Rationalisierung • Entwicklung • Automation

Elektronische Geräte und Systeme REA Elektronik

GmbH

Maintenance advice for the REA-JET RPS system

When using the REA-JET RPS system on-going in production, a monthly maintenance (in all steps as
described below under “Preventative Monthly Maintenance” of the RPS system is recommendable resp. in
many cases required, even under the condition that the RPS system still is or appears operating properly one
month after the last “monthly maintenance” had taken place.

Typically in rough industrial production environment, dust and dirt can attach to the print head and so can
block the ink jet nozzles of the RPS system just through its physical presence of sticking to the front plate,
which can cause deterioration of the print result. It is possible to avoid this with minimal preventive daily
measures such as wiping off the nozzle plate once a day with a paper towel moisturized with CL-TPNF
Cleaner, see also below under “Preventative Daily Maintenance”

“Preventative Monthly Maintenance” to be carried out by an interval of at least 4-6 weeks

a) - Stopping the REA-JET RPS system, cleaning the TPNF ink out of the ink tank and ink lines
-- stopping the RPS ink supply,
-- release air pressure and ensure the ink from the line flows back into the ink tank, so the head and tubes
are emptied from ink
-- screw off the screw connectors from the tubes sitting on the tank
-- take out the plastic tank from its holder inside of the ink supply
-- empty out and dispose all ink out of that plastic tank
-- fill with a small amount of the respective cleaner CL-TPNF or CL-TPNA brush out the ink tank so that are
no pigment sediments anymore on the bottom of the bottle as well as no filling level sediments on the interior
walls of the plastic ink tank

b) Cleaning the RPS print head

-- unplug and take out the print head from the line
-- open the nozzle plate of the print head
-- after having screwed off the nozzle plate, make sure to lay down the nozzle plate with the out side face
downwards on an underground (in order to make sure that the nozzles inserts, which are designed to
protrude on the inside face of the nozzle plate, may not be scratched, grinded at their protruded face)
-- clean the print head chamber (now been laid free by removing the nozzle plate) carefully by flushing with
CL-TPNF or CL-TPNA cleaner(Do not use any sharp tools inside of the ink champer to clean the plungers,
as they close from inside against the nozzle plate if if they are damaged they do not close any more properly)
-- Check the ink chamber is to be checked and eventually cleaned from any pigment sediments
-- Check the nozzle plate and flush it with CL-TPNF or CL-TPNA, clean the nozzle plate in a ultrasonic bath
and with nozzle cleaning needle when it is blocked
-- Test the RPS system for all nozzles operating properly working properly by repeatedly pressing the purge
button whilst holding a paper towel gainst the nozzle plate for collecting the ejected ink. Repeat this until ink
shoots out and all nozzles are actively releasing ink dots
-- If not all nozzles can be activated again to print proper dots, please repeat b) Cleaning the RPS print head
-- see also under 6.3. Head clening procedure

After successful cleaning and reassembly of the print head, please refill the ink tank with fresh TPNF- … or
TPNA-… ink and restart the ink supply as well as the RPS system.

“Preventative Daily Maintenance”

-- moisturize a cloth or paper towel with CL-TPNA or CL-TPNF cleaner and wipe off the nozzle plate with it
-- press this cloth or paper against the nozzle plate at press repeatedly the purge button at the print head
-- make sure that all nozzles are releasing properly ink dots
-- if one ore more nozzles may be blocked , if this may be not the case please proceed with head cleaning
procedure as described above.

Copyright © 2008 REA Elektronik

Rationalisierung • Entwicklung • Automation
Elektronische Geräte und Systeme REA Elektronik
GmbH

Checking and cleaning procedure of the ink

tank of the TV-PL
– here: Cleaning the bottom screws

Steps:
1.) “Fish out” the two ink tubes so that the
1 end of the ink tubes with the two bottom
5 screws look out of the bottle

2.) Screw off and take out the two bottom

screws from the ink tubes

These bottom screws have a little hole in

Little hole in the
2 center of the
screw
the middle through which the ink is
sucked through. When this is blocked,
the ink cannot travel so easily and the
pump needs more force to suck through
resp. sucks less ink through. When this
hole is entirely blocked the whole ink
pump could be forced to halt over time

3.) Clean the detached bottom screws. Use

4 a nozzle cleaning needle with the bold
end or something similar to clean the
hole in particular

4.) Screw the two screws back to the end of

the ink tube

5.) Push the ink tubes back into the tank,

making sure the bottom screws at the ink
tube end point down to the bottom
of the tank

3 REA Elektronik GmbH

Copyright © 2008 REA Elektronik

Rationalisierung • Entwicklung • Automation
Elektronische Geräte und Systeme REA Elektronik
GmbH

Disconnecting the Ink Supply Lines

1. Press and hold the metal tab on the ink supply line connector.

2. Gently rotate or twist the connector clockwise and counterclockwise while pulling the connector
straight off.
Do not apply a prying or back and forth motion to the connector! Pulling the
connector off with a prying motion may break off the end of the male
connector.

