Application Note:

Cleaning Ink Supply Systems

Using Clean Room Techniques

1.0 Purpose
This Application Note provides information for an ink jet system integrator to develop
processes and procedures to reduce the amount of contamination delivered to Spectra
jetting assemblies during the manufacture and assembly of an ink supply system.

There are many systems and procedures that can be used for cleaning an ink supply
system. The one presented in this publication is a relatively low risk system. Following
this procedure results in an ink supply system clean enough to prevent jetting defects and
jet outages due to contamination. Many customers use systems and procedures that are
quicker and less stringent than the procedure described here. Manufacturers may modify
this procedure to fit their unique situation.

The term ink is used throughout this publication to include all jetting fluids.

2.0 Related Documents

AN000001: Mechanical & Fluid Interface Recommendations for Jetting Assemblies and
Printheads

AN000011: Ink Delivery System Design for Ink Jet Printers

AN000031: Preparing a New Nova, Galaxy, or S-Class for Initial Use

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2 Cleaning Ink Supply Systems

3.0 General Considerations

Cleaning of ink supply components and the finished ink supply system is a commonly
overlooked area of ink jet system development. A number of precautions must be taken
to eliminate sources of contamination that cause jetting defects or jet outages.

Spectra printheads (PHs) and jetting assemblies (JAs) have no appreciable filter
capacity. There is a built-in rock trap filter, which is a thin membrane with small holes
prior to the orifice. The primary purpose of the rock trap is to collect any particles
introduced in the manufacturing process. The rock trap can also remove a small amount
of contamination from the ink supply system. The rock trap, located after the ink jet
pumping chamber and before the orifice, is not meant as a final filter for the printhead.

Figure - 1 Fluid Path, S-Class AA

Figure - 2 Fluid Path, 256 Jet AAA

There is one descender tube per jet. As the ink travels down each of the descender
tubes, it passes through the rock trap. There are approximately 60 holes in the rock trap
per descender. Therefore, a 256 jet printhead has a total of 15,360 holes in the rock trap.
Blockage of more than ~20% of the holes in the rock trap may cause detectable jetting
differences, especially at higher jetting rates.

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4.0 Types of Contamination

There are two general types of contaminants that must be removed before connecting a
printhead to the ink supply system.

4.1 Liquid Contaminants

Liquid contaminants include greases, oils, and solvents. If present in the fluid, these may
cause gels to form or cause the pigments to come out of suspension and clump together.
Also, liquid contaminants may lodge in or around the nozzles, changing wetting
characteristics and causing crooked or weeping jets.

Figure - 3 Magnified view of rock trap with unacceptable amounts of liquid contamination

4.2 Particulate Contaminants

Particulate contaminants include skin flakes, metal filings, paper fibers, etc.

Figure - 4 Magnified view of rock trap with unacceptable amounts of particulate contamination

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Each of these contaminants requires different cleaning methods to successfully prevent

failure.

5.0 Sources of Contamination

Contaminants originate from a variety of sources. The following sections describe the
various types of contamination.

5.1 Surface Contamination

Contamination on the inside of the ink supply components is called surface

contamination. During the manufacturing of components, particles are generated and
settle in or on the parts. Some parts can have liquid contaminants present, such as
cutting fluids or lubricants.

5.2 Airborne Contamination

Room air typically contains a wide variety of suspended fibers and dust. When these
particles are present in the air, they can settle on components and enter the ink supply.

5.3 Rinse Contamination

Contaminants build up in the rinse solutions during the cleaning process. These
contaminants must be removed by filtering or replacing the solution.

5.4 Touch Transfer Contamination

Touching a contaminated surface and then touching the component can easily transfer
contaminants. Such contamination could include particles from unclean parts or tools,
as well as skin oils and skin cells.

5.5 Degraded Materials

Materials used in the ink supply system must be compatible with the jetting fluid.
Incompatible materials degrade over time and may shed particles or cause gel
formation. Common problems occur when solenoid valves, pumps, or filter housings
have seals or adhesives made of material that is incompatible with the specific fluid
being jetted. Even if these materials are located before the main filter, the gels
generated can be extruded through the filter and cause printhead failure.

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Note: Contact the ink supplier to obtain a list of materials known to be compatible
with their ink and flushing fluids. Any materials used in the ink delivery
system that are not on the list must be sent to the ink supplier for approval.

6.0 Reducing Contamination at the Source

It is often easier to eliminate the source of contamination than to remove the
contamination after it has entered the system. This is especially true with silicone-based
contaminants and other lubricants. When purchasing machined parts, the buyer should
specify that parts be degreased in a vapor degreaser prior to shipment. It is also useful to
find a supplier who uses cutting fluid that is water-soluble and does not contain silicone.

