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Maxima Pro Operators Manual

DESCRIPTION
The Maxima Pro Plus continuous-feed ink-jet printer is designed to provide a non-contact
application of alpha-numeric and/or graphical information to products and/or packaging on a
constant-feed conveyor system.

PRINTER OPERATION
This printer is a drop jet device producing a continuous flow of monodisperse drops moving
at a speed of 10-15 m/s. Some of the drops are electrostatically charged, so their trajectory
can be directed by the action of an electrostatic field. Uncharged drops do not change their
trajectory and return to the hydraulic system through an ink trap assembly. Characters to be
printed on an object are created with an array of drops which are electronically aimed within a
vertical column. Horizontal coordinates are reached by the movement of the object as it is
printed.

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DESCRIPTION OF PRINTER
The appearance of the MAXIMA PRO PLUS is shown in Fig. 1. An outline drawing of the
ink-jet printer is shown in Fig. 2. The functional diagram of the printer consists of two main
parts: the stainless steel printing head (with umbilical conduit) and the printer control unit).
The control unit consists of the hydraulic system, and the electronics system (with keyboard),
all mounted in a painted steel frame with removable covers over each system.

PRINTER SPECIFICATIONS:
Maximum print speed:
Number of Lines:
Number of Characters per Line:
Character Height:
Resolution:
Number of Fonts:
Number of Print Heads/Nozzles:
Nozzle size:
Nozzle frequency:
Length of Umbilical:
Optimum Operating Environment:
Graphic Capabilities:
Displays Operating Parameters:
Memory Capacity:
Interface Capacity:
Programmable Output Available:
Printing Direction:
Synchronization of Printing Speed:
Ink Consumption:
Make-up Consumption:

984 feet/minute or 300 meters/minute


1 to 4
248
1.2-25 mm
3-5 dots/mm
7
1
50, 60, 70, 80, 90 Microns
20 to 70 kHz
Standard: 6.56 (2m) Custom up to 13.12 (4m)
Humidity 10% to 80% Temperature -41-104
Yes
Yes
Up to 100 Messages with 200 Logos
RS-232, extra serial port
Yes
Forwards & Backwards
Yes
65,000,000 Characters per quart
150 hours/quart*
*Depends on ambient temperatures & condition of the printer

Additional Features:

Printer Cabinet:
Dimensions:
Weight:
Electrical Requirement:
Pneumatic System:

Product Detect
Real Time Clock & Calendar
Manufacturers Week
Julian Time
Postdate
User Initials
Upload Logo Capability
Painted Steel
15.6x 14.4x 8.2/ 390 x 360 x 205 mm
26.4 lbs. / 12 kg.
Adjustable Power Supply 90-260v, 50 & 60 Hz, 30w
Not Required

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Note: The type of ink used will determine if the printer requires a hydraulic system equipped
with devices for viscosity checking and automatic solvent (make-up) replacement.
Fig.1. Appearance of printer MAXIMA PRO PLUS 3

PRINTING HEAD
The printing head is connected with the control device by means of a flexible umbilical
conduit to protect electrical and hydraulic circuits against damage. Appearance of printing
head is shown in Fig. 3.
Printing head consists of:

an electrical ink valve;

an ink valve toggle switch (Fig. 3, 2);

drop generator (Fig. 3,3)

replaceable nozzle (50-90 microns) (Fig. 3, 4);

ink drop charging electrode with drop charge sensor (Fig. 3, 5);

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Printing Head and Control Unit:


1. Keyboard panel
2. Printing head (PH)
3. Umbilical conduit
4. Power cord
5. Electronic equipment compartment
6. Hydraulic system compartment
7. External connectors, controls and connecting parts of printer
8. Front cover
9. Rear cover
10. Front and rear cover fasteners
11. Keyboard

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- Electrodes for the deflecting system (Fig. 3,6)


- fixed on dielectric base (Fig. 3, 7)
- Stroboscope (LED) lighting to view ink stream (Fig. 3,8)
- Return trap for unused drops (Fig. 3, 9)
- Return trap sensor
- Printing head cover interlock micro-switch disables high voltage when cover is open
- Flow indicator (Fig. 3, 18)
- Mechanical latch for printing head cover (Fig.3,15)
- Charge sensor amplifier board-located in recess under screen at the hinged cover.
Note: charging electrode and deflecting system are mounted on the hinged cover.
Drop generator is a vibrating jet on which there is located a replaceable nozzle with a
pressed-in watch stone with opening 50-90 microns in diameter.
The drop generator is secured to the adjusting plate, allowing adjustment of its position. The
flow location relative to the charging electrode is adjusted in this way. The adjustment of drop
generation is viewed through the lens with stroboscopic lighting installed at base of the
charging electrode. The upper cover may be opened to provide access to the nozzle (Fig. 4, b,
14). The negative deflecting electrode is located closer to flow of uncharged drops while
positive electrode is more distant. The drop path is shifted towards the positive electrode
although some deflections exist towards the negative electrode, so the negative electrode is
located at a distance of 1,0-1,5 microns from uncharged flow. Location of trap in relation to
flow of uncharged drops is adjusted by horizontal movement of a caprolone holder (Fig. 4, b,
16). The adjustment holder is fastened with two screws (Fig., b, 17). Flow should enter into
trap between center and left edge of pipe (if viewed from the open end of the trap).

HYDRAULIC SYSTEM
The hydraulic system produces ink drops by building up ink pressure and for maintaining it
within design limits as well as creating suction to collect unused ink drops. A diaphragm
pump system is used with this ink-jet printer. The pump assembly uses an electric motordriven eccentric wheel to actuate the two connecting rods for the pressure and suction
cylinder pumps (PC and SC). The pumps are identical except for their location in the system.

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Construction of liquid pump is depicted in Fig.6:


-

Pump consists of electric motor (Fig.6, 1),


Single -reduction gear unit consisting of pinion (Fig.6, 2)
Toothed gear wheel (Fig.6, 3),
Eccentric shaft (Fig.6, 5),
Connecting rod (Fig.6, 20)
Connected with crosshead (Fig.6, 28)
By means of finger (Fig.6, 21),
Guide post (Fig.6, 27)
For stock (Fig.6, 26) fixed in crosshead
Pumping and suction cylinders Fig.6, 15) are connected to crosshead.
Places of application of lubrication are marked with arrows.

System differences based on ink type


The following two types of ink are usually used as the work liquid with continuous drop-jet
printers: Type 1: Water-based food ink (WF)
Type II: Methyl ethyl ketone ink (MEK), Spirit (alcohol) food ink, and (SF) Ethyl cellulose
ink (EC)
Due to solvent evaporation during system operation, Type II inks require replacement of the
solvent (make-up) in order to maintain the correct operational viscosity. Type II ink printers
are equipped with additional devices for checking ink viscosity and the automatic
replacement of solvent. Type I inks normally do not require the addition of any solvent or
other liquid, so printers using water-based inks (Type I) do not require the additional devices
(listed above) of the Type II printer system.
Functional diagram and layout diagrams of specified above hydraulic systems are shown in
Fig. 7, and Fig. 9, correspondingly.
Hydraulic systems usually consists of the following parts:

(PC) and (SC) pressure cylinder and suction cylinder. They each have two ports: an
input port (unmarked), and an output port (marked with black dot or indentation).

