8 - Print Head Doctor
Contents
1. Used for Clogs depending on Ink Type OEM amp Eco Friendly Solvent Solutions 1X 4X 1X Used for Minor Clogs or Nozzle Deflections Also good for Flush Solution 2X 3X Used for Clogs depending on Ink Type OEM amp Eco Friendly UV Solutions 1UV 4UV 1UV 4UV Used for different types of UV ink Water Based Solutions 1W 4W 1 W 4W Used for Clogs depending on Ink Type OEM Eco Friendly amp T Shirt Extended Packs on Eco Solvent Solvent amp Waterbased 5 Series amp 6 Series Industrial amp Military grade surfactants used to recover that head which other solutions can t recover The newer version of the kit comes in two packages The storage container is in one pack age and the chemicals come in a separate package If you remove all the packing materials from the storage case all the kit contents should fit inside It is best not to store the recovery solutions inside the machine storage con tainer The solutions can affect the electronics if stored for an extended period of time PROPER KIT STORAGE Your Storage Container is made of a solvent resistant plastic so you can safely store your ma chine and other kit contents in side Wipe everything down with a lint free cloth before placing it into the container Store your opened and unopened solution bottles in anearby cool dry place outside of the storage container Keep out of reach by children or employees that act like children T2. 3 Make sure everything 15 dry before putting it back into the case 4 Test the seals of the solution bottles to make sure they are closed properly 5 Make sure no residual liquid is still in the tubing You can shoot a little canned air through the lines to clear the tubing 6 Don t store dirty rags or swabs with the kit 7 Store the Stage 1 Filter with its solution container 8 Place the storage container in a clean dry place until the next use When do I replace the solu tions The most obvious time to change the solution is when it doesn t effectively recover your head If a solution has lost 30 50 of its volume chances are it s not effective Ifthe solution has so much ink contamination it chang es viscocity it s time to change 19 APPENDIX 1 Reverse Flushing Option Make sure you are using goggles and gloves We supply the reverse flushing adapter with the necessary screws to fasten it onto the printhead Only use the screws supplied and use only a mini screwdriver to attach the adapter to the printhead A mini screwdriver will limit the torque you can put on the bolts and prevent printhead damage We supply only one Reverse Flush adapter when you purchase this option On dual head templates only use one RF adapter at a time 1 Make sure printhead is securely attached to the template before proceed ing 2 Always remove the Pressure Relief Screw from the side of the RF adapt er Thi
3. propylene LDPE Low Density Polyethylene and HDPE High Density Poly Ethylene If you find the need to use other plastic parts in the recovery process make sure it is one of these types of plastics Acrylics Polycar bonates ie Lexan PVC ie Sintra Nylon and other related plastics are not recommended They tend to melt and make a big mess They also tend to solidify really well inside printhead noz zles Clogging your nozzles with plastic would not be considered printhead recovery Luer Fittings This kit makes extensive use of Luer fittings They are a stand ardized small scale system of leak free connections utilizing male twist lock fittings mat ing with female parts They are used extensively in medical and laboratory equipment They were named after Hermann Luer They are very useful but they are not foolproof They can still leak if not tightened completely So check your connections Print Head Doctor Philosophy Tech in Training OUR GOALS When we decided to make Print Head Doctor for our customers we researched the market extensively We looked at machines already on the market and built many test machines before we came up with the final de sign Ittook over two years to develop the design for this kit The machines we use in our in house recoveries are all custom built to our specifications The parts and controls are expensive and not really suited for consumer use We knew we would have to d
4. a little more air time That extra blast of air can dislodge stubborn clogs Pulsonic Cycle It s a totally different process to remove the clog The constant switching between the 3 phases with the right solution will break down the clog and flush it out Syphon Cycle It s gentler cycle is excellent to help with nozzle deflections The pumping and the pumping with ultrasonic flush the head nicely MACHINE OPERATION cow RECOVERY PHASE cont Make sure you are using goggles and gloves Please don t rush into the recovery phase Follow the direc ions below and let s do this slowly and carefully 9 Watching the Pressure Gauge and Adjusting the Relief Valve Before you start adjusting the relief valve check the sticker on the back of the machine for the maximum pressure for the printhead you are recover ing You want the Max Pressure in MPa Then slowly close the relief valve clockwise as the machine is pumping fluid You should see the pressure guage start to climb from zero Keep turning until the guage reaches the maximum pressure of the printhead Don t adjust the pressure above the maximum pressure allowed for that printhead If you can t reach the de sired pressure check your filters and replace them if necessary 10 Check flow through nozzles Loosen the thumb screw on the template and lift it part ways off the tank and check to see if solution if flowing through the nozzles 11 Solution not Flowing Th