Another source of contamination is any lubricant added to pumps and valves to maintain
good seals during shipping and storage. Ask the vendor not to add this lubricant. All liquid
contaminants such as oils or grease must be removed prior to beginning the final flushing
procedure. This includes solenoid valves and pumps. A separate flushing process may be
required for these components. These components need to be cleaned prior to assembling
in the ink supply system.

7.0 Cleaning Stations

The parts used in the ink supply system must be precision cleaned so contamination is not
flushed into the printhead. Cleaning stations that do not clean parts to the required degree
result in crooked or clogged jets.

The best cleaning systems and procedures depend on a wide range of factors including:
· ink to be used in the ink jet system
· expected range of contaminants (size and type)
· production rate
· acceptable manufacturing yield
· image quality requirements of the system
· expertise of the manufacturer
· available manpower
· filters – size, type, and material
· filter replacement frequency
· compatibility of parts and fluids

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7.1 Clean Room

A clean room is an environment, typically used in manufacturing or scientific research,

that has a low level of environmental pollutants such as dust, airborne microbes,
aerosol particles and chemical vapors. More accurately, a clean room has a controlled
level of contamination that is specified by the number of particles per cubic meter at a
specified particle size. To give a perspective, the ambient air outside in a typical urban
environment might contain as many as 35,000,000 particles per cubic meter, 0.5 μm
and larger in diameter, corresponding to an ISO class 9 clean room. Clean rooms are
not sterile (i.e., free of uncontrolled microbes) and more attention is given to airborne
particles. Particle levels are usually tested using a particle counter.

The air entering a clean room from outside is filtered to exclude dust, and the air inside
is constantly recalculated through high efficiency particulate air (HEPA) and ultra low
penetration air (ULPA) filters to remove internally generated contaminants.

Staff enter and leave through airlocks (sometimes including an air shower stage), and
wear protective clothing such as hats, face masks, gloves, boots and cover-alls.

Equipment inside the clean room is designed to generate minimal air contamination.
There are even specialized mops and buckets. Clean room furniture is also designed to
produce a low amount of particles and to be easy to clean.

Common materials such as paper, pencils, and fabrics made from natural fibers are
often excluded; however, alternatives are available.

Some clean rooms are kept at a positive pressure so that if there are any leaks, air leaks
out of the chamber instead of unfiltered air coming in.

Clean room HVAC systems often control the humidity to low levels, such that extra
precautions are necessary to prevent electrostatic discharges.

Low-level clean rooms may only require special shoes, ones with completely smooth
soles that do not track in dust or dirt. Entering a clean room usually requires wearing a
clean room suit.

In lower level clean rooms, in which the standards of air contamination are less
rigorous, the entrance to the clean room may not have an air shower. There is an
anteroom, in which the special suits must be put on, but then a person can walk directly
into the room.

Some manufacturing facilities do not use fully classified clean rooms, but use some
clean room practices together to maintain their cleanliness requirements.

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7.2 Flow Hood also known as Laminar Flow Cabinet/Closet

In a flow hood design, Laminar flow cabinet, or laminar flow closet the cleanliness of the
air is controlled in the small area where assembly and cleaning occurs. This design is less
expensive and easier to maintain than a clean room, but requires more careful handling
procedures to maintain adequate cleanliness.

It is a carefully enclosed bench designed to prevent contamination of any particle sensitive

devices. Air is drawn through a HEPA filter and blown in a very smooth, laminar flow
towards the user. The cabinet is usually made of stainless steel with no gaps or joints
where spores might collect.

Such hoods exist in both horizontal and vertical configurations.

· vertical - the HEPA filters are above the work area blowing clean air down.
· horizontal - the HEPA filters are behind the work area blowing clean air towards
the operator; this design tends to keep the parts cleaner.

There are many different types of cabinets when it comes to Airflow patterns and
acceptable uses of these cabinets. NSF49 is the commonly accepted regulatory standard
for these cabinets.

Laminar flow cabinets may have a UV-C germicidal lamp to sterilize the shell and
contents when not in use. (It is important to switch this light off as it will quickly give any
exposed skin sunburn, and may cause cataracts).

Before starting to work using the clean bench it is recommended to switch the clean bench
ON for roughly 30 minutes prior to work in it. It is also recommended to clean the clean
bench upon switching it on, using clean wipes in combination with filtered IPA or any
other recommended fluid.

The clean hood fan should be left on at all times, even when the area is not in use.