(RC) Pressure damper. Decreases the level of pressure pulsation in the hydraulic
system. It has two ports: a central one (input, with a check valve) and a peripheral one
(output).

(HV) Hydraulic valve (three ports). The two outer ports are connected internally. The
central port has a control valve. When the valve is not actuated, (without control
voltage) the central port is closed. When the valve is open, the three ports interconnect
(like a T-pipe).

(F) Ink filter. Its input is located at side of fixture (see Fig. 8 and 10).

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(BC) Bypass channel. It is a metal tube containing a hollow needle pressed into a
polyethylene plug. The needle is of calibrated length and diameter to create a specified
resistance to ink flow.

(T) Trap. Collection point in the print head for unused ink drops.

(Tp) T-pipe. A three-way connection for hydraulic tubing

(C ) Container for work liquid (ink or solvent reservoir)

(PS) Liquid pressure sensor

(VS) Viscosity sensor

(TS) Trap sensor (thrombus sensor). Designed to automatically switch the ink stream
off (in 10-15 s) under emergency conditions (if ink flow fails to enter trap or if there is
no movement of ink from the trap)

(LS) Ink/solvent level sensor for containers

(DG) Drop generator. Induces ink stream to break into droplets

(PH) printing head

(N) Ports (also called nipples). Connection points for polyethylene tubing in the
hydraulic system.

Other elements that are not parts of the hydraulic system, but are necessary for
charging of the drops and directing their trajectory, are also represented in Fig.7 and 9:

(SE) system of electrodes (charging electrode combined with charge sensor)

(DS) - deflecting system (deflecting electrodes DE).

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In addition to that, it is seen from Fig. 7 and 9 that both hydraulic systems have the same
outer hydraulic circuits:

Positive pressurization of printing head: Consists of a polyethylene tube with two free
ends: one end is connected to the central port (NVI) on the printer chassis and the
other end is inside the printing head. With the addition of an optional air supply, this
circuit is designed to develop a slight positive air pressure in order to prevent dust,
dirt, and flammable vapors from entering the printing head.
Atmospheric vents for ink/solvent containers: Designed to allow the release of
saturated vapor from ink container (and solvent container) and prevention of
condensation buildup. If necessary, this circuit may be connected to an external
ventilation network.

Next: Describing the operation of each part of hydraulic system specified above. We remind
you that the start of the hydraulic system and control of its operation is effected with HSCU.
1. Typical diagram of a printer hydraulic system of utilizing ink that does not require
automatic filling up with solvent is shown in Fig. 7. Layout diagram of such hydraulic
system is shown in Fig. 8.

When operating power is switched on, the pumps start and exhaust valve EV is
opened for approximately 20 seconds. During this time some ink is pumped
through charging circuit:
F input> PC> (Tp) > RC and exhaust circuit RC > PS > FDG > HV> BV>C.

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Thus ink is regenerated in receiver and drop generator circuit. It is seen in Fig.9
that additional branch - recirculation circuit - is installed from the T-pipe of
charging circuit: BC -> C.

Ink is being constantly mixed in container through this circuit. But if bleeding
valve BV is open, the amount of ink delivered to container C falls far short of
amount of ink delivered if BV is closed due to liquid resistance developed by
bypass channel BC. Thus within 20 seconds pump rotation rate is rather small,
about 1 Hz (8-10 rotations). After 20 seconds of hydraulic system operation,
bleeding valve BV is closed and the hydraulic system begins to build up pressure.
As this takes place the pump rate increases gradually up to as much as 3-3.3 Hz
(30-33 rotations) and the process of building up pressure in receiver RC
(controlled by pressure sensor PS) is started.

At the same time, the major portion of ink is delivered to container C through
bypass channel BC (recirculation circuit with the flow restriction installed) as
hydraulic valve HV and bleeding valve BV are closed. After building up of normal
working pressure of hydraulic system, a command is given for switching off ink
flow.

If the ink stream valves toggle switch at front side of the printing head (PH) is in
the "OFF" position, (away from .) then bleeding valve (BV) will be opened at
regular intervals to relieve excessive pressure buildup in the hydraulic system.
While this takes place, the pump rate remains at maximum.

If the toggle switch is in the "ON" position when the working pressure is achieved,
the ink supply valve is opened automatically and flow will be supplied for the ink
stream. At this time the LED at front side of the printing head (PH) is lit. The ink
stream falls into trap (T) from the nozzle and is returned to container (C ) through
the trap sensor (TS) and trap filter (TF) due to the vacuum developed by the
suction cylinder (SC). As the ink pressure stabilizes, the pump rotation rate falls
off slowly to its nominal value (1.5-2.0 Hz, 15-20 rotations).

During operation, the electronic control system will maintain ink pressure within
the specified limits. Note that pressure cylinder (PC) and suction cylinder (SC) are
operated by the same electric motor. Since it is necessary to maintain the specified
value of constant pressure (in receiver (RC)) for the operation of the drop
generator (DG), there should be a constant vacuum in the suction circuit (T> TS >
TF > SC > C) to provide prompt removal of unused drops from the trap. The
continuous operation of the pump is required for this to occur.

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In order to meet both conditions simultaneously, a special restricted circuit, (BC) >
recirculation branch, is provided. Rate of ink recirculation through the bleeding
channel (BC) far exceeds (by 1 order of magnitude) the rate of flow through the
nozzle. The rate of ink flow through of the bleeding channel (BC) is such that the
pump rate is 1,5-2,0 Hz (15-20 rotations) when the control system maintains
constant working pressure.

A diagram of a hydraulic system equipped with a viscosity-checking device and


device for automatic refilling with solvent is shown in Fig. 9. A layout diagram for
this type of hydraulic system is shown in Fig. 10. As the diagram shows, the
hydraulic system is equipped with a viscosity checking device and a device for
automatic refilling with solvent.

In that connection the following parts of hydraulic system are provided:


- auxiliary container (C2) for solvent
- input valve for supplying ink (VI)
- input valve for supplying solvent (V2)
- viscosity sensor (VS)
- T-pipe, in that case it is equipped with measuring chamber with rubber diaphragm.

With reference to Fig. 9, it can be seen that either ink (through VI) or solvent (through
V2 and through input communicating ports of V1) is supplied to input of the charging
cylinder. In both cases ink and solvent are supplied through submersible input filters
Fl and F2. So, charging circuit is connected as follows:
Fl VI -> PC -+ VS -+ Tp -> RC F2 V2

After startup of the hydraulic system, VI is opened (delivery of ink) and remains open
for all printer operations. Vl does close briefly for periods when V2 is opened to add
solvent to correct ink viscosity. Operation of the viscosity-checking device depends on
the process of ink recirculation through the hydraulic circuit:
VS --+ Tp ---> BC -> C.

Resistance developed by bypass channel (BC) is dependant on ink viscosity. Output


signal of the viscosity sensor (VS) is directly proportional to pressure developed by
bypass channel (BC) in measuring chamber of (Tp). In case of a buildup of the ink
viscosity in container (Cl), addition of solvent from C2 takes place automatically.

Solvent is added in small amounts several times: An addition of solvent occurs when
V2 is opened and VI is closed. Then the ink is recirculated for some time when V1 is
re-opened and V2 is closed. After 8 refill cycles (during a period of about 5 minutes)
the addition of solvent to ink ends. This system of maintaining desired ink viscosity
provides protection against over-dilution of ink in the receiver (RC). Total amount of
solvent added during refill cycles is approximately 4.5 ml.