5. and dry there Component Breakdown There can be many components of an ink that are supposed to co exist in a homogenous mixture Over time the components break down and the chemical reac tions that result can create a clog Evaporation Ink components can also evapo rate away leaving hard to remove clogs UV Inks UV inks don t usually dry but some of their components can still break down or evaporate leaving a sticky or hard mess be hind UV inks also use adhesion promoters that can clog inside of printheads Cleaning Flushing Agents Some cleaning agents provided by printer and ink companies can cause the ink to form clogs over time The flush doesn t always break down the ink Sometimes they just loosen the ink so it can be cleaned 15 MACHINE OPERATION cow RECOVERY PHASE cont Make sure you are using goggles and gloves Please don t rush into the recovery phase Follow the direc ions below and let s do this slowly and carefully 5 Safety Check Make sure that relief valve is open Make sure everyone within 10 feet of yutton Start Cycle e Alam iin Stop Cycle the machine is wearing safety goggles and gloves Even gloves are necessary if an emergency happens and someone close by has to handle something covered with solution 6 Check Appendix C Appendix C has the recommended procedure to recover your printhead You can come up with your own procedure but for now
6. removed from the machine use a rag moistened with 9096 Isopropyl Alcohol to wipe down the machine inside and out 5 Dry the machine with a clean towel and place it in the storage case Please the case in a cool dark and dry place away from any heat sources Note Leaving solvent residue in side the stainless steel tank may cause it to oxidize over a period of time Stainless steel is chemi cal resistant but it isn t chemical proof 13 MACHINE OPERATION cow een ates STEP 3 HOSE CONNECTIONS Make sure you are using goggles and gloves Check Appendix A for Hose Connection Diagrams 1 Connect Filters to Inputs on Machine Connect both filters to the two input ports on the machine Make sure the triangle shape arrows on the filters point into the machine 2 Connect Input hoses Connect the input hoses to the filters and allow the ends to extend down into tank Make sure the connects are snug so you get proper flow into the machine The solution will flow from the tank through the hoses and filters into the machine 3 Connect Output Hose s from Tower to Printhead s The machine has two outputs that you can use to connect to your printhead s You will use either one or two outputs depend ing on how many connections and or printheads you are recovering at one time Some larger printheads require two connections because of their size and some templates allow you to do more than one printhead at a time If
7. with the solution first then immediately switch to alcohol to wash off any solution residue 4 Cleaning Connector Soak the connector with a little alcohol or contact cleaner and use canned air to blow the connector out Use Canned air until the connector is totally dry 12 Your solutions were designed to be used multiple times before buying replacements But in order to maximize the life of the solutions you need to minimize contamination whenever pos sible The dried ink on the sides and bottom of the printhead can be easily cleaned off so not to contaminate the solutions If your printhead has a reservoir or damper which is filled with ink it would be a good idea to drain the ink out if possible It would be one less component to recover once the recovery process starts Also consider purchasing a new damper to replace the old one Don t worry about cleaning out all the ink out of the printhead just the obvious stuff Printhead Etiquette Always hold your printhead firmly like it s worth thousands of dollars Wet gloves or wipes can cause you to lose your grip on the printhead Don t allow it to slip out of your hands onto the table or the floor Use only lint free wipes or foam tipped swabs with solution to clean the printhead Little pieces of lint can cause deflections Towels can cause scratches MACHINE OPERATION ee STEP 2 TEMPLATE SETUP Make sure you are using goggles and gloves Mak
8. EMPLATE STORAGE Make sure to place the template parts back into the bags provided before storing them inside the container Keeping the parts together helps you the next time 5 SAFETY LATEX GLOVES PROPER SAFETY PROTOCOL Using proper safety protocol is essential to the safe operation of this recovery kit Safety Goggles and Latex Gloves are provided with the kit to protect eyes and hands from exposure to the chemicals When we say Safety Goggles we don t mean Safety Glasses or Safety Shields Goggles don t Just shield the eyes they seal against your face to prevent any pressurized chemicals from getting into your eyes Any Safety Goggle you purchase must have air holes that are not facing forward They should allow air to enter from the sides SPECIAL WARNINGS This deluxe kit uses an electrical fluid pump and compressed air pump This means that the tubing could develop pressure and the luer fittings if not tightened properly could fail Anyone standing across the room could be hit in the eyes with warm solvent Also shooting compressed air into the solvent bath may cause mist to form in the bath This mist may be harmful to your lungs DUE TO THESE TWO SPECIAL WARNINGS PLEASE MAKE SURE YOU ARE IN A WELL VENTILATED AREA AWAY FROM OTHER PERSONNEL 1 Safety Goggles and Latex Gloves must be worn at all times when using this kit 2 Anyone watching someone using the kit must also wear Safety Goggles That means anyone
9. ISK BLUE Change Something 28
10. NG DX4 REVERSE FLUSHING IL h RF ADAPTER DX5 25 26 APPENDIX C RECOVERY CHART Program Machine Program displayed on X2 Tower Readout Note Checking Nozzles Unscrew Thumbscrew and lift printhead out of machine while DR Check to see how many nozzles are shooting FORWARD FLUSHING Step Program Pressure Cycles Temp Comments 3 Evaluate Unclogged Step 11 Clogged Step4 FR DR 3 4 Max 1 350 Check Nozzles Again 6 Eva Unclogged Step 11 Clogged Step 8 DR Max 1 359 CheckNozzlesAgan 9 Unclogged Step 11 Clogged Step 10 10 Changes 1st Round Change Temp to 45 2nd Round Change Solution gt Step 1 13 Eval No Deflections Step 15 Yes Deflections Step 14 14 Changes ist Round Temp 459 2nd Round Change Solution gt Step 11 GREEN LOW RISK BLUE Change Something Step Program Pressure Cycles Temp Comments Evaluate Unclogged Step 11 Clogged Step4 5 DR 1 2Max 1 3007 Check Nozzles Again 6 Unclogged Step 11 Clogged Step 7 8 DR 3 4 1 30 Check Nozzles Again 9 Eval _Unclogged Step 11 Clogged Step 10 OO 10 Chan