8.0 Cleaning Station Example

This section describes one example of a cleaning station suitable for preparing ink supply
system components prior to assembly. This system has a relatively small cleaning
capacity. Less stringent systems may also be acceptable for early prototypes where yield is
not a significant factor. Conversely, a larger system with improved cleanliness may be
needed for production systems requiring higher capacities and improved production
yields.

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The purpose of the cleaning station is to precision clean ink supply components so they
do not introduce contaminants into the printhead. To successfully perform precision
cleaning, a clean area with a clean hood is required. A clean area is not a clean room,
but an area isolated from and cleaner than the rest of the manufacturing plant. A clean
hood is a workbench with filtered air blowing out of the bench to prevent airborne
contaminants from entering. Components come into the clean hood, are cleaned, dried,
and assembled. All ink passages in a component are sealed before the printhead leaves
the clean hood.

Normally, the clean hood is located in a clean area in a small room. This can be similar
to a room in a standard office environment. It should have enamel paint, no carpet, a
painted ceiling, and the air vents should be blowing away from the clean hood. Items
that can generate particles should not be located in this room. These items include
cardboard, rags, sweaters, unnecessary paper such as packing slips, etc.

The equipment and storage racks should be positioned to allow for a good workflow. A
good workflow moves relatively dirty components from one side of the room, through
the cleaning process, to a storage area for the precision cleaned components on the
opposite side of the room.

The clean hood must have a stainless steel tabletop. The fan in the clean hood should
provide positive, filtered laminar air flow out of the hood at all times.

A humidifier is recommended to reduce electrostatic forces that attract airborne

particles. A room humidifier, available at a local department store, is all that is needed,
assuming that the output capacity is matched to the room dimensions. It should be set
to achieve approximately 45% humidity.

Located inside the clean hood should be:

· two ultrasonic tanks with cleaning baths
· two rinsing baths
· a clean nitrogen spray-off nozzle
· a small oven
· enough room to assemble components into finished assemblies.

The following figure shows an example layout.

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Figure - 5 Example Clean Area Layout

9.0 Clean Area Equipment and Materials

There is a wide range of equipment that can be used successfully in a final precision
cleaning system. The list below reflects equipment used in the examples throughout this
Application Note.
Table 1 Clean Area Equipment and Suppliers

Equipment Potential Supplier Contact Information

Stainless steel sink with two wells Local hardware store or industrial www.grainger.com
supply company such as Grainger
Cleaning brushes, nylon Local hardware store or industrial www.grainger.com
supply company such as Grainger
Humidifier Local department store
Clean Hood – Class 10 with stainless steel Terra Universal Inc. or see “laminar www.terrauniversal.com
floor and HEPA filter flow stations”
Nitrogen bottle Welding supply company Local phone directory

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Table 1 Clean Area Equipment and Suppliers

Equipment Potential Supplier Contact Information

2 hoses with 2 spray-off nozzles (outfitted Hoses and spray-off nozzles: Local www.grainger.com
with 5 micron filters at the end of the hardware store or industrial supply
nozzles); one to be located next to sink company such as Grainger
used to partially dry components, the other www.coleparmer.com or
located within, or in the immediate area of 5 micron filters for nozzles: Cole- www.fishersci.com
the clean hood to dry components after Parmer or Fisher Scientific
final rinse. Note: We do not recommend
using the air hose within the clean bench
as this can spray debris into the HEPA or
ULPA filters.
2 small ultrasonic tanks (heated tanks Cole-Parmer or Fisher Scientific www.coleparmer.com or
preferred) www.fishersci.com
2 small rinse tank Cole-Parmer or Fisher Scientific www.coleparmer.com or
www.fishersci.com
Small drying oven Cole-Parmer or Fisher Scientific www.coleparmer.com or
www.fishersci.com
2 large syringes Cole-Parmer or Fisher Scientific www.coleparmer.com or
(for flushing ink passages) www.fishersci.com
Miscellaneous assembly tools Hardware store
2 Storage racks Hardware store
Evaluation filter 25 mm diameter & 0.8 GE part # E08WP02500 www.fishersci.com
micrometer pore size
Filter holder for 25 mm evaluation filter Fisher part # 09-753-10C www.fishersci.com
Microscope Cole-Parmer or Fisher Scientific www.coleparmer.com or
www.fishersci.com