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When printer power is switched off, the bleeding valve is opened for several seconds
(BV, see Fig. 7 and 8 or V3, see Fig. 9 and 10) in order to relieve pressure in receiver
(RC). This is necessary because of the presence of a check valve at the input port of
receiver (RC).

As working pressure is built up in both systems described above, the ink stream
control valve is opened (V or V4) and ink flow is delivered to drop generator (DG)
which is a vibrating jet with a changeable nozzle on the output end.

Vibration is performed through the supply of alternating current at an ultrasonic


frequency to a piezoelectric ceramic bimorph generator. The frequency to break the
flow into drops coincides with the frequency of vibration. Parameters of voltage
supplied to drop generator are such that break-off point of the continuous ink flow
occurs within system of electrodes (SE). Inducing a charge into the drops is performed
by means of electrode system (SE) to which rectangular pulses of different amplitude
are fed. The unbroken part of the ink stream (flow) and system of electrodes form a
capacitor. As the value of the charging voltage changes, the electrical charge of the
capacitor and the drops that form part of its coating change also. Charged drops are
deflected by an electrostatic field, while non-charged drops fall into the trap and are
returned to ink container (C ) through suction filter (F) and suction cylinder (SC).

During printer operation, the device performs self-testing by means of SE and


adjustment of operational modes is performed automatically if necessary. In order to
ensure drops pass above the trap without touching its edge, their initial charges are not
equal to zero, but have a slight initial value. The system of electrodes (SE) and
deflecting system (DS) control trajectory of the drop path only along one axis
(vertical).

To do this, it is necessary to charge drops with increasing voltage (and increase drop
deflection trajectory) in order to obtain an image of a continuous vertical column on
the surface of the object to be printed. But in order to obtain an image of
non-continuous line, it is necessary to charge only some of the drops with the
appropriate voltage. The horizontal coordinate of the image is gained through the
motion of the surface to be printed as it moves past the printing head.

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ELECTRONIC SYSTEM
The compartment for electronic parts is located in the control unit frame and consists of HSC
(hydraulic system controller), Cp (print controller), PSU (power supply unit) combined with
HVTU (high-voltage transformer unit) and KCU (keyboard control unit).
Hydraulic system controller (HSC) is intended to synchronize and control the operation of
liquid supply and liquid suction system. HSC board is a microprocessor device generating
signals for controlling the electric motor for the pumps, switching on/off liquid valves. Input
signals are pressure (signal from pressure sensor), manual switching on/off of liquid valve,
and signals from trap, level and viscosity sensors. After switching on the power by pressing
the POWER button, the CP and HSC boards are initialized. After that, the HSC enters
operation mode. This program maintains the specified operating pressure by means of
monitoring ink flow into trap, checking the liquid levels in ink and solvent containers, taking
measurements of ink viscosity and the current pressure value, and the number of pumping
cycles per second (rotations). When the HSC board is set in operation mode, it automatically
switches on the ink valve of the printing head.
Print Controller (CP) Its functions include synchronization of the drop producing process,
testing of moment of drop detachment, generation of characters, input and storage of all
system information. The drop generator (DG) is used to convert the ink stream to drops. It is a
vibrating jet with a removable nozzle. Two piezoelectric ceramic rings to which alternating
voltage of ultrasonic frequency is fed produce vibration. Ink flow moves through the jet, and
is pushed from the nozzle as a continuous stream. This stream is broken down to drops by
synchronization with the vibration frequency. The voltage amplitude of ultrasonic frequency
of synchronization is that which allows continuous flow to be broken down inside gap
between board and charging electrode. The generation of drops takes place because of the
action of a synchronizing voltage with the same frequency. The unbroken part of the flow and
charging electrode create an electrical capacitor. Drops should be charged at the moment of
break-off from the ink stream. However, the moment of drop release depends on nozzle
characteristics and other factors such as temperature, pressure, vibration amplitude, and
others. To achieve a stable drop charge, it is necessary to conduct tests to determine the
moment of drop release (break-off).
This testing procedure is conducted before the beginning of printing of each character and
always consists of two main stages:
First stage: CU board sends testing pulse of a certain amplitude and duration to charging
electrode in order to charge drop.
Second stage: CU board waits for this drop to reach the sensor and initiate response at output
of charge sensor amplifier. It may be necessary to make several attempts for a successful test.
Results are indicated with the LED "PHASE" located on the CU board (Fig.15, 10) as well as
with the LED on the keyboard. If indicators are green, testing has been completed
successfully. If indicators are of other color (or went out), it is an evidence of failure.
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Typical failures are as follows:


- no flow of drops
- spillage of conducting liquid on internal surface of the charging electrode
- over-stimulation of the unbroken part of ink stream
The character generator located on the CP board produces charging pulses of different
amplitude to be supplied to charging electrode for drop imaging. Multiple separate columns
are required to create an image. The character generator turns the representation of the
character image into a sequence of charging pulses of different amplitude. Drops that will
produce the image are diverted by an electrostatic field from the continuous flow of drops
moving to the trap. In order to correctly direct a drop to the surface to be marked, it should
acquire an initial charge ("Step") in addition to informational charge ("U char). Character
and/or message height is changed by the adjustment of "U char. Raising or lowering the
entire character in relation to the path of uncharged drops is done by adjustment to "Step". If
initial charge for "Step" is not adjusted correctly, then symbol image may lack a lower line of
drops. Such distortions may be eliminated by raising the initial level of "Step" or by
mechanically lowering the trap. Initial charge is selected during adjustment and guidance for
this selection is to provide for passing of drop above trap without touching its edge.
Adjustments to "U char " and "Step" are performed with keyboard commands INS Z and INS
Y respectively.

HIGH-VOLTAGE POWER SUPPLY


The power supply unit is an independent functional assembly placed in its own metal case.
This unit is connected by means of a low-voltage connector (PC-10) and two high-voltage
single-pole connectors. Actions of the high-voltage power supply are based on the principle
of forced back magnetization of a line-output transformer core. Frequency of the
transformation is equal to the frequency of the internal RC-generator. A time diagram of drive
pulses fed to the transformer winding, eliminating the occurrence of a through current, is
generated by means of pulse distributor. Output winding of line output transformer of
transformer unit is connected to bipolar multiplier with single polar connectors at outputs.
The high voltage power supply is equipped with a protective device to prevent damage from a
high-voltage short circuit (grounding). If the protective device is activated, output voltage is
switched off and an indicator begins to flash (Fig.13, 2).

POWER-SUPPLY UNIT (PSU)


Integrated electronic stabilizers 7805, 7812 and 7912 are used as stabilizing elements. Power
supply unit provides the following voltages and currents:
Stabilized: +5 V (1 A) +12 V (0.2 A) -12 V0.2 A)
Non-stabilized: +10 V (0.5 A) +14 V (0.2 A) +22 V (1 A) 140 V (0.05 A) +250 V (0.02 A).

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OPERATIONAL INSTRUCTION
GENERAL REQUIREMENTS FOR PRINTER INSTALLATION
1

Printer should be used under normal ambient condition:


Ambient temperature should be 2050C (68 to122F)
Relative humidity should not exceed 90% at temperature of 25C (80F).
Atmospheric pressure is within range of 630-800 mm Hg

The printer should be supplied from AC mains, 90-250 V 50-60 Hz. No high-load
equipment should share the same power supply unless a surge protector, or similar
device, is used. A power failure will require the printer to be restarted.