11. Print Head Doctor 3 also known as Deluxe X2 Kit INSTRUCTION MANUAL Revision 3 1 Print Head Doctor 3 Recovery Kit TABLE OF CONTENTS SECTION PAGE SECTION 1 GETTING STARTED WELCOME PHD KIT PHILOSOPHY KIT CONTENTS e SAFETY DON T DO THAT DISCLAIMERS SECTION 2 RECOVERY PROCEDURE PREPARING PRINTHEAD THE MACHINE OPERATING MACHINE APPENDIX 1 APPENDIX A APPENDIX B APPENDIX C 22 24 26 INTRODUC TION Solvent Resistance WELCOME Thank you very much for purchasing our Print Head Doc tor 3 Kit Many years of research have gone into producing this kit Printhead and printer servicing prices have spiked since the economy took a downturn It seems that printer manufactur ers and dealers are not selling printers as easily as before Some people have suggested that companies are raising their parts and service prices to make up for dwindling equipment sales reve nues Printhead prices have increased 20 40 in the last year We ask that before you start recovering your printheads you read this entire manual and study the procedures Every page has a sidebar on the right with helpful information that you should read If you have any questions about this kit please don t hesitate to contact us Thanks Again The Print Head Doctor Team The parts in this kit that come into contact with solvent are solvent resistant The main plastics used in this kit are Poly
12. Step 28 Yes Deflections Step 27 27 Changes 1st Round Temp 45 2nd Round Change Solution gt Step 24 GREEN LOW RISK BLUE Change Something 27 APPENDIX C RECOVERY CHART Program Machine Program displayed on X2 Tower Readout Note Checking Nozzles Unscrew Thumbscrew and lift printhead out of machine while DR program is running Check to see how many nozzles are shooting REVERSE FLUSHING Program Pressure Cycles Temp Comments Change Remove Pressure Screw from RF Adapter gt Step 2 3 Check Fluid Flow thru Debris Hose Hose from Printhead to bath 4 Evaluate Debris Hose Flow Good Step 8 No Flow Step 5 Check Fluid Flow thru Debris Hose Hose from Printhead to bath Debris Hose Flow Good Step 8 No Flow Step 12 Change Insert Pressure Screw into RF Adapter gt Step 9 Check Fluid Flow thru Debris Hose Hose from Printhead to bath 11 Evaluate Debris Hose Flow Good Step 13 No Flow Step 12 iit 12 Change Solution gt Step 1 13 Change to Forward Flushing gt Step 14 16 Evaluate 006109966 Step 24 Clogged Step 17 18 DR 1 2 1 309 Ce NZ EG 19 Unclogged Step 24 Clogged Step 20 ESE 3 4 BO Check Nozzles Again 22 Eval Unclogged Step 24 Clogged Step 23 23 Change Solution gt Step 14 26 Eval Deflections Step 28 Yes Deflections Step 27 27 Changes Change Solution gt Step 24 GREEN LOW R
13. cle with the air pump so here it is A little blast of air couldn t hurt NOTE Each cycle is affected by the running pressure Mon itor pressure to make sure it is at an optimum level 17 MACHINE OPERATION cow RECOVERY PHASE cont Make sure you are using goggles and gloves Please don t rush into the recovery phase Follow the direc ions below and let s do this slowly and carefully 14 Evaluating the Nozzles Manually Make sure that no cycles are running before removing the template Place the empty 6 round stainless dish on the workbench Use a clean syringe to extract 15 30 mil from the bath to inject pv into the printhead Unscrew the thumb screw and slowly remove the template from the machine Place the head over the 6 dish and connect the syringe to the printhead hose 4 Inject the solution into the printhead and watch the nozzles shoot out the nozzle plate You should see a steady even stream of nozzles from one side of the nozzle plate to the other If you see some nozzle shooting off to the side instead of straight out you will have to run additional recovery cycles to fix it Syphon Cycle If you see the nozzles shooting perfectly straight you are almost done 15 Everything looks good Finishing the printhead 7 Empty the syringe completely and fill it with your ink compatible flush ing solution Inject your solution through the nozzles to check the align ment If everythin
14. color which are floating in the base They fade in layers Dyes Smaller particles of color which are floating in the base They are semitransparent and fade at the same time Resins What makes the ink stick together or to the substrate Lubricants Used in reducing friction in mechanics distribut ing heat dissolving and or trans porting particles Solubilizers Increases the solubility of the ink Surfactants Reduces surface tension between oil and water Particulate Matter Additional particles For instance Metallic Ink Drying Agents Chemicals to speed up drying time Reducers Chemicals to slow down drying time Fluorescers Causing fluores like with fluorescent inks KIT CONTENTS UNPACKING THE KIT WHAT S IN THE KIT Eco Solvent Solution Pack Solvent Solution Pack UV Solution Pack Waterbased Solution Pack Extended Solution Pack 2 Stage 1 Filters Pump Power Supply amp Cord Safety Goggles Wipes Recovery Machine Power Cord Printhead Template s Syringe Latex Gloves Which solution pack you receive will depend on the kit configuration you ordered Included templates you receive depend on your kit configuration you ordered Actual contents of kit may change from description amp picture shown THE SOLUTIONS Eco Sol Solutions 1DX 4DX DX4 amp DX5 Printhead Eco Solvent 1DX Main Recovery Solution 2DX 4DX