CAUTION

1. Clean the female connector by spraying CL-TPNF cleaner in the opening and
around the metal tab. Wipe as necessary. Press the small pin to release the metal tab.
2. Clean the male connector by wiping with a clean chip-free cloth or paper towel moisturized with
CL-TPNF cleaner.

Copyright © 2008 REA Elektronik

Rationalisierung • Entwicklung • Automation
Elektronische Geräte und Systeme REA Elektronik
GmbH

REA-JET RPS Print Head Cleaning Procedure

Clean the Print Head only with CL-TPNF cleaner that is

compatible with pigmented inks.

Refer to Section 12 for components included in the Cleanup Kit.

1. Clean the outside of the head to prevent contaminants from getting inside when the nozzle plate
is removed.

Using the spray bottle, spray down the outside of the head with CL-TPNF cleaner to
remove dirt and ink. Wipe with a clean paper towel as necessary to remove stubborn
stains.

 Spray down the external surface of the nozzle plate to remove any dried ink buildup. Wipe
with a clean paper towel as necessary. Repeat spray.

 Dry head with a clean paper towel.
2. Remove the nozzle plate.

 Spread out several layers of paper towels on a clean surface that is
resistant to solvents.

 Position the head on its side and carefully loosen each of the
nozzle plate screws. Do not remove the screws at this timejust
loosen them slightly.

 Position the head on a couple of blocks with nozzle plate facing
upward as shown below.

Copyright © 2008 REA Elektronik

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GmbH

 Remove the nozzle plate screws and the nozzle

plate. Set the nozzle plate face down on a paper
towel. The backside of the nozzle plate should
be facing upward.
3. Clean and flush the nozzle plate.

 Using the spray bottle, spray off excess ink on
both sides of the nozzle plate. Continue this step
until plate is clean. If you have an ultra sonic
cleaner, place the nozzle plate and solvent in a
jar and place in the sonic cleaner for 15 to 20
minutes (recommended).
Dirty Head with Nozzle Plate Removed

 Using the nozzle plate flush bottle, remove the
red cap and place the end of the tip over one of
the nozzle jewels on the backside of the nozzle
plate and squeeze the bottle to force solvent to
pass through the orifice. Repeat this step with
every nozzle. Place the nozzle plate with the
outside face facing down on a paper towel until
you are ready to replace the nozzle plate on the
Print Head.
4. Flush head ink reservoir.

 Carefully dump the excess ink from the
head ink reservoir into the waste ink
container.

 Set the head face down on top of several
paper towels to absorb any excess ink
remaining in the ink reservoir.

 Attach the head flush adapter to the ink
supply connection.

 Insert the spout of the head flush bottle
into the end of the head flush adapter
Head with Flushing Adapter Connected
tube.

 Hold the head over the waste ink container and squeeze the flush bottle to force solvent
down through the ink supply tube and out the bottom of the head.

 Continue this process until the solvent runs clear.

 Repeat this process for the other ink supply tube.

 Set the head face down on clean paper towels.

 Remove the flush bottle and disconnect the flush adapter.

 Using the spray bottle, spray down the ink reservoir and plunger tips.
5. Put the nozzle plate back in place.

 Place the head back on the blocks with the ink reservoir facing upward.

 Position nozzle plate back in place on top of ink reservoir. Take care to match the
alignment pin on the reservoir with the alignment hole in the nozzle plate. Care must be
taken to make sure that you put the nozzle plate back on correctly.

 Insert all the screws. Replace any that show visible signs of the head stripping. Tighten
the screws one by one until they just begin to touch the nozzle plate.

Copyright © 2008 REA Elektronik

Rationalisierung • Entwicklung • Automation
Elektronische Geräte und Systeme REA Elektronik
GmbH

 Then go around evenly and gently tighten the screws one by one to draw the nozzle plate
down and compress the nozzle plate O-ring.