Printing head can be installed in positions ranging from horizontal (with print side
slightly inclined downwards to provide flow release) to vertical position (with print
side facing either upwards or downwards).

Distance between the print side of printing head and the print object should be within
range of 5-50 mm.

It is recommended to install printer and printing head at the same level. The
maximum allowed difference between installation levels is 1m.

Travel of printing objects should be in the direction toward the printing head lens (top
of printing head) during forward printing and away from the printing head lens during
backward printing.

The printing head mounting fixture should provide easy detachment and access to the
head and cover to allow inspection of the ink stream through the lens and also for
preventive maintenance of parts under the cover.

Photocell sensor (included in delivery set) may be installed in any position at distance
of 5-130 mm from object. This type of photocell sensor uses the infrared range of
light. There is a slot at the front side of photocell sensor for adjustment of sensitivity
by mechanically opening or closing the shutter for the light flux hole). Photocell
sensor sensitivity decreases when adjusting the screw inward (closing shutter).
Photocell sensor sensitivity also depends on surface reflectivity and object shape and
should be tested and adjusted on-site. The best backgrounds should have a nonreflective surface. Recognition of an object is indicated at the rear of the photocell
sensor with a glowing LED. Red is detecting, and green is no detection. Maximum
speed of the photocell sensor is 1,5 kHz.

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During conveyor line operation, vibrations that affect the printing head, umbilical
conduit, and its mounting, should be reduced to the minimum or eliminated if
possible. Otherwise printing will be distorted and the process of drop generation will
be disturbed. Smooth and steady movement of print objects on the conveyer line also
contributes to optimum print quality.

CHECKING PRINTER OPERATION


1. After switching power on, the ink stream enters the trap between its center and left side (if
you look at the trap from the nozzle side). If ink stream does not fall into the specified
place of a trap, switch the print head toggle switch on and off in order to break through
dried ink that is clogging the nozzle. If that did not bring the desired results, you may
moisten a soft cloth with the correct solvent for the ink and press carefully against front
side of nozzle (with the printing head switch OFF!). You may also take a syringe with a
short length of tubing attached, fill it with solvent. Turn print head switch OFF! Remove
air from syringe tube and attach to nozzle tip. Apply gentle pressure to syringe, and set the
printer to go into standby mode. During shutdown operation, the printer will briefly
suction ink from the nozzle and will also draw in some solvent from syringe. Take the
syringe tube off the nozzle and re-start printer. If the ink stream still fails to fall into the
trap, it will be necessary to remove the nozzle and to flush it.
2. If the ink supply valve toggle switch is not switched on, or a clogged nozzle stops ink
flow, the bleeding valve will open periodically in order to release excess pressure in the
hydraulic system. The pump rate will remain at maximum (see indicator 4, Fig.15 and
message at LCD).
3. The hydraulic system enters into normal operational mode approx. in 1 min after
switching ink flow on. The pressure reading and pump rate of hydraulic system will then
meet the system settings as specified in the certificate.
4. The ink stream flow of drops may slightly pulsate, but that does not affect printing quality
unless the pulsation moves the drops a distance exceeding half of a drop diameter.
5. To reduce solvent usage, the suction system is adjusted so that it provides a reliable
suction of unused ink under steady pump rate. At the moment of switching device on
(when suction pipe is not filled with thrombi (unused ink drops), ink may splash out from
trap. It is possible to fill suction pipe with thrombi without ink splashes by turning the
printing head switch on-and-off several times (3-5 times) to speed up setting the normal
mode of operation of the suction line. Remove ink drops outside trap (with cloth
moistened with solvent or acetone). The ink stream reaches the break-off point in the red
illuminated area of charging electrode. Various types of drop generation under different
values of amplitude of synchronizing voltage are shown in Fig.7 neared during startup.

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6. Deflecting and charging electrodes should always be dry and clean. Wipe them with a
cloth moistened in any kind of solvent (acetone, alcohol) if necessary and dry them.
7. With the printing head cover closed, the dependence of break-off distance on amplitude of
synchronizng voltage is sharply defined. With small values of this voltage, the break-off
point is located far from nozzle. If the break-off point reaches the electrostatic field of the
deflecting system, then the drops will receive their charge from the stationary field of
deflecting electrodes. The result is that drops either collect on the electrodes of the
deflecting system or will not fall into trap (changes its path) and spill on internal parts of
printing head. As the amplitude of synchronizing voltage increases, the break-off point
backs up toward the nozzle, and then distortion of drop generation occurs (drops are
turned in opposite direction, with their "tail" facing forward). Also, the breaking point
moves away from the nozzle abruptly, and then approaches the nozzle again, but the drop
generation is distorted. The effect of distortion of drop generation under increasing
amplitude of synchronization voltage is called remodulation. The remodulation effect is
most conspicuous only with water-based ink. With other types of ink, remodulation effect
may not occur due to film forming.
8. The phasing indicator will glow green after the first test printing. If that did not happen,
restart the unit several times (it is allowed to start the unit repeatedly) and watch the LED.

If the LED color did not change to green or changed from green to another color during test
printing, make sure that: a) charging electrodes are clean and dry or: b) drop generating
process is normal.

Appendix

page 19

INSTITUTE OF ELECTRICAL DROP-JET TECHNOLOGIES

9. Position of print output on the object surface depends on mutual arrangement of printing
head and photocell sensor relative to object.
10. Adjustment of printing parameters and parameters of drop generation (only of breaking
point) is allowed within limits specified in marker Certificate (see paragraph 1.1
"Amendment to Note" of Certificate) at initial installation and set-up of printer on the
production line.

1. Power cord.
2. Chassis grounding terminal
3. External encoder toggle switch (switch up only for external encoder use)
4. Alarm/warning light port
5. RS-232 port
6. Sensor/encoder port
7. Sensor/encoder port
8. Printing head umbilical conduit
9. Printing head air pressure feed port (use is optional)
10. Atmospheric vent for ink/solvent containers
11. Manual rocker-type Power Switch
Appendix

page 20

INSTITUTE OF ELECTRICAL DROP-JET TECHNOLOGIES

TROUBLESHOOTING GUIDE
No.
1.

Indicator State
Display:
PRINTING
DISABLE
High voltage OFF!

are red

2.

is orange
Sound signal!
PRINTING
DISABLED TRAP
ALARM OFF

are red

is orange

LED at the face side


of printing head
goes out.
Sound signal!

Appendix

Symptom
Electrical breakdown at
deflecting high voltage
electrodes of printing
head.
Printing is disabled.
1.
Electrodes and
their dielectric base
are:
ink
splattered
wet
dirty
2. Deflecting electrodes
are not parallel to each
other.

Remedy
1.Inspect deflection
electrodes for shortcircuit caused by ink
splatter, dirt, etc.
2. Wipe dirty part with a
lint-free soft cloth,
moistened with
acetone or alcohol,
then dry completely.