15. debris tube and a no debris Remove the adapter and do a nozzle test Cleaning Small Filters Make sure you are using goggles and gloves This procedure can be used to clean the small filters if your filters get clogged 1 Remove the small filters from the machine and replace them with new or previously cleaned filters 3 While the filters are still wet take them a clean out hose syringe and some distilled water and go to your nearest disposal basin Fill the syringe with water and connect it through the hose to the filter Make sure the con nection is backwards Reverse of arrow from the normal fluid flow Force the water quickly through the filter and the debris should come out Repeat if necessary Dry filter with canned air The Final Product 1 Printhead should be free of ink deposits If the printhead is tinted with ink that s ok 2 Electrical connections and cir cuits should be free of ink Make sure circuits don t have any ink or solution residue Clean all electronics with isopropyl alco hol 3 Ribbon cables should be free of ink and solution residue Clean with isopropyl alcohol 4 Any internal ribbon cables or connections should be connected 5 Printhead should not have lint particles on it 6 Brackets should be cleaned and bolts should be tightened to tolerances 7 All printhead nozzles should be addressable and firing prop erly 8 Nozzle deflections should not be present At most a few noz z
16. e sure the Machine is off before starting 1 Clean amp Dry Tank Check to make sure the recovery tank is clean and dry 2 Put Template on Tank Carefully place the template with the print head attached onto the recovery machine If the template doesn t fit nicely on top loos enn the locking screw enough to allow the template to sit level on top of the machine 3 Tighten Locking Screw Tighten the plastic locking screw until the template is locked on the machine Don t over tighten the screw finger tight is fine 4 Pour in Solution Pour the solution you picked during the precleaning phase into the recovery tank a ww 2 WARNING till it reaches above the printhead noz zle plate Make sure to recap the solution tightly after pouring to prevent spills 5 Open the Relief Valve Turn the black plastic relief valve knob counterclockwise to open in up all the way BEFORE STARTING CYCLES Once you start the program you can turn the knob clockwise to increase the pressure to the printhead Your recovery machine should last for years with proper care Here are some steps to clean your machine after use 1 Unplug the machine from the wall 3 If you see any ink stains on the outside of the machine you can also use one of the solutions on a rag to clean off the stain De pending on your solution pack use the lowest number solution you have to clean the machine 4 Once the ink is
17. ead is normally reinforced and can withstand a higher pressure without being damaged Plus you are going in a smaller diameter nozzle output to a larger diameter printhead input The nozzles become a built in pressure regulator The pressures inside the head will still be within allowable levels By back flushing the printhead you can get rid of clogs that forward flushing may not be able to achieve We support a large range of different printheads but we don t have a reverse flush ing option for every one Please contact us if your printhead isn t on our list and we may be able to make you one APPENDIX 1 Reverse Flushing Cont Make sure you are using goggles and gloves 9 Adjust Relief Valve to increase pressure to the maximum pressure indi cated on the pressure chart This will be a starting point 10 During the cycle check to see if debris is flowing through the debris hose If no debris is flowing try increasing the pressure to the peak maxi mum pressure on the pressure chart If no debris appears after a few min utes adjust pressure to 15 If that doesn t work consider changing solu tions 11 Once you have a steady amount of fluid and debris flowing through the debris tube you can turn off the cycle and reinsert the pressure relief screw back into the adapter Hand tighten it with a mini screwdriver 12 Place the template back into the tank and run a new cycle 13 Once you have a good flow a fluid through the
18. ed air using our custom solutions 5 Reliable digital controls with six automatic programs 6 Programs recover printheads automatically 7 Several solutions are available depending on the type of ink you use 7 Solutions are reusable several times to help save money and keep our kits effect on the environment minimal 8 Includes a comprehensive manual with diagrams amp pictures 9 We also have an online support centre with news user manual updates videos in the near future and knowledge base articles 10 Our machine has a lightweight design for easy transport 11 Clear safety protocols to help prevent operator injury 12 Handy storage case for safe storage of machine tools and solutions Our philosophy is to keep our kits inexpensive fast reliable envi ronmentally friendly easy to upgrade and easy to use We hope you can recovery many printheads with this kit That way you will save literally thousands of dollars on printhead purchases And you will get the full life out of your printheads Take a quick look at the side panel to see all the components that can make up your ink Some ofthe components or combinations of com ponents can be the cause of your head failure What Is Ink Made Of Ink is a liquid composed of some or all ofthe following compo nents Solvents base Used to sus pend the other components Can be water or a multitude of organ ic solvent bases Pigments Larger particles of
