9 Dot head may also be needed to align the printed text with other print heads on the production line. What are the part numbers I need to order if I have old brackets? You will need an adapter (P# 5770-219) if you have brackets that are round (tubular) in shape. See page 9. - 2 -
What does the new print head look like? A picture of the new head is included in this packet. See page 6. Can I have my old style print head repaired? Repairs on the old style print head will no longer be available after 1/31/07. Can I exchange my old head for a new style print head? Yes, if you want to move forward with the new improved head design you can do so today. New IV 9 Dot print heads are available for a 10% discount off list price through December 2006. Can I exchange my new style print head for an old style print head? No, the old design head is not manufactured as new any longer and is only available on the print head exchange program for a limited time. Will the new head plug in and print? Yes, the new style print head will be able to be plugged in and print right away on a Series 1 and IJ3000 system, you may need to adjust the print head to photocell distance on your IJ3000 controller. The new IV9 dot print head is not compatible with Telemark systems. How do I install the new head? Diagraph technicians are trained to install the new IV 9 dot print heads and are available to assist your company with the installation of new IV 9 dot print head(s). Installation instructions are also included in this packet. See page 10. How do I use the new features via the display and push buttons on the back of the print head? Instructions on how to use the display and buttons on the back of the new IV 9 dot print head are included in this packet. See page 11. How does a Diagraph Integrated Valvejet Print Head work? Documentation discussing the theory of operation for an Integrated Valvejet Print Head is included in this packet. See page 12. Who do I call if I have more questions? Diagraph Customer Service and Technical Support can be reached at 800-526-2531(7:00am -5:00pm CST). We are happy to help answer any questions you may have. You can also visit www.diagraph.com. - 3 -
New IV9 Dot systems are being sold with a more robust style of 80/20 bracketry, how can I get that style of bracket for my other lines? The more robust style bracket that is being shipped with new IJ3000 IV systems are twice the width of the single (1.5 ) pole 80/20 brackets. Both styles, the single (1.5 ) pole and the double (3 ) pole 80/20 brackets are compatible with the new IV9 Dot print heads. If you prefer the more robust style single head conveyor bracket, you can order part number 5760-821 $85 to upgrade your existing lines to the double pole bracket. Reference Mounting differences Old vs. New illustration below on this page. See page 13 for additional drawing. Quick Reference Chart: Controller Type Bracket Type What do I need Other Option IJ3000 IV System sold 80/20 Double (3 ) Current NO Current NO from 11/2006 - Present Pole=NEW UPGRADE NEEDED UPGRADE NEEDED IJ3000 IV System sold from 2001 10/2006 COMPATIBLE 80/20 single (1.5 ) pole=old COMPATIBLE Single (1.5 ) poles are Compatible with IV9 Dot Upgrade bracket to double (3 ) pole bracket P# 5760-821 Series 1 System Round Bracket Pole 5770-219 adapter plate Upgrade bracket to double (3 ) pole bracket P# 5760-821 Telemark System NOT COMPATIBLE NOT COMPATIBLE NOT COMPATIBLE Mounting differences Old vs. New 5 1 8 10 4 5 1 3 7 5 7 2 1 4 8 10 6 4 7 10 3 7 10 3 2 6 6 7 7 10 2 Configuration "A" 8 10 Configuration "B" OLD NEW - 4 -
IV9DOT-500 & IV9DOT-875 Print Head Features o One-piece die-cast Aluminum housing o Pre-formed high temperature tubing o LED display and membrane switch Built-in pressure gauge Channel purge at print head: Individual or all channels Pulse width adjustment at your finger tip o Automatic 1 st Dot Correction First dots will print consistently End users are recommended to wipe front orifice plate for overnight startup o Overdrive protection Protection against overzealous print speeds Protection against faulty cables Display shows Er indicating the error from overdriving the print head. This sample shows missing dots from overdriving o o o o Environmentally sealed Integral mounting bracket with 90 pivot capable Photocell bracket mounting holes Flammable vapor explosion tested safely vents - 5 -
Integrated Valvejet 9 Dot - 6 -
IV9DOT - 500 & IV9DOT - 875 Print Head - 7 -