3. Adjust position of
electrodes. Restore
initial parallel position
of electrodes.
Emergency actuation of
Check trap for ink
trap sensor (TS) at printing buildup-clean as
head (PH)
needed-then check ink
TS closes flow supply
stream to trap-valve at PH in 10-15
clean/adjust nozzle or
seconds if
trap as needed.
no ink flow is detected.
1. Flow does not enter trap
or there is no flow at all
after flow supply valve has
been opened
A. Nozzle is clogged or
See paragraph 43.1 or 8
has dried ink inside.
of this instruction
B. Ink has thickened (in
Remove thickened ink
case of quick-drying ink)
from hydraulic system,
In this case pump rotation flush system with
correct solvent, and
rate drops off from
nominal value to 10-8 and install fresh ink.
less, average ink viscosity
(MOD 6) increases by 5-7
units and more. There is
no sharp drop in pressure
at the moment of actuation
of bleeding valve.
page 21

INSTITUTE OF ELECTRICAL DROP-JET TECHNOLOGIES

No.

Indicator State

Symptom
Reason
1. Short circuit between
central and outer contacts
of high level sensor (LS) at
cover of ink container
(contacts are wet with ink)
2. Ink container is
overfilled with ink.
3. Air suction at filling-up
circuit
4. Bypass is clogged.
In cases specified above
solvent is not being refilled
or working viscosity of ink
is not being maintained.
II. No suction of unused
drops from trap. Ink
overfills trap.
Reason:
1.Trap or suction circuit
(T , TS F 4 SC) is
contaminated with dried
ink
2. Filter of suction circuit
is clogged (contaminated)
3. Air leaks in suction
circuit.

Appendix

page 22

Remedy
1. Eliminate fault: Flush
the contacts of LS to
remove ink causing a short
circuit between these
contacts.
2. Draw off some ink from
container down to
necessary amount (see
paragraph 6)
3. Check for air leaks in all
parts of the ink supply
circuit, including tubes and
tube connections.
4. Flush bypass thoroughly.
Use syringe for this
purpose (See paragraph 8).

1. Flush suction circuit


thoroughly (See Appendix
2, part 2)
2. Flush filter or replace
filter with a new one. (See
Appendix 2, part 1a)
3. Find air leaks in tubes or
at connections of tubes in
the suction circuit--bypass
parts of circuit to eliminate
them as source.

INSTITUTE OF ELECTRICAL DROP-JET TECHNOLOGIES

No.
3.

Indicator State
PRINTING
DISABLED
PUMP ALARM
OFF!

is orange
Led at the face side
of printing head
goes out.
Sound signal!
4.
is red

or is not lit or
changes color or
goes off. Sometimes
(or all the time)
print is:
- completely (or partially) deteriorated
- unreadable or
distorted
- upper or lower
lines are cut off

Symptom
Emergency actuation by
pressure sensor (PS) of
hydraulic system. Pump
stops operating.
1. Ink is thickened.

1. See No. 2.1 B of this


Troubleshooting Section

2. Filter at bleeding
system is clogged
(contaminated)

2. Flush defective part or


replace with a new one
(See paragraph l.a of
Appendix 2)

1. Charging electrode is
contaminated with ink,
causing HV short-circuit.

1. Wipe dirty part with


soft, lint-free cloth
moistened with acetone or
alcohol, then dry out. Use
syringe with needle for
washing through.

Attention! It is strictly
prohibited to use hard,
sharp objects for
cleaning the electrode
system (Fig.4, b, 5).

2. Umbilical conduit of
printing head or printing
head vibrates or trembles
severely at places where it
is mounted.

Appendix

Remedy

page 23

2. Eliminate vibration or
trembling by mounting
umbilical conduit and/or
printing head securely.

INSTITUTE OF ELECTRICAL DROP-JET TECHNOLOGIES

No.

Indicator State

Symptom
3. Poor flow break-off into
drops

are orange

No printing! Printhead
cover interlock
microswitch (for deflector
high voltage) has failed or
is out of position (Fig.4, b,
11)

is red
Continuous sound
signal!

During printing operation.


Failure of interlock microswitch for deflector high
voltage (at printing head)
(Fig.4, b, 11).

5.

6.

Appendix

page 24

Remedy
a) Make sure that nozzle
is tightened to stop
(should be screwed
with 2 fingers, up to
stop, without any tools)
b) Check main parameters
of the hydraulic
system: pressure and
number of rotations.
Check average
viscosity of ink
(through MOD 6) with
viscosity checking
device, if needed.
c) Check parameters INS:
FSR (or F), U, T, Z, Y.
Follow
recommendations
given in paragraph
4.3.9 of this instruction
manual.
d) Flush nozzle in
accordance with
paragraph 8.
Open cover of printing
head and press against
micro-switch button
several times. If
corresponding indicator
glows green at every
pressing of the button, then
loosen the fastening bolts
and move the micro-switch
upwards, then tighten bolts.
Otherwise replace
defective switch with a
new one.
WARNING! There is a
high voltage of + 3500V
at deflecting terminals!
Replace defective part with
a new one.

INSTITUTE OF ELECTRICAL DROP-JET TECHNOLOGIES

No.
7.

Indicator State

Symptom
Presence of an obstruction
(dirt, fiber, ink, and so on)
across the trajectory (at
electrodes, trap and slot of
decorative panel of
printing head) of flow of
drops

Remedy
Check and clean printing
head. See No. 4.1 of this
Troubleshooting Section

Printing stops from


1. Position of photocell
time to time. Control sensor relative to object to
panel indicators are
be printed is incorrect.
green.

1. Install photocell sensor


in accordance with
instructions specified at
paragraph. 4.1.8 and
4.3.10. Check LEDs for
detection of print object.

Sometimes (or
all the time) the
print is:
deteriorated,
unreadable or
distorted, upper
or lower lines
are cut off
In this case:

8.

9.

Hydraulic system
does not operate or
builds up pressure
slowly. Pump
rotation rate is
maximum - up to 33.

Appendix

2. Poor contact of the


connectors of signal cable
(e.g., from photocell
sensor)

2 a) Connect connectors
securely.
2 b) Clean contacts with
brush or wash them.

3. Printing head cover is


not closed tightly or lock
does not lock.

3. Make sure that cover is


closed tightly and that lock
locks. Otherwise eliminate
fault. Lubricate lock with
technical oil if necessary.

4. Interlock microswitch
for deflector high voltage
at printing head fails to
operate intermittantly
(Fig.4, b, 11)
1. Air leaks in pressure
circuit.

4. See No. 5 of this


Troubleshooting Section.

page 25

1. Find reason for air leaks


at tubes and at connections
of tubes with ports of
pressure circuit (input >
(V1> V2) > PC) and
eliminate it by bypassing
(test only).

2. Input filter in ink


container is contaminated.
10.

Hydraulic system
builds up working
pressure but as this
takes place- pump
rotation rate drops
down to 10-8 and
less.- flow is
switched off but
pressure is being
built. Bleeding valve
is opened.- average
viscosity is 20-25 or
more

1. Bleeding valve is
clogged or contaminated,
causing excessive
restriction in the circuit.
2. Excessive ink viscosity.

2. Flush filter or replace it


with a new one (see para.
1,b of Appendix 2
1. Flush bleeding valve.
Use syringe for this
purpose (See paragraph 8).
2. See No. 2B of this
Troubleshooting Section

ATTENTION! IT IS STRICTLY PROHIBITED TO DISCONNECT PIPES OR REMOVE


PARTS OF HYDRAULIC SYSTEM DURING PRINTER OPERATION.