19. esign amuch more cost effective technology to make a consumer kit We used some off the shelf components and adapted them to their new purpose to keep the costs down We have tried some machines built in China and Taiwan but they always seem to have the following problems 1 Many components of these machines were in constant contact with clean ing solutions and not solvent resistent They would melt over time and the melted plastic would end up inside the printheads 2 They had digital controls that were not reliable Many of the circuit boards were substandard 3 They were ineffective at recovering printheads The ones designing the machines didn t know how to recover a printhead They thought if you just ran some ultrasonic and pumped some liquid through the printhead it would recover itself Printheads aren t recovered that way 4 They had extra features that did nothing to help recover printheads Many Extras would end up breaking and causing the machines to fail 5 The solutions they recommended to use in the machine were not effective at recovering printheads 5 Machines were overpriced for what you get 6 Little or no user manual 7 No support whatsoever We wanted to make something much better and we did We spent two years developing this kit that not only beat the problems we saw above but also met goals we set for a machine that would blow the socks off the competi tion Our customers need a solution that wor
20. ess WARNING Solvent printers are high voltage devices Anyone attempting to repair a solvent printer could receive a severe shock which might result in injury or death Please learn the proper procedures before attempting to service your solvent printer Gaining Knowledge We can t tell you to start ripping apart your printer to learn more about it We can give you some suggestions to gain more knowledge We know that owning a sign shop means last minute rush jobs are a norm Solvent Printer problems mean your client will not get his job on time Which means a chance of getting yelled at and possibly a refund Waiting for 2 3 days for a technician to show up and charge you 100 per hour for service isn t a good option either The reality is most owners need to learn how to do some of the repairs themselves Learning a little preventive maintenance would be helpful too Ways to Learn More 1 Hang out with the Tech when he fixes your printer and ask him tons of ques tions If he doesn t give you answers get another tech next time 2 Find the service manual for your printer model It s the first step to find ing out how to repair your printer 3 Look online for as much information as you can get 4 Find an online users group like on Yahoo com or Google com where like minded individuals share their knowl edge and ask questions Make sure its for your printer Contribute what you can to the group so when
21. g looks great you can remove the printhead from the template and install it back into your printer 18 What s a deflected nozzle When there is buildup inside a nozzle or on the outside it can change the direction of fired dots so they don t exit perfectly straight from the nozzle to the media They get deflected to one side or the other When you inject fluid through a head it exits the nozzle as a stream This stream can be deflected at the same angle as a dot fired from the nozzle With this knowledge you should be able to detect which nozzles will fire straight and which ones will not The nozzles that fire are relatively small and hard to see Ittakes a keen eye to see which nozzles are out of alignment and which ones aren t We have a few sugges tions that may help 1 Look at the nozzle stream through directional lighting 2 If you can use a glass amp metal magnifying glass plastic is not good to work with here you can see the stream exiting the nozzle plate 3 Always look at the stream at different angles to see if you can tell if some nozzles are out of alignment 4 Run a nozzle test on the print head in the printer to see which nozzles are not firing correctly APPENDIX 1 Foaming Cycle Make sure you are using goggles and gloves 1 Check that the template 15 securely locked on the machine and the hoses are connected 2 Select the Foam cycle Program 3 The machine will generate foam and
22. ges 1st Round Change Temp to 45 2nd Round Change Solution gt Step 1 13 Eval No Deflections Step 15 Yes Deflections Step 14 14 Possible Change 2nd Change Solution gt Step 11 GREEN LOW RISK BLUE Change Something APPENDIX C RECOVERY CHART Program Machine Program displayed on X2 Tower Readout Note Checking Nozzles Unscrew Thumbscrew and lift printhead out of machine while DR program is running Check to see how many nozzles are shooting REVERSE FLUSHING Step Program Pressure Cycles Temp Comments 1 Change Remove Pressure Screw from RF Adapter gt Step 2 Check Fluid Flow thru Debris Hose Hose from Printhead to bath Evaluate Debris Hose Flow Good Step 8 No Flow Step 5 F Check Fluid Flow thru Debris Hose Hose from Printhead to bath 7 Eval Debris Hose Flow Good Step 8 No Flow Step 12 8 Change Insert Pressure Screw into RF Adapter gt Step 9 Evaluate Debris Hose Flow Good Step 13 No Flow Step 12 12 Changes 1st Round Change Temp to 45 2nd Round Change Solution gt Step 1 Change Change to Forward Flushing gt Step 14 16 Evaluate Unclogged Step24 Clogged Step 17 BEES ETE KE kA ren 19 Unclogged Step 24 Clogged Step20 DR Ma 1 35 Check Nozzles Again 22 Eval Unclogged Step 24 Clogged Step 23 23 Changes 1st Round Change Temp to 45 2nd Round Change Solution gt Step 14 26 Eval Deflections
23. he solutions without making sure the bottles are sealed properly Don t try to adapt some part to the machine that doesn t belong there If you need assistance from us just call us and we will help you 8 Since we released our Standard Kit and now our Deluxe Kit we have seen people go from being at the mercy of their printer technicians to becoming re covery gurus We have one gentleman named John that has recovered every printhead he has had to replace for the past 5 years He has gone through 35 printheads and managed to recover all of them His biggest problem with his Grand Format Machine was the ink He needed to use OEM ink to keep his 30 000 per year service contract in force And his contract only allowed for 2 printhead replacements in one year He kept every last printhead until the day he found a way to recover them John s Tips 1 Be Patient and don t rush the process 2 Read the manual more than once before starting your first recovery 3 Get your printheads into recovery before they go totally bad 4 Have several printheads already recovered and ready to go when your printer goes south during a big job 5 Stand next to your employees when you teach them how to use the machine and make sure they remember every thing And don t forget to wear goggles too 6 From Time to time do a refresher course with your employees and reteach them everything they forgot 7 Make your Technician explai