Table 2 Clean Area Consumables

Supplies Supplier Contact Information

Clean Wipes - 4” x 4”, lint-free, Class Dimatix P/N 07480 www.dimatix.com
10
Chem-Crest 2015 Crest Ultrasonics http://www.crest-ultrasonics.com
(non-ionic, ultrasonic cleaner)
Chem-Crest ADS 905 Crest Ultrasonics http://www.crest-ultrasonics.com
(aqueous displacement solution)
Luminox – produced by Alconox Fisher Scientific www.fischersci.com
(low-foaming, 7.0 working pH cleaner) P/N 50821313
Isopropyl Alcohol (IPA) – Clean room Cole-Parmer or Fisher Scientific www.coleparmer.com or
grade www.fishersci.com
DI Water – Clean room grade, filtered Fisher Scientific www.fishersci.com
to .2 micrometers, resistance between
15 and 18 megaohm
Hair nets – clean room grade Fisher Scientific, Cole-Parmer www.coleparmer.com or
www.fishersci.com

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Table 2 Clean Area Consumables

Supplies Supplier Contact Information

Shoe covers – clean room grad Cole-Parmer or Fisher Scientific www.coleparmer.com or
www.fishersci.com
Wrist straps – clean room grade Cole-Parmer or Fisher Scientific www.coleparmer.com or
www.fishersci.com
Plastic bags – clean room grade Fisher Scientific www.fishersci.com
Nitrile gloves - class 100, clean room Cole-Parmer or Fisher Scientific www.coleparmer.com or
grade www.fishersci.com
Tyvek sleeves or jump suit, clean room Cole-Parmer or Fisher Scientific www.coleparmer.com or
grade www.fishersci.com

10.0 Installation of Equipment

The equipment should be installed in the clean area as follows:
· Before installing equipment in the clean area, clean the walls, ceiling, vents, and
floor with soapy water. Repeat if necessary.
· Install equipment in the clean area as shown in the example clean area layout.
Wipe down all objects in the clean hood with lint-free cloths and IPA.
· When installing the nitrogen bottle, route two lines with one line to the sink area
and one leading to the clean hood. Make sure that there is an airtight seal between
the line and the back of the clean hood. Attach the nitrogen spray-off nozzles
(outfitted with 5 micron filters) to the end of the lines in the sink and clean hood.
· A good procedure for determining the desired fan speed in the clean hood, and
therefore the flow rate, follows:
1.Clean a 380 mm [15 inches] piece of lightweight nylon or polyester thread with
semiconductor grade IPA (isopropyl alcohol) to remove contaminants and
static charge; tape the thread to the top of the clean hood opening.
2.Turn on the clean hood fan and slowly increase the speed until the thread moves
out to an angle of 10 or 15 degrees.
3.Mark the fan speed and discard the thread.
· The direction of the air flow is also important in confirming proper flow across the
HEPA filters. The thread test above can also be used to see the direction of flow.
Another method to detect air flow direction is to use a commercial ultrasonic
humidifier with a large exit port. Replace the exit port cover with a large diameter
hose, such as a hose from a wet/dry vacuum cleaner. Run the humidifier with de-
ionized water. This provides an inexpensive, but sensitive and clean method for
visualizing air patterns.

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11.0 General Clean Area Rules

· All clean area personnel must be trained in proper clean room practices.
· Supplies and components must be unpacked outside the clean area. Cardboard
and other packing materials must never be allowed in the clean area.
· Gloves and Tyvek sleeves or jump suits must be worn in the clean hood. Do not
touch clean room garments with bare hands. Dress in coveralls legs first, then
arms, without letting the sleeves touch the floor; zip completely.
· Avoid touching any unclean surface with gloves. This includes avoiding contact
with the face, clothing and any areas outside of the clean hood. If an unclean
surface is touched, remove the contaminated gloves and put on a new pair.
· Cosmetics, strong perfumes, colognes, and greasy lotions are prohibited in the
clean area.
· Food and drinks are prohibited in the clean area.
· Anyone smoking within 30 minutes before entering the clean area should drink
water before entering the clean area.
· Chewing gum is not allowed in the clean area.
· Do not wear dirty shoes into the clean room. Shoe covers may be required.
· Use sticky mats at the clean room entrances and replace them frequently.
· Only use pens; pencils are not allowed in the clean area.
· Use only clean room paper.
· Nonessential items (tools, books, etc.) should not be allowed in the clean area.
· Try not to sneeze or cough in the clean area. If unavoidable, be sure your head
is turned away from the opening in the clean hood.
· Do not let your skin touch any surface in the clean room.
· Do not stack components in the clean hood.
· Use a hairnet and beard cover as required.
· Use a full-cover hood with facemask. The hood should cover the entire hairnet.
Keep the mask over the mouth and nose at all times. Do not pull the mask down
to talk. No facial hair should be visible.
· Follow proper procedures for chemical usage and waste disposal.
· All items going into the clean room should be wiped down with IPA and clean
room wipes.
· Do not use the pass-through for conversations with those outside the clean
room. Only one door may be opened at a time.
· Clean the telephone after use and replace your gloves. The phone is high risk
for cross-contamination by touch transfer.