 Finally, go around one more time and gently snug the screws one by one. Do not over-
tighten.

Nozzle Plate Alignment Marks (16-Dot Head shown)

Notes: Take care to tighten the nozzle plate screws in three (3) steps as described above.
DO NOT over-tighten the screws, they will break. Match up the hole in the nozzle plate
to the pin on the Print Head for correct nozzle plate alignment. Each nozzle plate is
matched to a particular Print Head.
DO NOT mix and match the nozzle plates.

Copyright © 2008 REA Elektronik

Rationalisierung • Entwicklung • Automation
Elektronische Geräte und Systeme REA Elektronik
GmbH

Rubber Printing System (RPS) White Connectors

Purpose:
This service bulletin points out the importance of the white connectors and how to use them
correctly with the Rubber Printing System (RPS).

Figure 1 – White Plastic Connectors

General Information - Compatibility of inks and cleaner:

The white connectors that are supplied with the RPS system are the only connectors that are
compatible with the ink and solvent used with the RPS system. Both the male and female
connectors are valved and contain internal O-rings. The internal O-rings are not replaceable.
Failure to use the correct connectors can cause over-pressurization of the print head, which
damages the stem seals. The end result is head failure caused by ink flooding the electro-
mechanical compartment of the head.

Solely REA JET inks (as e.g. TPNF-...) and REA-JET cleaners (as e.g. CL-TPNF) are
compatible with the RPS system. The internal sealing elements are specificly designed to
be compatible with the REA-JET TPNF-… ink and the REA-JET CL-TPNF cleaner. No other
inks, solvents and cleaners than REA-JET TPNF-… ink and the REA-JET CL-TPNF are
admitted for use with the RPS system, because those can damage the functionality and
components of the RPS system

Copyright © 2008 REA Elektronik

Rationalisierung • Entwicklung • Automation
Elektronische Geräte und Systeme REA Elektronik
GmbH

Diagnosing Connector Problems:

1. Female Connectors
The two ink supply lines from the RPS ink supply system each have a white female connector.
The female connector body utilizes a metal tab for one-hand connection and disconnection. The
connector clicks when completely coupled to indicate a secure connection.
Each time the female connector is removed, a small amount of ink leaks from the connector.
REA-JET CL-TPNF cleaner should be sprayed in the opening and around the metal tab to remove
the ink. If ink is left on the connector, the metal tab will stick and make it difficult to connect and
disconnect the ink supply line.

CAUTION

If too much force is exerted while connecting or disconnecting the ink supply
lines, the male connector on the ink jet print head will break. The result will
be an ink spill and an out-of-service print head.

Figure 2 – Ink Supply Lines

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2. Male Connectors
There are two white male ink supply connectors at the top of every RPS print head. There is an
external O-ring on each male connector. The center stem is a spring-loaded valve that depresses
when coupled to allow ink flow to and from the head. Each time the ink supply line is removed, the
male connector should be wiped with a clean chip-free cloth or paper towel moisturized with CL-
TPNF cleaner to remove the excess ink from the stem and to clean the O-ring. The center stem
must be kept clean so it operates freely.
After repeated connecting, disconnecting and exposure to solvent, the external O-ring will
deteriorate and swell. This condition will also make it difficult to connect and disconnect the ink
supply line. Typically a swelled O-ring will tear and then leak. It is important to replace an external
O-ring showing signs of deterioration.

Figure 3 – Male Connector O-Rings

O-Ring Replacement & Compatibility:

New RPS print heads are supplied from the manufacturer with black O-rings containing a small
white dot on the white male connectors. If you look closely, you will see the small white dot on the
outside perimeter of the O-ring. The dot indicates that the O-ring is compatible with the RPS
system.

New white male connectors are also supplied from the manufacturer with black O-rings containing
a small white dot.

NOTE: The tiny white dot usually wears off after the first connection. Replacement O-rings for the
RPS system white male connectors are green.

Connecting the Ink Supply Lines:

1 Check that both connectors are clean. Clean if necessary.
2 Press the metal tab on the ink supply line connector until it clicks.
3 Gently press the female connector straight down over the male connector until the metal
tab clicks to indicate a secure connection.

CAUTION
A slight axial rotation or twisting action clockwise and counterclockwise may
be required while pressing. Do not apply a prying or back and forth motion
to the connector! Forcing the connector on with a prying motion may break
off the end of the male connector.

Copyright © 2008 REA Elektronik