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Adapter Plate Mounting to Round Bracketry Kit Assembly Instructions 5770-219N Integrated Valve Print Head, 9 Dot, Revision A Page 1 of 1 ITEM PART NUMBER DESCRIPTION QTY 1 5770-369 PLT,ADPTR,IV9 PH TO RND BRCKTRY 1 2 5760-434 BRCKT,PHOTOCELL 1 3 5082-001 SCR,5/16-18 X ½ BUT HD CAP, SS 4 4 5101-511 SCR,#8-32 X 3/8 PH FL HD, 82,SS 2 Note: The photocell offset will need to be adjusted at the print head controller per the view below. 8.78 6.12 5.37 3.54 3.08 3.33.46 OLD STYLE NEW STYLE - 9 -
Installation Instruction Sheet 5770-362N Integrated Valve Print Head, 9 Dot, Revision B Page 1 of 3 Wear safety goggles when performing the procedure.! Disconnect power during installation. INSTALLATION 1. Remove shipping tape from print head orifice plate. 2. Install print head on bracketry. Diagram 1 is an example of typical mounting. 3. Align print head with substrate. 4. Mount the regulator included with the print head.! DO NOT ATTEMPT TO CHANGE THE REGULATOR PRESSURE. IT IS SET AT THE FACTORY. 5. Ensure that the driver controller and ink delivery system have been installed. The print head electronic cable should be installed into the driver controller and routed to the print head. The ink outlet tubing (trunk line) from the ink delivery system should be installed and bled. 6. Connect the female (inlet side) of the regulator to the ink supply trunk line. 7. Connect the male (outlet side) of the regulator to the Ink Inlet, Supply Port on the rear of the print head. 8. Connect the print head electronic cable from the controller to the appropriate Print Head Cable Inlet port on the rear of the print head. 9. Every print head is shipped with a clear conditioning fluid. Connect an effluent bottle or comparable device to the Ink Outlet, Bleed Port on the rear of the print head until ink flows thru. 10. Hold an absorbent cloth(s) in front of the print head. Press and hold the PURGE button on the rear membrane switch until ink is ejecting from the print head front orifice plate. 11. While not printing or purging, the pressure on the print head LED display should be approximately 7 psi. This pressure will fluctuate while printing. 12. The print head is ready for printing. - 10 -
Installation Instruction Sheet 5770-362N Integrated Valve Print Head, 9 Dot, Revision B Page 2 of 3 PRINT HEAD OPERATION (Diagram 2) Initial Startup and Power Save: When the print head is connected to the electronic cable, the display shows the center decimal point to signify there is power. This is the Power Save mode. This mode saves energy by not powering all the LED display segments. The print head has full functionality in Power Save mode. Any of the four push buttons on the membrane switch will illuminate (wake up) the display. When awake, the display will always start in the Home Screen. Inactivity: After 30 seconds of inactivity in the Home Screen, the display will change to Power Save mode. If the LED display is in any other mode such as Purge or Pulse Width Adjustment, the LED display will default to the Home Screen after 30 seconds of inactivity, then Power Save mode (an additional 30 seconds). Home Screen: The LED state after waking up the print head display or the default after 30 seconds of inactivity. It displays the print head pressure in psi (pounds per square inch). LED DISPLAY PRINT HEAD CABLE INLET PUSH BUTTON MEMBRANE SWITCH PURGE Button: The PURGE button can be used in two different ways, one, to PURGE all channels at once, or two, to PURGE one channel at a time. From the Home Screen, press and hold the PURGE button on the rear membrane switch for one second. All of the channels will fire/eject ink for two seconds. If you continue to hold the PURGE button, then the print head will purge ink until you release the button. To purge individual channels, press the ENTER button once then the up and down arrows to select the desired channel (e.g. 1 thru 9). Again, press and hold the PURGE button for one second. Ink PRINT HEAD CABLE EXIT. DAISY CHAIN TO NEXT PRINT HEAD. INK OUTLET, BLEED PORT Diagram 2 INK INLET, SUPPLY PORT will eject from the selected channel for two seconds. To return to the home screen, press the down arrow button until Pr is selected, and then press ENTER. Otherwise, the print head will automatically return to the home screen after 30 seconds of inactivity. Pulse Width Adjustment: Hold down the up and down arrows simultaneously. The last channel to be accessed will be displayed. Press the ENTER