Appendix

page 26

INSTITUTE OF ELECTRICAL DROP-JET TECHNOLOGIES

APPENDIX I
PRINTER POWERING ON
Attention! Before operation it is necessary to ground the printer!
N
1

ACTION
INDICATOR STATE
Insert plug of power cable
into electric socket (90260 volts, 50-60cycleschange plug if needed).
Switch to standby power
mode by pressing the
"POWER" button (Fig.
16, 11). Note: If
Other indicators are not glowing.
plug/socket is not
grounded, surge protector
must be installed and
chassis must be grounded.
Open cover of printing
head and inspect it.
Remove nozzle cap and
trap cover.

Other indicators are not glowing.


3

ATTENTION! REMOVE NOZZLE CAP and TRAP COVER!


Power on the printer by
pressing this button on
the keyboard.

Note: If printer was turned


off or unplugged, enter
<Mod> <P><111> to
start.

Appendix

page 27

INSTITUTE OF ELECTRICAL DROP-JET TECHNOLOGIES

N
4

ACTION
INDICATOR STATE
Toggle the switch at front
side of printing head
towards indicator (.)
About 1 minute after
turning on the printer,
Indicator at front side of printing head will
flow starts, panel indicator glow red when flow starts.
turns green
Close cover of printing
head after checking the
ink stream-to-trap
alignment.
Other indicators - see paragraphs 3 and 4.
Perform test printing by
pressing PRINT button
on the keyboard after
entering the desired
message by following the
instructions in System of
Commands
Note: Press the Power
button, then <Y> to power
down the printer into
sleep mode.

Appendix

page 28

INSTITUTE OF ELECTRICAL DROP-JET TECHNOLOGIES

APPENDIX 2
1. Instructions for Filter Flushing
Filters should be flushed through 3-4 times by means of syringe in the direction opposite of
flow. The filter should be flushed through with acetone or alcohol (if marker is filled with
water-based ink, then it is possible to use 5% solution of ethanoic acid), and then it should be
flushed through 2-3 times in both directions with work solvent (or with distilled water for
water-based ink). A lack of resistance to pressing the syringe is evidence that filter is clean.
Otherwise:
1) The filter should be filled with solvent; its inlet and outlet should be connected to each
other by means of tubing. Then set the filter aside for 15-20 minutes. After that it should be
flushed through again in accordance with this instruction.
2) Replace the filter with a new one.
In case of a submersible filter, it should be disassembled and the filter element should be
removed from it. Then place the filter element in a flushing solution for 15-20 minutes (in
acetone, or in 50/c weak solution of ethanoic acid or alcohol if the filter is used with a printer
filled with water-based ink), and then rinse it with work solvent (in case of water-based ink,
rinse with distilled water).

2. Instruction for Flushing of Suction Circuit of Hydraulic System


Turn off printing head switch. Fill syringe with 10-12 ml of work solvent (or distilled water
for water-based ink). Fit polythene tubing (8-10 cm) over the tip of the syringe. Connect the
free end of this tube to the trap. Make sure to expand the free end of the tube before fitting
over trap so that it could be fitted over easily, in order to prevent displacement of trap. Then
pump the liquid into suction circuit slowly. Remove tube from trap and switch on ink flow.

Appendix

page 29

INSTITUTE OF ELECTRICAL DROP-JET TECHNOLOGIES

Safety Information
PrintJet Corporation is dedicated to providing quality equipment, replacement parts, service,
and supplies for the coding and marking needs of industry, and to promote their safe and
environmentally responsible use.
1. All print equipment should be installed in accordance with the manufacturers
instructions, particularly with regards to electrical connections and chassis grounding.
Bypassing of any safety system is prohibited and will void the equipment warranty.
2. Always wear eye protection when handling any ink, cleaning solvents, or makeup
fluids, or when servicing the equipment. If splashed in the eyes, flush with water or
approved eye flush solution and see a doctor promptly.
3. Avoid fluid contact with exposed skin or mucous membranes. Wear protective gloves
when using inks, solvents, or cleaning solutions. In the event of skin contact, remove
contaminated clothing and wash the skin with soap and water. Seek medical assistance
if irritation persists.
4. Avoid exposure to fumes. Proper ventilation is necessary in the printer area. If
additional protection is needed, an organic vapor respirator is required.
5. Never pour inks, solvents, and cleaning solutions into sinks, sewers or drains. This is
both dangerous (risk of explosion) and a violation of environmental regulations,
because of the potential for water, ground, and air contamination. Follow proper
waste disposal standards. Consult the appropriate agency for information.
6. Read and understand the appropriate Material Safety Data Sheet (MSDS) prior to
using any cleaning solution, ink, or solvent. MSDS for our products are available from
PrintJet Corporation on request, and are included with all shipments of ink and/or
make-up solvent.

7. Flammable inks, make-up fluids, and cleaning supplies must be stored according to
local regulatory codes. Consult the appropriate agency for further information. When
test-printing or dumping ink from the printing head, use of a metallic tray connected
to the printing head with a ground strap is required to prevent electrostatic discharges.

Appendix

page 30

INSTITUTE OF ELECTRICAL DROP-JET TECHNOLOGIES

4.4. MARKER SWITCHING OFF


1

ACTION
Open cover of printing head.

INDICATOR STATE

Switch off flow delivery by switching


toggle tumbler switch at front side of
printing head from indicator.
Indicator at front side of printing head is
going out.

Switch off the marker by pressing


button

and button "Y" at keyboard after that.


Switch off standby power unit by
pressing "POWER" button (Fig. 16, 11).

Wipe nozzle tip and shutter surface with cloth moistened with acetone (or alcohol) and
then cover nozzle with shutter. If electrodes (charging and deflecting), trap and slot at
decorative panel and printing head became contaminated during operation, it will be
necessary to perform preventive cleaning. Remove dirt with soft cloth (with out fiber,
for example with rag) moistened with acetone (alcohol) or flush it (with medical syringe
with needle).

Attention! 1) It is strictly prohibited to use hard and sharp objects for preventive
cleaning of system of electrodes (Fig.4, b, 5). 2) Make sure that acetone or other foreign
liquids do not get into trap during preventive cleaning.
If marker has been switched off in accordance with this procedure, it may be stored in "OFF"
state up to 5 days when employing ink on the basis of methyl ethyl ketone or alcohol and up
Appendix

page 31

to 10 days when employing ink on basis of ethyl cellulose and water. For longer storage
periods it will be necessary to undertake preservation measures.