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· Always follow the proper Start-up and Shut-down procedures described below.
· If you believe something has been contaminated, contact the lab manager.

12.0 General Cleaning Rules

WARNING
Do not ultrasonic clean silicon nozzle plates.
Ultrasonic cleaning of silicon nozzle plates
fractures the fine silicon structures of the nozzle.

!
· Nonmetallic parts must be washed before metallic parts.
· After washing metallic parts, all tanks must be emptied and cleaned. Wipe down
the inside of all tanks with a lint-free cloth and IPA. See the Start-up & Shutdown
procedure details.
· After each batch of components, the DI water from Tank #3 is to be discarded.
Wipe Tank 3 with a lint-free cloth. Pour the DI water in Tank #4 into Tank #3.
Clean the inside of Tank #4 with a lint-free cloth. Pour new, clean room grade DI
water into Tank #4. This assures a clean final wash.
· Do not clean more components than necessary at one time. Clean parts in
manageable batches, perhaps all the components for one complete ink supply
system, or the amount required for one shift. Clean parts must be assembled as
soon as possible. If clean parts sit on shelves they may become contaminated
again, even in the clean room. An exception to this rule are parts such as screws,
fittings, and O-rings; these may be washed in a batch and bagged into heat-sealed
bags.
· The sink should be washed down prior to the first wash of the day. Brushes should
also be cleaned.
· Never use shop compressed air to blow off components. Shop air contains oils
used to lubricate the compressor.
· Never run the ultrasonic source when fluid levels are low or the tank is empty.
· All parts should be degreased prior to arriving in the clean hood area. Machine
shops and molding shops can degrease the components before shipping.

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13.0 Cleaning Procedures

The following is one possible set of procedures for cleaning and flushing components.
These procedures use the cleaning system and consumables described earlier. These
steps are offered as a starting point for the development of your specific procedures.

13.1 Start Up Procedure

1. Turn on the clean bench 30 minutes before using.
2. Wipe down the clean hood surfaces, tanks, and tools using lint-free wipes and a
50/50 mixture of clean DI water and clean IPA.
3. Fill all clean hood tanks with clean room grade DI water.
4. Add 3.0% of Chem-Crest 2015 and 3.0% of Chem-Crest ADS 905 to the two
ultrasonic washing tanks.
5. Set temperature to 55 C [130 F] if the ultrasonic cleaner has a heater. Verify
that all components being cleaned can withstand this temperature.
6. Turn on ultrasonic tanks and allow them to run for 15 minutes before
beginning a cleaning operation. This removes dissolved gasses in the DI water.

13.2 Shutdown Procedure

1. Empty all the tanks.
2. Blow out the tanks with clean nitrogen.
3. Wipe down the tanks with a dry, lint-free cloth.
4. Wipe down again with a lint-free cloth and IPA.
5. Wipe down clean hood surfaces and tools with a lint-free cloth and IPA.

13.3 Rough Cleaning Procedure

This procedure details the rough washing of components. The rough cleaning
procedure removes loose contaminants, including particles and oils, from the surface of
the parts before they enter the clean hood and ultrasonic tanks.

For all components with seals or valves, the component manufacturer must be
contacted to make sure no lubricants are used in or on the component.

Any component that may have been exposed to a liquid contaminant such as oil,
grease, or machining fluid, should be cleaned with a solvent and dried prior to
beginning the rough cleaning procedure.

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1. Remove components from cardboard or paper packaging outside the clean room.
2. Place components on shelves next to the sink.
3. Remove parts from bags if required.
4. Fill one side of the sink with water.
5. Mix in Luminox until it reaches approximately 4% solution.
6. Clean parts with a nylon brush.
7. Clean all ink passages, especially long holes, with a brush.
Note: Long narrow ink passages are difficult for the ultrasonic bath to clean.
Therefore it is important that they be very well rough cleaned. This may
require fixtures to force water through the passages.
8. Rinse in tap water in the other half of the sink.
9. Repeat cleaning with Luminox solution.
10. Repeat rinse in tap water.
11. Blow off excess water with nitrogen.
12. Immediately place parts in the first ultrasonic tank. Do not allow parts to sit inside
or outside of the clean hood.

13.4 Precision Cleaning Procedure

This procedure details the precision cleaning process, which removes contamination from
the surface of the parts before final assembly of the ink supply system.