24. isa 110V or 220V cord that plugs into the wall and into the back of the ultrasonic Cleaner The second is a 12V Power Supply Brick that plugs into the wall and into the back of the X2 Tower Make sure both are connected properly Once the 12V sup ply is connected the power button should light up on the X2 Tower Note Make sure the solution is in the machine Step 2 on Page 13 If you heat the tank without fluid you may burn it out 2 Press the power button Press the power button on the machine to power iton This turns on the temperature bath Don t touch the ultrasonic controls on the left The controller will automatically use ultrasonic when it needs too 3 Set tank temperature Press the left temperature button that says 5 degrees until the temperature readout above it says 35 degrees Celsius 30 degrees Celsius for DX4 amp DX5 The readout on the right will show the current tank tempera ture It takes a few minutes to heat up the tank to temperature id Note Max Temperature for DX4 amp DXS is 30 degrees Others 45 degrees 4 Soak Dry Printhead If you printhead is clogged and totally dry soak it for 30 minutes prior to starting the recovery process Why Solvent Ink Clogs Solvent Inks can clog due to sev eral different factors Drying First of all solvent ink has resins and drying agents which make ink stick and helps it to dry It s inherent in the ink design to find somewhere to stick
25. it comes time to ask a question people will want to help you For example if you know the answer to a posted question take the time to write an answer If you found a new media that prints great on the printer let them know Become part of your printer s online community 10 THE MACHINE The Competition Our competition likes to make DIAGRAMS recovery machines that use ultrasonic and fluid pumping to No Goggles or Gloves needed in this section recover printheads They even have fancy stepper motors that Input amp Output Connectlons x X2 Tower make the printheads go up and PEEN down into the solution BTW 5 Pa M they break easily What they Ed mim are mainly trying to do is loosen Se Tempouro 2 BE REE the clog and flush it out of the printhead That is not easy do The ink has deposited itself inside the printhead and basically 5 Degrees 5 Degrees Front View stuck itself to the nozzle walls Ultrasonic is controlled by the built in programs You don t have to use the ultrasonic controls It entered through a large hole and is expected to exit through a much smaller hole Even with a Virasonle Cleaner ton of ultrasonic energy you can t pulverize ink down to the 80 to 30 microns or smaller necessary SS to exit the printhead nozzles Not going to happen What we do d m An important step in the proc ess is to use a solvent tha
26. ks out of the box with every thing they need to recover their printheads As our technology improves we want to be able to provide upgrades to our customers that they can install themselves 2 Before you get started recovering your printheads it s important to understand what it takes to be a good tech Whether you re a company owner or an employee it s important to not only follow directions but to have a certain frame of mind when working with small expensive parts 1 Follow Safety Protocols Always wear proper protection when working with chemicals 2 Handle parts carefully You are handling sensitive parts Be careful 3 Patience Don t be in a hurry take your time during the process 4 Be Meticulous Take the time to do a complete job 5 Stay Organized Keep your station organized so you don t lose any parts or cause a safety hazard 6 Concentrate Pay attention to what you are do ing Turn off any distractions so you can handle the task at hand 6 Read Read this manual before start ing Read your printers service manual too Print Head Doctor Philosophy coo OUR RECOVERY KIT 1 We created a kit with quality affordable parts 2 Allthe parts that come in contact with solvents are solvent resistant 3 Everything is modular which makes part replacements and upgrades easy 4 Recovers printheads easily and effectively using heat solution pumping ultrasonic and pressuriz
27. les can be less than 1 degree from intended trajectory 9 AII printhead seals should be intact 10 Multi Part printheads should be reattached with parts fitting tightly and aligned properly 2 APPENDIX A FORWARD FLUSHING FORWARD FLUSHING 7 1 Port Printhead FORWARD FLUSHING Sh ag 2 Port Printhead 22 APPENDIX A FORWARD FLUSHING FORWARD FLUSHING FORWARD FLUSHING 23 APPENDIX REVERSE FLUSHING REVERSE FLUSHING EJ Output Output RF ADAPTER 1 Port Printhead REVERSE FLUSHING Output EJ Output Input c e Input RF ADAPTER 2 Port Printhead 24 APPENDIX REVERSE FLUSHING REVERSE FLUSHI
28. n every thing they do and learn learn learn John still has his contract but he turns in two printheads a year to get his two free ones and recovers the rest He has saved over 100 000 so far in new printhead costs DISCLAIMERS PRINTHEAD REMOVAL Unfortunately we cannot advise you on the procedure to remove install your printhead s on your printer We cannot advise you via email or on the phone to do a procedure that could result in damage to your machine if not executed properly Also calibration procedures are necessary after re moving and reinstalling a printhead If you are unfamiliar with these proce dures your recovered head will be out of alignment resulting in poor print quality It is worth the investment to hire a technician watch ask questions and learn the procedure OUR LIABILITY We are not liable for any damage to your printer or printhead s resulting from removal recovery or installation performed by you or your technician We will also not be liable for any lost income additional repair charges or any other resulting expense from such procedures Anyone with out the necessary knowledge should not be repairing their solvent printer Additionally while many of our customers have successfully used this kit to recover their printheads you may have different results We are not liable for your failure to recover a printhead or for you causing a print head to become worse after the recovery proc