button. The pulse width setting will be displayed. This value is relative and can range between 15 and 65. The higher the value, the larger the dot size, and vice versa. Generally, pulse width adjustment on a new print head is not recommended. These values are factory set. However, it may be necessary to increase pulse widths if there are long print head cable lengths in the daisy chain. Decreasing the pulse widths will likely result in missed dots at first start-up. If a pulse width is changed, the ENTER button must be pressed to save the new value(s). Again, press the down arrow until Pr is displayed. Press ENTER to exit to the Home Screen. Note: If the ENTER button is not pressed, the display will revert to the home screen after 30 seconds and the pulse width value will not be saved. ENTER Button: This button is used to move from one function to the next or saving pulse width adjustments. Up and Down Arrows: These buttons are used to select channels, enter Pulse Width Adjustment mode, and to adjust the pulse width values up or down. Er Display Code: If the display on the rear of the print head shows a flashing decimal, this means the print head has been driven in excess of its normal printing range and is now in overdrive protection. Pressing any of the four buttons on the rear of the print head will reveal the Er code. Consult the factory. To clear the code, press the ENTER button on the rear of the print head. Note that this code will only clear when the print head is not being overdriven. - 11 -
THEORY OF OPERATION Installation Instruction Sheet 5770-362N Integrated Valve Print Head, 9 Dot, Revision B Page 3 of 3 Integrated Valve inkjet technology utilizes electronically controlled solenoid valves to open and close the flow of pressurized ink thru a series of holes, channels, and small orifices. Regulated ink pressure is supplied to the rear of the print head. While the print head is printing or purging, ink is flowing thru the inlet port, tubing, filter, and finally into the valve control mechanism. When the print head printed circuit board receives data signals from the controller via the print head cable, a microcontroller on the pcb generates pulses to the appropriate solenoids. These solenoids in turn, connect directly to a sealing piston. The sealing piston presses against a membrane that seals off the flow of ink to the appropriate orifice(s). When the solenoid is energized the piston pulls away from the sealing membrane and ink pressure allows flow of ink thru that channel and out the orifice. The time that the solenoid is powered on is called the pulse width; therefore, if the pulse width is increased, the valve is allowed to flow more ink (bigger dot). Pressure is monitored via a sensor that is teed into the print head bleed tubing. The sensor sends voltage signals to the display board that are scaled and displayed as gage pressure on the rear of the print head. 9 Dot PRINT HEAD SPECIFICATIONS Weight: 5.4 lbs [2.4 kg] Enclosure: Paint over anodized Aluminum Electrical: 15 VDC input from controller Ink Filtration: 25 micron in-line Print Speed: Up to 650 ft/min (Print Resolution Dependent) Ink Type: Porous (Water Based) or Non-Porous (Alcohol or MEK based) as indicated on label. Operating Pressure: 7 psi ink input Environment: Ambient operation temperature: 40 F to 104 F (10 C to 40 C Operating humidity: 10 90% non-condensing - 12 -
Print System Conveyor Mounting Kit Assembly Instructions 5760-821N Revision A Page 1 of 1 ITEM PART NUMBER DESCRIPTION QTY 1 5760-401X01400 BAR,1.5 X 3 X 14 LONG 1 2 5760-400X01400 BAR,1.5 X 1.5 X 14 LONG 1 3 5760-403 BRACKET, CORNER, 3 HOLE 2 4 5760-402 BRACKET, CORNER, 4 HOLE 1 5 5760-415 END CAP, 1.5 X 3 2 6 5760-404 END CAP, 1.5 X 1.5 2 7 5760-405 T-NUT, DOUBLE, 5/16-18 3 8 5760-406 T-NUT, SINGLE, 5/16-18 8 9 5305-026 NUT, 5/16-18 HEX 2 10 5310-730 SCREW,5/16-18 X 5/8 BUTTON HD CAP,SS 10 11 5081-521 SCREW,5/16-18 X 1-1/2 SOC HD CAP,SS 2 12 5310-308 WASHER, 5/16 LOCK 2 13 5310-033 WASHER,5/16 FLAT 2 Note: This bracket kit can be assembled in two different configurations and can be used to mount either a 9 dot printhead or a 7 dot print system. CAUTION: When the print system is setup in configuration "B" it may be possible for the carton being printed to make contact with the ink can. Items 9, 11, 12, and 13 are used to fasten the bracket assembly to the side of the conveyor. 5 1 8 10 4 5 1 2 8 10 4 7 10 7 10 3 6 6 3 2 7 10 Configuration "A" 8 10 Configuration "B" - 13 -