INSTITUTE OF ELECTRICAL DROP-JET TECHNOLOGIES

5. MARKER PRESERVATION FOR STORAGE


If it is supposed that marker shall not be operated for a long time, it is imperative that it
should be preserved.
Marker preservation should be carried out as follows (depending on duration of storage):
A. For up to 2 weeks
5.1. Switch marker off as it is specified in paragraph 4.4.
5,2, Remove dust and dirt from marker. Carry out preventive
cleaning of parts and units of printing head (charging and deflecting electrodes, nozzle an d
trap).
5.3. Fit polythene pipe of 8-10 cm long over nipple of syringe and fill syringe with 10 ml of
solvent appropriate for working ink or distilled water if hydraulic system is charged with
water-based ink. Syringe and polythene pipe are supplied togeth
er with marker.
5.4. Fit free end of polythene pipe over trap and pump all ink (slowly) into suction circuit.
Attention: Before fitting free end of polythene pipe over trap, make sure to expand so that
it could be fit easily it in order to prevent displacement of trap.
5.5. Detach pipe with syringe from trap and fit a piece of polythene pipe (2-3 cm long) with
sealed end over it.
5.6. Fill another similar pipe with sealed end with working liquid by using syringe with
needle and fit it on face end of nozzle. Leave printing head cover semi-opened. In order to
prevent contamination with dust and dirt, place printing head in polythene bag.
B. For up to I months and for longer periods
Perform actions in accordance with paragraphs 5.1-5.6. 5.7. Fill ink container with 20 ml of
solvent appropriate for working ink or distilled water (if hydraulic system is charged with
water-based ink) by means of syringe.
With this method of conservation marker may be stored for - up to 1 month (in case of
quick-drying ink) - up to 3 months (in case of water-based ink).
Appendix

page 32

INSTITUTE OF ELECTRICAL DROP-JET TECHNOLOGIES

Attention!
Amount of ink in hydraulic system container of marker prepared for
preservation should be not less than 1/3 of volume of working container.
In order to store marker for periods longer than specified above, it is necessary to perform the
following actions: - remove sealed pipes from nozzle and trap;
- switch on marker and flow for service run for I hour
- check main parameters of hydraulic system: pressure, pump rate and average viscosity (for
quick-drying ink) for correspondence with data of marker Certificate.
- if marker is operable and main parameters of its hydraulic system correspond to those of
technical data, carry out actions in accordance with paragraphs 5.1-5.7 for further
preservation of marker.
5.8. After preservation it is allowed to store marker
- for up to 3 months (for marker filled with quick-drying ink) - for up to 6 months (for marker
filled with water-based ink) - for up to 12 months (for marker filled with appropriate solvent).
On expiration of storage period it is necessary to switch marker on for service run for 1 hour.
5.9. Marker should be stored under following conditions: - Ambient temperature: +5 - +25oC
- relative humidity: up to 90% at +25oC without condensation.

6. FILLING WITH INK


Frequency of filling container of hydraulic system with ink depends on consumption rate.
Filling of hydraulic system with ink should be done immediately after indicator 2 at front
panel of marker (Fig.15) has started to glow with red and there has appeared the following
message at LCD:
ALARM VOLUME
Check color!
Hydraulic system container should be filled with appropriate (working) ink as follows:
6.1. Remove back cover of marker (Fig.2),
6.2. Remove central plug of container (open cover by taking it by its outer tab). 6.3 Insert
funnel (included in Spare parts set) and fill more than 1/2 of container volume with ink.
Filling allowances for containers of capacity of 0,5 1 - not more than 0,4 1 of capacity of 2,0 1
Appendix

page 33

- not more than 1,9 1. 6.4. After filling with ink, remove funnel and rinse it with acetone
(alcohol) or distilled water for water-based ink, then place in polythene bag.
INSTITUTE OF ELECTRICAL DROP-JET TECHNOLOGIES

Attention! Do not allow ink splashes to wet contacts of level sensor LS. Otherwise it may
result to false readings of level sensor LS, it will cause failure of automatic filling up.
6.5 Close cover or insert plug in central opening in cover of container. 6.6. Place cover of
marker back to its position.

7. CHARGING WITH SOLVENT


Hydraulic systems of markers using quick-drying ink (metil ethyl ketone, alcohol and ethyl
cellulose ink) are equipped with viscosity checking devices and device for automatic filling
up with solvent.
Frequency of charging container for automatic filling with solvent depends on consumption
rate.
Marker should be charged with solvent immediately after indicator 2 at front panel of marker
(Fig.15) has started to glow with orange and there has appeared the following message at
LCD:
ALARM VOLUME
Check solvent!
Hydraulic system container for automatic filling should be filled with appropriate (working)
solvent as follows:
1. See paragraph 6.1.
2. Remove central plug of container cover C2 (Fig.10. 3. See paragraph 6.3.
4. After finishing charging with solvent, remove funnel and place it polythene bag.
5. Insert plug in central opening of container cover. 6. See paragraph 6.6.
Attention! In order to detect presence of solvent in container C2 with level sensor (LS), it
is necessary to add working ink in amount of 5-10 ml.
Note.

Appendix

It is allowed to fill containers of hydraulic system


with work ink or solvent without interruption of
marker operation.

page 34

Attention! Charging of containers of hydraulic system with ink and solvent should be
performed strictly in accordance with technical data of marker specified in Certificate where
type of work ink and solvent are specified.

INSTITUTE OF ELECTRICAL DROP-JET TECHNOLOGIES

It is strictly forbidden
- to charge containers of hydraulic system with inappropriate ink and solvent!
- to allow foreign liquids (acetone, water and so on) get into hydraulic system, container and
trap. Otherwise physical and chemical properties of ink may become irregular (in particular ,
coagulation of ink), so it may lead to failure of entire hydraulic system!

8. INSTRUCTION FOR NOZZLE WASHING


8.1 Evidences of nozzle clogging are as follows: a) absence of flow after switching hydraulic
valve on; b) flow does not fall into trap, under multiple switching on flow is directed to
different directions; c) distortion of drop shape;
d) significant displacement of breaking point (breaking point is displaced towards trap or
there is no breaking point at all);
e) presence of satellite drops (tiny drops between main drops).
8.2. The reason for nozzle clogging is that ink dried inside passage in nozzle or at its outlet
port. In that connection it is necessary to close shutter protecting nozzle against air entering
inside nozzle and over-drying of its outlet port (watch stone) after switching flow off.
8.3. If it is found that nozzle is clogged, it should be washed through.
Attention! It is necessary to replace nozzle with a new one only in case of mechanical
failure or if nozzle is missing.
8.4. Nozzle should be washed through by means of syringe included in delivery set. A piece
of polythene pipe not longer than I cm should be fit over metal nipple connected to syringe.
8.5. It is allowed to wash nozzle through with strong solvent (acetone, alcohol, lean solution
(5%) of ethanoic acid), but final washing through should be performed with working solvent
(with distilled water for markers filled with water-based ink) in order to prevent entering of
foreign liquids into hydraulic system of marker.
8.6. Process of washing nozzle through should be performed as follows:
a) Fill syringe with 5 ml of solvent. Syringe should be filled in such way that there should not
be air bubbles inside syringe.

Appendix

page 35

INSTITUTE OF ELECTRICAL DROP-JET TECHNOLOGIES

b) Screw nozzle out of jet of drop generator. If it is difficult to do that manually, use forceps,
wrench N 5 or small pliers
c) Insert nozzle in syringe pipe as it is shown in Fig. 18.
d) Turn syringe so that nozzle faces downwards and direct it toward glass or polythene bottle.
Press against piston so that 3-5 drops should be ejected. (Fig.18, a)
e) Pull piston backwards so that air bubbles should clean nozzle passage, as this takes place
flow of bubbles is seen through solvent in syringe. (Fig.18, b)
f) If air bubbles do not pass through nozzle passage, it should be removed and soaked in
alcohol or acetone for 3-5 minutes, after that actions in accordance with 8.6 c) - 8.6 e) should
be repeated.

g) If air bubbles pass through passage unimpeded, press against piston of syringe again and
repeat actions in accordance with 8.6 c) - 8.6 e) if necessary until flow from nozzle issues
freely. (Fig.18, c)
h) Steady issue of flow from nozzle after pressing against piston for 3-5 seconds is an
evidence of washed passage.
i) After steady flow obtaining, pull syringe piston backwards again and as soon as a steady
flow of air bubbles in nozzle is seen, remove nozzle from syringe (Fig. 18, b).
Appendix

page 36

INSTITUTE OF ELECTRICAL DROP-JET TECHNOLOGIES

Attention! Perform final through washing with work solvent. j) Screw nozzle onto drop
generator jet. Nozzle should be screwed on jet without any tools, by 2 fingers with the force
up to the stop.

