The Strataprinter Desktop Printing System

The Strataprinter is a modularly expandable printing system centered on the function of a patented printhead structure and process controls.

Setting up the System's Main Components

The Strataprinter is a versatile, multi-application system made for quick setup. Its light weight, small scale and small number of quick-connect attachments make set up and change over between tasks fast and effortless.

Setting up the Master Control Module

The Master Control Module is the center of all Strataprinter functions. To make it active three connections and one adjustment are required.

1. A common power cord exactly like that used for home computers is supplied with the system. On the front of the Master Control Module is a power switch. Make certain this is off, then connect the power cord to the lower right rear of the Master Control Module and then plug it into a grounded AC outlet.
2. Above the power cord connection is the receptacle for compressed air. Attach the quick-connect fitting supplied with your system to the compressor hose and connect the compressor to the Master Control Module.
3. On the upper right front of the Master Control Module is an air gage and on the upper left rear is an air regulator marked "Pressure Adjust". If the gage in the front does not read 80 psi, adjust the pressure knob on the rear clockwise or counter-clockwise until it does.
4. Once the air and electricity are connected, plug the foot pedal into the front at the position marked cycle switch.
• A thumb lever is at the top of each pneumatic quick-connect. Be careful to depress this lever before inserting the male connector. Failure to do so will damage the O-ring and cause an air leak.

Connecting the Exposure Module to the Master Control Module

There are three connections for the Exposure Module. One is to external power and the other two are to the Master Control Module.

1. Plug the Exposure Module power cord into a grounded AC outlet.
2. Attach the thin cord on the front of the Exposure Module to the lower left rear of the Master Control Module in the outlet marked Exposure Lamp.
3. A black mask with a manifold and a double hose is included with your system. Place the mask over the glass of the Exposure Module and connect the double male end of the hose to the center, lower front pneumatic quick-connect of the Master Control Module marked Printhead.
• A thumb lever is at the top of each pneumatic quick-connect. Be careful to depress this lever before inserting the male connector. Failure to do so will damage the O-ring and cause an air leak.

Connecting the Flatbed Screen Printer to the Master Control Module

Note: All connections from the Exposure Module are removed from the Master Control Module before connecting a printer module.

There are three connections made between the Screen Printer and the Master Control Module. All are pneumatic.

1. Connect the male twin tube connector from the Screen Printer to the center, lower front pneumatic quick-connect of the Master Control Module marked Printhead.
2. Connect the male end of the tube attached to the lower rear junction on the printer to the pneumatic quick-connect on the extreme left, lower front of the Master Control Module marked Output A.
3. Connect the male end of the tube attached to the upper rear junction on the printer to the pneumatic quick-connect on the left, lower front of the Master Control Module marked Output B.
• A thumb lever is at the top of the each pneumatic quick-connect. Be careful to depress this lever before inserting the male connector. Failure to do so will damage the O-ring and cause an air leak.

Auxiliary Device Connections to the Master Control Module

The quick-connect located to the lower right front of the Master Control Module marked Pressure Out is used for the air brush that develops the screen after exposure. It is also used for the foot operated regulator that pumps ink from the air syringes.

The Printhead

The Strataprinter 2030 Printhead is the device central to all the functions of the Master Control Module and the Strataprinter Desktop Printing System. The Printhead is used in the Exposure Module for imaging the screen for printing and used in each of the printing modules for the actual printing.

Putting the Printhead, Screen Cartridge and Air/Sensor tubes together

1. Snap the cartridge frame over the Printhead's metal wall starting by pressing with thumbs on the corners of one long side, then the opposite side allowing the bevels of the frames to act as guides. Press until each corner is firmly seated. Twist a screw driver into grooves at the short ends of the Printhead for snapping the cartridge out (removal). Practice inserting and removing the screen cartridge is necessary until the operator is familiar and confident.
2. Pressing the protruding ends of the small twin tubes into the ports in the Printhead's silicone exterior connects the Printhead to the Master Control Module. These twin tube ends are found both on the exposure mask manifold and on the registry head of the Screen Printer.

The Ink Pump

DiaStrata packages inks for the Strataprinter in air syringes. Ink flow from the syringe is controlled by a pedal-operated air regulator.

Connecting the Ink Pump to the Master Control Module

1. One of the two hoses attached to the Ink Pump foot pedal has a male end connector. Plug this into the quick-connect located to the lower right front of the Master Control Module marked Pressure Out.

Preparing the Syringe for pumping

1. The second of the two hoses is the air lock cap for the syringe. Attach this cap by pressing the O-ring center into the large end opening of the syringe. Lock it in with a clockwise quarter-turn twist.
2. Choose a nozzle that matches the precision with which you want to place the ink on the screen. Remove the cap from the small end of the syringe with a counter clockwise twist. Replace the cap with the nozzle locking it in with a clockwise twist.
• Avoid using nozzles that pressure-fit onto the syringe. The density of the ink and the pressure used to pump it will dislodge this style of nozzle from the syringe.

The Printing Jig

Printing jigs for the Screen Printer are made of steel. Each separate jig has a different arrangement of pins for precise registry of a specific size and shape of product. Specially die-cut masks are attached magnetically to the jig plate to create a vacuum seal around the product.

Attaching the Jig Plate to the Shuttle Bed

1. Match the jig plate to the product to be printed.
2. Rotate the jig and product to match the horizontal or vertical printing direction of the Printhead.
3. Use the four flathead screws to secure the jig plate to the shuttle bed.