13.4.1 Preparing tank solutions:

1. Tank #1: 3.0% Chem-Crest 2015 plus 3.0% Chem-Crest ADS-905.

2. Set temperature to 55 C [130 F] if the ultrasonic cleaner has a heater. Be sure the
components can withstand this temperature.
3. Degas by running ultrasonic for 15 minutes before cleaning any parts.
4. Tank #2: Same as tank #1.
5. Tank #3: DI Water.
6. Tank #4: DI Water.

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13.4.2 Procedure for Nonmetallic Parts

1. Tank #1: 2 minutes (minimum). Be sure all ink passages are filled with
solution, or the ultrasonic cleaning will not work.
2. Tank #2: 2 minutes (minimum). Again, all ink passages must be full.
3. Tank #3: 2 minutes (minimum). Shake part while inserting and removing.
4. Tank #4: 2 minutes (minimum). Shake part while inserting and removing.
5. Blow excess water off components with nitrogen.
6. Oven-dry for a minimum of 20 minutes at a maximum of 85 C [185 F], or as
long as required to be sure the parts are dry. Alternatively, use a wash bottle to
hand rinse with clean room IPA (Isopropyl Alcohol), letting the excess IPA fall
into a separate tub or into the sink. Allow the part to air dry in the clean hood
for 20 minutes.

13.4.3 Procedure for Metallic Parts

1. Tank #1: 10 minutes (minimum). Be sure all ink passages are filled with
solution.
2. Tank #2: 10 minutes (minimum). Shake part while inserting and removing;
flush deep channels with a large syringe.
3. Tank #3: 5 minutes (minimum). Shake part while inserting and removing; flush
deep channels with a second large syringe.
4. Tank #4: 5 minutes (minimum).
5. Blow excess water off component with nitrogen.
6. Oven-dry for a minimum of 45 minutes at a maximum of 85 C [185 F], or for
as long as is required to assure the parts are dry. This takes much longer for
large metal parts.

13.5 Abbreviated Method for a Precision Clean

The systems and procedures described in this publication are only examples. There are
many other possibilities that can be used to prevent contamination of ink within the
printing system. Other systems and procedures that are less involved may provide
acceptable results.

An abbreviated version of the precision cleaning procedures described above can be

effective for those systems without specialized equipment. Listed below are
modifications to the precision cleaning procedure, which take into account systems
without access to a clean hood, oven, or nitrogen.
1. Select a relatively clean area of the manufacturing facility. An office type
environment is preferred.

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2. Prepare ultrasonic and rinse tanks as described in the Start-up and Shutdown
procedures.
3. After completing rough cleaning of components, allow water to drip for 30
seconds. Place components in the first ultrasonic cleaner without blowing off
excess water.
4. After completing the ultrasonic cleaning and rinsing, hand rinse parts again over
the sink or into a separate tank with IPA dispensed from a wash bottle. Flush all
passages with IPA. Allow component to drip for a few seconds.
5. Place the part on a lint-free cloth; cover with a lint-free cloth.
6. Allow parts to air-dry completely between the cloths. IPA can react with certain
inks and cause clogging of printheads, so be sure all the IPA is evaporated.
7. Repeat for all components. Begin with nonmetallic components such as O-rings
and plastic fittings, followed by metallic components.
8. Build the system on a lint-free cloth following standardized assembly procedures.
9. Seal all openings with tape or plugs.
10. Attach the printhead or jetting assembly.
11. Flush the model fluid out of the printhead as per the Dimatix flushing procedure
detailed in the Dimatix Application Note #AN000031, Preparing a New Printhead
or Jetting Assembly for Initial Use.

14.0 Ultrasonic Cleaning Variables

One of the most effective methods for cleaning components and assemblies is an ultra
sonic bath. The following operating parameters are critical for reliable washing.
· ultra sonic frequency
· wash fluid temperature
· soap concentration (See AN000011.) High soap concentrations may not rinse off
completely in the rinse tanks.
· type of boat or basket material (plastic vs. stainless steel) - Plastic containers
dampen or lower the energy delivered by the ultrasonic cleaner.
· flow rate if using a recirculating wash tank - High flow rate also dampens the
energy from the cleaner.
· wash time - Prolonged wash time may cause damage such as pitting to the
components.
· type of finish on components - Smoother finishes are better for cleaning.

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· position of parts in the basket - Rotating the parts during wash and avoiding
overfilling the basket improves the effectiveness of the wash.
· design of the parts - Long or winding channels can trap air bubbles, preventing
the ultrasonic cleaning from reaching those areas. If this can’t be avoided, place
a LCF (Last Chance Filter) just before the exit side of the ink delivery system.
LCFs do not have a high capture capacity and contamination affects the flow
coming into the printhead. The maximum flow rate per second out of the LCF
must be larger than the number of jets running X drop volume X jetting
frequency.