29. pump it through the printhead 4 It is recommended that you stay close by during the foaming cycle to keep an eye on the machine and not let the foaming get out of hand De pending on environmental conditions you may generate a large amount of foam or a small amount 5 Once the foaming cycle ends allow the foam to subside before draining the bath Most of the foam should turn itself back into solution Draining Fluids Make sure you are using goggles and gloves 1 Close the relief valve before draining fluids 2 Turn ultrasonic cleaner off by pressing the power button The display should shut off 3 Place the open solution bottle behind the ultrasonic cleaner next to the output connectors 4 Connect one or two output hoses to the output and run into the bottle 5 Start the Drain program to start pumping the fluid back into the bottle 6 Once the fluid is back into the bottle press the Program Button to stop 7 Open the relief valve and run the Air cycle till all fluid is in bottle 8 Remove the template from the machine and clean all the equipment with 90 Isopropyl Alcohol immediately Make sure everything is dry before placing the equipment into the storage container Proper Cleaning amp Storage of the Deluxe Kit Equipment You should carefully clean all the equipment before storing it in the storage case 1 Remove all ink residue from the equipment 2 Wipe down equipment with Isopropyl Alcohol using lint free cloths
30. rough Nozzles If you can t seem to get any fluid to come out the nozzles press the Pro gram Button to stop the cycle and let the printhead sit in the bath for at least 30 minutes before trying again 12 Flow Looks Good If the flow through the printhead looks good place the template back down on top of the machine and hand tighten the thumb screw 13 Closing the Relief Valve As the recovery progresses the flow through the printheads will increase This will cause the pressure to drop You should adjust the pressure to keep it at the maximum pressure until the head is fully recovered Explanation on Cycles cont Foam Cycle The foam cycle is another unique feature of our machine It com bines the air and solution to gether with a surfactant that is in some of the solutions You can test if your solution will foam by shaking a tightly closed botle to see if foam develops The cycle produces a foam which is able to get deep into the printhead and dissolve the clogs Once the surfactant is activated it can help loosen ink from inside the print head Just imagine turning the inside of your printhead into a slip and slide Nothing wants to stick to the inside surfaces of the printhead LPRF foam free This cycle is used with our re verse flushing attachment to put constant pressure on the clog to flush it out Check in the appen dix for instructions on reverse flushing LPRF foamy Customers asked for reverse flushing cy
31. s will allow excess pressure to escape if the head is totally clogged 3 Make sure interior of adapter is clean rubber pressure ring is in place and the nozzle plate of the printhead is clean and dry 4 Place the adapter carefully over the printhead and fasten with 2 4 screws supplied Hand tighten screws evenly with mini screwdriver so adapter is sitting parallel to the template 5 Place template into machine and connect adapter hose to one output Seal other output with supplied cap Your normal output hose from the machine to the printhead inlet will now be connected from the printhead input to the extra hose connection on your template which will deposit de bris back into tank If your template doesn t have an extra hose connection run the hose directly into the tank behind the template We will call this the debris hose 6 Attach the two filters and inlet hoses as explained in Template Setup 7 Open relief valve all the way 8 Run the LPRF Foam Free cycle 20 Why Reverse Flush Reverse flushing allows the ma chine to use a much higher pres sure to remove clogs from your printhead By sending the pres surized solution back through the nozzle side of the printhead and exiting the input side you reduce the risk of blowing out the head during the recovery process Printheads are not de signed to take high pressure fluid through their normal ink feed inlets However the nozzle plate side of the printh
32. t breaks Rear View down some of components of the ink see page 3 and helps to dissolve it We use ultrasonic air temperature and fluid pump ica ing to get the solvent into the clog and allow it to dissolve the ee _ ink Then the machine can flush out the clog once it s broken down enough Ultrasonic Cleaner Power Sid e Vi ew 11 PREPARING THE PRINTHEAD Why Preclean the Printhead STEP 1 LET S GET STARTED Make sure you are using Safety Goggles and Gloves Precleaning your Printhead 1 Test Solutions on Head Use a lint free cloth or swab to test each of the solutions on dried ink deposits to see which one dissolves the ink best Remember which solution you used so you can put some in the machine when it comes time to start the recovery process 2 Pour Solution into Cup Pour a small amount of the best solution into one of the small cups provided in the kit 3 Pre Clean Printhead Carefully clean the sides and bottom of the print head using the solution and a swab or cloth Let the solution break down the ink and do most of the work for you Cleaning the Electronics 1 Pour Alcohol into Cup Pour some 90 100 isopropyl alcohol into one of the small cups 2 Clean Electronics Use the alcohol along with a clean swab or cloth and clean the electronic compo nents on the printhead 3 Use Solution for tough residue If you simply can t break down the ink with the alcohol clean the ink off