Preparing the Jig Plate for Printing

1. Position a few small pieces of hold-down tape close to the outer edge of the jig plate to prevent the magnetic jig seal from shifting.
2. Match a magnetic jig seal to the product and position it edge-to-edge on the jig plate.
3. Position two small pieces of hold-down tape as necessary to the top and bottom of the product position on the jig plate to secure it to the bed while printing.

Testing the Setup

Each Strataprinter package contains a blank screen cartridge. This is used for testing the system setup.

Test Procedure

The setup will be tested by loading the test screen into the printhead and using this to check the operator adjustments of the Master Control Module and the functions of the Exposure Module and the Screen Printer.

Testing the Printhead, Master Control Module and Exposure Module

After following the instructions for set up of the Master Control Module and connecting it to the Exposure Module:

1. Snap the test screen into the Printhead taking care that all the corners are firmly seated.
2. Observe the molded silicone of the Printhead. The resilient lip around the outside edge and concentric bands along the contact surface form primary and secondary vacuum seals. Also observe the two small ports on one long side of the Printhead. Install the Printhead in the Exposure Module by placing it in the window of the exposure mask with the protruding hose ends of the mask manifold pressed firmly into the Printhead ports. Be certain that the contact surface of the Printhead rests fully on the glass of the Exposure Module. This is the position of the Printhead for cartridge screen exposure.
3. From above the Printhead, place a finger in the center of the screen and deflect it down to the glass. Observe the resistance of the screen and its distance above the glass.
4. If the thin cord from the Exposure Module is connected to the back of the Master Control Module at the outlet marked Exposure Lamp, remove it at this time.
5. Observe the front of the Master Control Module. Starting from the bottom are, in a line straight up, the Power switch, the two digit Sensor adjustment and the three digit Time adjustment. Switch on the power. Set the sensor at "10" (10% of vacuum) and the timer at "100" (100 milliseconds or 1/10 of a second).
6. Depress the foot pedal (Cycle Switch) and release it. A burst of air forms 10 % of a vacuum in the printhead and, after 1/10th of a second, releases the vacuum. Repeat this enough times to become acquainted with the relationship between the foot pedal and the Printhead function.
7. Increase the three digit timer to "999" and again depress and release the foot pedal. The vacuum formed in the Printhead will hold for nearly a second before releasing. Repeat this with several different time settings to become familiar with the duration of the print cycle.
8. Now, at the back lower left rear of the Master Control Module, to the left of the outlet marked Exposure Lamp are a mode select switch marked Print <> Expose and a rotary adjustment knob marked Exposure Time. Toggle the mode switch to Expose and turn the Exposure Time adjustment fully counter clockwise.
9. Again, actuate the foot switch. The Printhead holds the vacuum for 15 seconds before releasing it.
10. With the select switch still on Expose mode (8 above) lower the "%" of vacuum to "02", actuate the cycle switch (foot pedal) and during the 15 seconds of the timed cycle observe the contact area of the screen in the glass as you increase the "%" of vacuum from "02" to "03" to "04" and upward through 15% or 20%.
11. Finally, return the sensor setting to "10", plug the thin cord from the Exposure Module into the outlet marked Exposure Lamp. Cycle the printhead. The lamp of the Exposure Module will light and stay on for 15 seconds.
• To abort the exposure cycle at any time or return to the millisecond timer (3 digit timer on the front) toggle the mode switch from Expose to Print.

Testing the Flatbed Screen Printer

Remove the Printhead, disconnect the Exposure Module and attach the Screen Printer to the Master Control Module. After following the setup instructions for the Screen Printer:

1. Mount the Printhead on the printarm by lifting the printarm back on its hinge, swinging the latch away from the Printhead clamp and sliding the Printhead into the clamp until the protruding hose ends of the manifold are pressed into the Printhead ports. Swing the latch back and secure the Printhead against the manifold. Return the printarm forward to the print position.
2. Mount a jig plate on the shuttle bed following instructions for preparing the jig for printing.
3. Release hose from Output B of the Master Control Module and slide the shuttle bed to a position under the Printhead but not far enough back to contact the printarm lever. (See Caution at end of section)
4. Loosen the vertical slide clamps using a 3/16" allen wrench and adjust the height of the Printhead vacuum seal to be exactly 5/8" above the magnetic vacuum seal on the jig plate. Tighten the vertical slide clamps.
5. Replace the hose to Output B returning the shuttle bed to the front of the printer.
6. Use the 3/16' allen wrench to "zero" out the rotational and transverse registry adjustments on the printhead clamp and a 1/4" allen wrench to center the front-to-back registry adjustment on the shuttle bed.
7. Set the toggle switch on the back of the Master Control Module to "Print" mode. Switch the power on. Set the sensor to "10" and the time to "010".
8. Cycle the printer with the foot pedal. The shuttle bed travels back under the Printhead and contacts the printarm lever. The Printhead is lowered against the bed, seals, completes the print cycle and the shuttle bed is returned to the front of the printer. All of these functions are fully automatic.
9. Cycle the printer a few times making adjustments as needed at the brass needle valves on the rear right of the printer to control the speed of the shuttle bed.

Never attempt to move the shuttle bed backward by hand unless the air is disconnected. Forcing the bed against the air in the drive cylinder will cause the bed to become detached from the magnetic drive piston inside the rodless cylinder. (If detachment occures, remove the front mount of the non-drive rod and slide the bed forward until it snaps back onto the magnet. Once the magnet is reattached, disconnect the air from the printer, replace the front mount of the non-drive rod and reconnect the air.)