15.0 System Assembly

See Dimatix Application Note #AN000011, Ink Delivery System Design for Ink Jet
Printers.

System assembly should be performed in a clean room and the system must be properly
sealed and capped before leaving the clean area. Clean the assembled system before
connecting the printhead(s). The cleaning fluid must pass through all the channels the
jetting fluid will pass through when the system is in use. If necessary, a jig, fixture, or
non functioning printhead can be attached to the on-head reservoir or secondary ink
tank. A reasonable flushing cycle might be the volume of ink the system should output
in three months of use. Determine the baseline particle count data for future system
builds by using the Flush and Catch method.

16.0 Example Flushing Procedure for Assembled Ink Supply

System
All components other than tubing, pumps, and solenoid valves must be precision
cleaned prior to assembly of an ink supply system. Pumps, solenoids, and any other ink
supply components that can not be cleaned in the ultrasonic tanks must be thoroughly
flushed prior to the final flushing process to remove lubricants and any particulate
matter. Components that have liquid contaminants such as oils or greases must be
cleaned prior to the final flushing procedure.

16.1 Set Up Procedure

1. Assemble the entire ink supply system, except for the printhead or jetting
assembly. This may be done on the final machine or in a subassembly area,
depending on the type of equipment.
2. Wipe ink tank with a lint-free cloth and IPA.
3. Allow to dry completely.
4. Verify that the flushing fluid is compatible with the final ink.

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5. Fill tank with desired flushing fluid. Potential flushing fluids include flushing
fluid supplied by the ink vendor or clean room grade DI water. Consult with the
ink supplier for recommended flushing fluid.
6. Attach evaluation filter at location where printhead or jetting assembly is
connected after the flushing procedure is completed. The purpose of the
evaluation filter is to determine the amount of contaminants being flushed from
the system.

16.2 Flushing Procedure

1. Verify that the printhead or jetting assembly is not attached to the ink supply
system.
2. Turn on the pump and pump ink through the ink supply system, evaluation filter,
and into a waste container.
3. Pump ink for 2 minutes.
4. Remove evaluation filter.
5. Place the filter under a microscope and evaluate the amount of contamination. As
a general rule, the total contamination for the life of the jetting assembly should
not exceed approximately 2,000 particles that are greater than 10 microns. Each
manufacturer should determine the amount of acceptable contamination for their
application.
6. Install a new evaluation filter.
7. Pump ink for an additional 2 minutes.
8. Remove evaluation filter.
9. Place this filter under the microscope and evaluate the amount of contamination.
10. Continue flushing and evaluating the filter until an acceptable amount of
contamination is present.
11. Mount printhead.
12. Wipe the end of the tubing with a lint-free cloth.
13. Attach tubing to precision cleaned mounting block.
14. Flush the model fluid out of the printhead per Dimatix flushing procedure in the
Dimatix Application Note #AN000031: Preparing a New Printhead or Jetting
Assembly for Initial Use.

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20 Cleaning Ink Supply Systems

The evaluation filter can be removed from the procedure once the amount of acceptable
contamination is determined and the cleaning procedures are under control. Occasional
sampling should be done to be sure that the process continues to perform well.

CAUTION All Spectra liquid printheads are shipped with a

small amount of model fluid coating the inside of

!
the printhead. This is a nondrying fluid that assists
with wetting the interior surfaces of the printhead.
Certain inks react to the model fluid causing
printhead degradation or failure. To protect the
jetting assembly, this model fluid must be flushed
out with a flushing fluid compatible with the final
ink.

17.0 Monitoring Cleanliness

Before any parts are cleaned, a suitable clean room or clean environment is required.
Following are some tests for monitoring the cleanliness of the area.

17.1 Ultrasonic Cleaning Test

To verify that the ultrasonic cleaner is working correctly and the energy is distributed
uniformly throughout the cleaning area:
1. Cut a piece of standard household aluminum foil to fit the width of the cleaner
chamber. For example, a tank measuring 9 inches long by 5 inches wide by 4
inches deep requires a foil sample 9 inches by 5 inches.
2. Prepare a fresh solution of ultrasonic cleaning solution and fill the tank
according to the manufacturer’s instructions. Do not turn the heater on for this
test.
3. Insert the foil vertically into the cleaner chamber with the length of the foil
running the length of the chamber, and the bottom of the foil about one inch
above the bottom.
4. If the unit has a high/low switch, set it on high. Holding the foil steady, turn on
the ultrasonic cleaning unit for 20 - 60 seconds.
5. Remove the foil sample and check for small indentations (pebbling) or holes.