8.7. Notes:
1) Do not exert excess force to syringe as syringe may get broken under heavy pressure or
negative pressure.
2) Replace syringe with new one not more seldom than once in half a year using nipple from
older one.
3) It is difficult to wash through nozzle in which ink has dried a long time ago. In that case it
is necessary to put nozzle in strong solvent (alcohol, acetone) for 10-15 minutes. After that
wash nozzle through.
4) When pressing against piston within 4-5 seconds, flow is being issued from nozzle. You
should not wonder at sudden disappearance of flow in 4- seconds -this may happen due to
presence of unfiltered liquid in syringe. In that case follow instruction of paragraph 8.6,

9. CONNECTION OF SOURCES OF EXTERNAL PRINTING


CONTROL SIGNALS
9.1. CONNECTION OF SOURCES OF PRINTING INITIATING SIGNALS
Mark printing is initiated by photosensor supplied together with marker. If customer has any
sensor or other device that may produce initiating pulse (duration "1" to "0" jump is not less
than 20 mcs), this signal may be used for initiating printing of mark.
Connection of source of external triggering signal is shown in Fig.19.
This pulse signal is supplied to terminal 7 of connector XS5 or XS6, Fig. 19 of Technical
Description, in this case positive voltage E (3-27 V) is fed to terminal 2.
9.2. CONNECTION OF EXTERNAL SOURCES OF SYNCHRONIZING PULSES
Markers print columns of mark symbols triggered by both internal and external synchronizing
pulses. Mark length depends on traverse speed of object to be marked.
When triggered by internal synchronizing pulses, mark length will be affected by conveyer
motion speed. If it is undesirable, it is necessary to use external synchronizing pulses
frequency of which is related to conveyer speed. Velocity sensors either already installed at
customer's equipment or purchased at the Institute of Electrical Drop-Jet Technologies are
suitable for this purpose.
Appendix

page 37

INSTITUTE OF ELECTRICAL DROP-JET TECHNOLOGIES

For triggering by external synchronizing pulses it is necessary to set switch 3 in upper


position. Velocity sensor is connected together with supplied photosensor to one of
connectors. XS5 or XS6, Fig. 19.

Fig-19 Connect' *on of external sources of signal to marker connectors SENSORY (XS5) or
SENSOR2 (XS6)
If customer's velocity sensor is employed, its output signals are sent to terminal 4 of
connector XS5 or XS6, while connector 3 should be fed with voltage E of 3-27 V. Frequency
of synchronizing pulses may change within limits of 2 to 2000 Hz
9.3 CONNECTION OF SOURCES OF EXTERNAL SIGNAL CONTROLLING PRINTING
DIRECTION
If it is necessary to change printing direction during marking process, then external signal
controlling printing direction should be sent to terminal 1 of connectors XS5 or XS6. High
level of this signal sets printing in forward direction, low level sets printing in backward
direction. Positive voltage of 3-27 V should be fed to terminal 3 of this connector. Connection
of external signal controlling printing direction is shown in Fig.19.

Appendix

page 38

INSTITUTE OF ELECTRICAL DROP-JET TECHNOLOGIES

Spare Parts List


Maxima Line of Products

Price List - Hydraulic Compartment


Models: Maxima Pro, Maxima Pro Plus, Maxima Pro XHS

Item No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

Description
Pump Assembly
Pump Board
Pump Motor
Pressure Pump
Vacuum Pump
Pressure / Vacuum Filter
Reservoir Filter
Restrictor
Solenoid Valve
Solenoid Valve - Bleeding
Damper 4M
Pressure Viscosity Sensor M55-4M
Viscosity Chamber 4M
Ink Reservoir 4M
Make up Reservoir 4M
T-Connector
Tube Polyethylene (1m)
Hydraulic Assy 3+
Hydraulic Assy 4M

Part Number
MP3
PI3
EM25
PC3
SC3
CF3
FF3
BC3
HV3
HV33
R4
PSM554
MVC4
IC4
SC4
TP
PT
HU311
HU411

Price List - Cylindrical Printhead and Umbilical Assembly


Models: Maxima Pro, Maxima Pro Plus, Maxima Pro XHS

Item No
1
2
3
4
5
6
7
8
9
10
Appendix

Description
Printhead and Umbilical Assy 4M
Charge Amp. Board 4M
Charge Electrode 4M
Drop Generator Assembly 3M
Nozzzle (50-80 micron)
Printhead Valve 3+
Return Block 4M
Return Block Sensor 4M
Loop 4M
Printhead Interface Board 4M

Part Number
PHC4
CSA4
E4
DG3
No 350, No 360, No 370,
No 380
HV3
TC4
TSC4
LC4
PI4
page 39

INSTITUTE OF ELECTRICAL DROP-JET TECHNOLOGIES

Price List - Square Printhead and Umbilical Assembly


Models: Maxima Pro, Maxima Pro Plus, Maxima Pro XHS

Item No
1
2
3
4
5
6
7
8
9
10
11

Description
Printhead and Umbilical Assy - 3+
Charge Amp. Board 3+
Electrode 3M
Drop Generator Assembly 3M
Nozzle 3M(50-90 micron)
Printhead Valve 3+
Return Black 3+
Return Black Sensor 3+
Magnifier Glass 3+
Printhead Interface Board 3+
Mechanical lock 3M

Part Number
PHS3
CSA3
E3
DG3
No 350, No 360, No 370,
No 380, No 390
HV3
TC3
TSS3
LS3
PI3
ML3

Price List - Electronic Compartment


Models: Maxima Pro, Maxima Pro Plus, Maxima Pro XHS

Item No
1
2
3
3
3
4
5
5
6
7
8
9
10
11

Appendix

Description
Part Number
DC Power Supply 3+
PSU3
High voltage Power Supply 3+
HVU3
Control Board - Maxima Pro
PN4233C1
Control Board - Maxima Pro Plus
PN4233C2
Control Board - Maxima Pro XHS
PN4233C3
Keyboard Interface Board - Maxima Pro
KD7128.2
Board of controller - Maxima Pro Plus
STCU.A90.01
Board of controller - Maxima Pro Plus XHS STCU.A90.0102
Keyboard - Maxima Pro
DR097
Keyboard - Maxima Pro Plus
EG104
Keyboard - Maxima Pro XHS
EBR154
Liquid Crystal display 2x16
PC1602LRS-HLH-B
Liquid Crystal Display 2x20
PC2002LRU-LNH-K
250 volts Board 3+
HVA3

page 40

INSTITUTE OF ELECTRICAL DROP-JET TECHNOLOGIES

Notes:

Appendix

page 41

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