33. th cold water and soap Avoid contact with open cuts Ingestion Seek medical atten tion immediately DON T DO THAT Becoming a Recovery Guru We made a special section for all the things we don t want you to do So please don t do them THE OBVIOUS ONES Don t submerge any or part of the machine in water or solvent to clean it or somehow help it Don t hook it up to 220V unless you know for certain that this model is for 220V If you are not sure please ask us Don t use steel wool or other abrasives to clean the unit You may damage the metal finish and cause the machine to deteriorate quickly e Don t heat up the bath without fluid present Don t even try to run the machine without safety goggles and gloves on While you may know what you are doing serious injury can happen at any time Be prepared LESS OBVIOUS BUT STILL IMPORTANT Don t use other solvents other than the ones provided to recov er your printheads The filters pump tubing and fittings can be damaged with improper solvents Don t run the temperature of the bath over 45 degrees Celsius 30 degrees for DX4 amp DX5 Printheads Ultrasonic energy can increase the heat enough to damage your printheads if the temperature gets too hot Don t mix two solutions together to come up with some new solution They may be incompatible with each other and cause a precipitate which will clog up the filters etc Don t store t
34. with 10 feet of the machine needs to wear Safety Goggles 3 Broken Latex Gloves must be immediately replaced to prevent skin expo sure 4 Chemical spills must be cleaned up immediately 5 The kit should only be used in a well ventilated area 6 Any used swabs rags and chemical wipes should be disposed of properly in a sealed trash receptacle Disposal of chemicals and used swabs rags and chemical wipes should be done in compliance with your government s regulations These are the same regulations that govern the disposal of your solvent printer refuse If you are not sure please check with proper government officials to find out more information If anyone using this kit has a latex allergy please substi tute Nitrile gloves for the latex gloves Nitrile gloves are avail able at your local drugstore or some hardware stores Chemical Warning While the chemicals contained in this kit are not extremely hazard ous or flammable they are still considered eye irritants Do not exposure your skin or eyes to any of these chemicals Do not ingest any chemical or leave any of these chemicals around where young children or pets could gain access to them Chemistry These chemicals do not contain any oxidants flammable liquids or neurotoxins Exposure Eye Contact Flush eyes imme diately with cold water If pain or swelling develops seek medi cal attention immediately Skin Contact Wash affected area wi
35. you are only using one connection make sure and cap the other output with the provided caps to keep fluid from leaking out The two outputs are con nected together on the inside of the tower so you will not restrict flow if you cap one of them up 14 We decided in the spirit of not letting people cause their luer fittings to fail and solution to spew all over the place to in stall relief valve in our machine You may have partially clogged printheads or totally 100 dried up ink printheads that you need to recover The relief valve can be opened or closed depending on the condition of the printhead We want you start with the valve fully open and slowly close it as the printhead gets unclogged You will use the pressure gauge to adjust the pressure to get opti mum results What s with the two stage filtration We decided to use a two stage filtration system with our Deluxe PHD3 kit The Stage 1 Filters are 10 micron filters that will catch all the junk before it reach es the 3 micron Stage 2 Filter on the inside of the unit The Stage 1 Filters are cheap and the Stage 2 Filter is expensive Stage 1 s will protect your Stage 2 so it will last for a long time depend ing on how many printheads you recover MACHINE OPERATION cow STEP 4 RECOVERY PHASE Make sure you are using goggles and gloves 1 Plug in both power cords The machine has two power connections for proper operation The first
36. you should follow the one outlined there 7 Start Program To start a program press and hold the program button to select the desired program The programs will display in sequence as a two digit code on the LED display Wait to the program you want shows on the display and release the program button The program will start The display will alter nate between displaying the current program and the time left until finished If a leak occurs or you want to shut off the program press and release the program button The program will terminate and and pumping ultrasonic or air blast will cease 8 Check the fittings Make sure the hose fittings are tight and there aren t any leaks in sys tem Also make sure that fluid is not escaping the tank onto the workbench 16 Explanation on Cycles Normal Cycle The Normal Cycle uses 3 min 3 min 5 sec cycles of pumping ultrasonic and air The pumping occurs first and tries to pump as much solution into the clogged area as possible The ultrasonic loosens up the clogs with the help of the solution and the blast of air ejects the loosened clog The cycle repeats for 30 minutes Extended Cycle It s the same process but extends the time to 5 min 5 min 5 sec cycles This Extended Cycle produced excellent results in test ing just by extending the times by a few minutes The cycle repeats for 30 minutes Extended Plus Cycle It s another variation of the Extended Cycle with just
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