If the unit is functioning correctly, the entire surface of the foil will be uniformly
covered with a tiny pebbling effect. If areas greater than 1/2 inch square show no
pebbling or if the pebbling is not uniform, the unit may require servicing.

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17.2 Airborne Particle Count

There are minimum recommended levels for clean rooms and clean hoods. A clean room
has a controlled level of contamination that is specified by the number of particles per
cubic meter at a specified particle size. For example, the ambient air outside in a typical
urban environment might contain as many as 35,000,000 particles per cubic meter, 0.5 μm
and larger in diameter, corresponding to a Class 100,000 or ISO Class 9 clean room (ISO
14644).

Clean rooms are classified according to the number and size of particles permitted per
volume of air. Large numbers like “class 100” or “class 1000” refer to the number of
particles of size 0.5 μm or larger permitted per cubic meter of air. A minimum level of air
cleanliness for printhead system cleaning and assembly is 1000.
Table 3 Maximum particles per cubic unit of measure

FS 209E ISO 14644  μm  μm  μm  μm  μm
(ft3) (m3)
ft3 m3 ft3 m3 ft3 m3 ft3 m3 ft3 m3
N/A 1 10 2
N/A 2 100 24 10 4
1 3 35 1000 7.5 237 3 102 1 35
10 4 350 10000 75 2370 30 1020 10 352
100 5 100000 750 23700 300 10200 100 3520 29
1,000 6 1000000 237000 102000 1000 35200 7 293
10,000 7 10000 352000 70 2930
100,000 8 100000 3520000 700 29300
N/A 9 35200000 293000

Use an airborne particle counter if available, to check the particle counts in the clean room
or flow hood.

17.3 Open Face Filter and Vacuum Source

This is a technique for checking the contamination levels on the working surface areas
such as table tops, equipment, garments, and gloves.
· The filter holder can be found at the Pall website: www.labfilters.pall.com. Search
under “filter holder”, 25 mm open-face Delrin plastic.
· A recommended vacuum source can be found from Buck Pump, VSS-5:
www.apbuck.com.
· Use any suitable flexible tubing.

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· Use any suitable microscope cover slides.

· The membrane filter can be a Millipore 25 mm diameter, 1.2 μm pore size,
white filter with black grids, part number RAWG02500.

Pump, tubing, and filter Pall filter holder

Figure 6 Supplies for test

After running the pump and tubing over the clean station, remove the filter, place on a
microscope slide, and cover the filter with a microscope cover glass. Inspect under a
microscope and count the particles per square. Each square is 9.5 mm2. Divide the
number of particles by 9.5 to get particles/mm2. Dimatix recommends counting inside
the center nine (9) squares and taking the average.

Membrane filter Membrane filter inside 2 cover slides

Figure 7 Membrane filter

17.4 Ultraviolet Black Lights

Spectroline Ultraviolet black lights (www.spectroline.com) can be used to perform

quick inspections of critical areas. The black light picks up fibers and skin cells but not
metal particles. These light sources are good for particles down to what the human eye
can see, which is about 45 - 50 micrometers in size.

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17.5 Flush and Catch

After the components have been cleaned and the unit is assembled, the system should be
flushed. This requires circulating several liters of the appropriate flushing fluid through
the system, filtering to perhaps 5 - 10 microns on each cycle. To be sure the process has
thoroughly cleaned the system, perform a flush and catch test. This requires that a volume
of flush is passed through a filter and the filter examined for contamination.
· Stainless steel, 25 mm filter holder with a Luer locking inlet obtainable from
www.fishersci.com, part number 09-753-10C
· 60 ml plastic syringe with Luer-Lok tip; www.fishersci.com, part number 309653
· microscope slides, microscope cover glass, and 25 mm membrane filters (verify
material compatibility)

Filters and filter holders Filter holders and syringe

Figure 8 Flush and Catch Requirements

Pour flushing fluid into a clean beaker. Assemble the stainless steel filter holder with the
filter. Pull the plunger from the syringe and install the filter holder. Never try to remove
the syringe plunger with the filter holder in place. Carefully pour the liquid into the
syringe. Install the plunger and slowly push the fluid out of the syringe and through the
filter. Repeat until all the fluid in the beaker has been pushed through the filter.

Remove the filter and place it on a microscope slide; cover with clean (IPA wiped)
microscope cover glass. Tape the edge of the cover glass to the microscope slide. Using
the microscope, count the number of particles and fibers for each square on the filter.
Divide the total number of particles measured by the area of the squares. The result equals
the particles/mm2/60 ml of flush. This is now the baseline cleanliness level

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Doc. #AN000010 Rev. 06 FUJIFILM Dimatix, Inc. Confidential Information

September 24, 2009