Leibinger Jet 2 User manual

Group 1 Table of contents Page 1
Release 3.00 Leibinger-Jet 2 se
1.1 Table of contents
1.1 Table of contents............................................................................................................1
1.2 Group directory...............................................................................................................7
1.3 Menu level index.............................................................................................................8
1.4 Publisher.......................................................................................................................10
1.5 Introduction...................................................................................................................12
1.6 Document information ..................................................................................................13
2. Safety.................................................................................................................................14
2.1 Scope of risks...............................................................................................................14
2.2 Safety instructions and recommendations....................................................................14
2.3 Intended use.................................................................................................................17
2.4 Sources of danger........................................................................................................17
2.5 Safety sticker................................................................................................................21
2.6 Operating staff..............................................................................................................22
2.7 Dangers due to electric energy.....................................................................................22
2.8 Personal protective equipment.....................................................................................22
2.9 Protective devices ........................................................................................................22
2.10 Safety measures at the place of installation...............................................................23
2.11 Dangers through consumables...................................................................................23
3. Accident prevention.........................................................................................................25
3.1 Storage and handling (normal use)..............................................................................25
3.2 First aid measures........................................................................................................26
3.3 Fire fighting measures..................................................................................................26
3.4 Measures in the event of accidental release (spillage).................................................27
4. Technical data ..................................................................................................................28
4.1 Dimensions, weights, connections ...............................................................................28
4.2 Ambient conditions.......................................................................................................28
4.3 System interfaces.........................................................................................................28
4.4 Power parameters ........................................................................................................29
4.5 Font forms ....................................................................................................................29
4.6 Forms of printing...........................................................................................................30
4.7 Font combinations........................................................................................................30
4.8 Manner of working........................................................................................................30
4.9 Software .......................................................................................................................31
5. Transport/Start up............................................................................................................32

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5.1 Transport, storage, shipping.........................................................................................32
5.2 Mounting.......................................................................................................................32
5.3 Installation ....................................................................................................................33
5.3.1 Mains connection.................................................................................................33
5.3.2 Data interface X2 .................................................................................................34
5.3.2.1 Transmission protocol for operating system LJOS........................................34
5.3.2.2 Pin assignment plan......................................................................................35
5.3.3 Print Go interface X5............................................................................................36
5.3.4 Shaft encoder.......................................................................................................36
5.3.4.1 Description and pin assignment....................................................................36
5.3.4.2 Mechanic installation.....................................................................................37
5.3.5 Print head.............................................................................................................38
5.4 Start up.........................................................................................................................39
5.4.1 Initial start up in an empty condition.....................................................................39
5.4.2 Initial start up in a full condition............................................................................41
6. Operation ..........................................................................................................................43
6.1 Construction/Structure..................................................................................................43
6.2 Functional principle.......................................................................................................44
6.2.1 Method of working................................................................................................44
6.2.2 Drop creation .......................................................................................................44
6.2.3 Drop charging ......................................................................................................44
6.2.4 Drop deflection.....................................................................................................45
6.2.5 Creation of a character ........................................................................................45
6.2.6 Summary of the individual procedures.................................................................46
6.3 Operating procedures and operating elements............................................................47
6.3.1 LCD touch display................................................................................................47
6.3.1.1 Switching on/switching off procedure............................................................47
6.3.1.2 Interval operation...........................................................................................49
6.3.1.3 Status line in normal operation......................................................................50
6.3.1.4 Status line in error condition..........................................................................50
6.3.1.5 Software Reset..............................................................................................51
6.3.2 Ink switch .............................................................................................................52
6.3.3 Hardware Reset...................................................................................................52
6.3.4 Potentiometer – Display illumination....................................................................53
6.3.5 Menu structure.....................................................................................................54
6.4 Interfaces......................................................................................................................57

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6.4.1 Data interface.......................................................................................................57
6.4.2 PrintGO interface .................................................................................................57
6.4.3 Shaft encoder interface........................................................................................57
6.4.4 Optional outputs...................................................................................................58
6.4.5 Optional inputs.....................................................................................................58
6.5 Description of the device..............................................................................................59
6.5.1 Electronics caabinet with LCD touch display .......................................................59
6.5.2 Controller board ...................................................................................................60
6.5.3 DC power supply..................................................................................................62
6.5.4 Hydraulics part.....................................................................................................63
6.5.4.1 Main pump.....................................................................................................65
6.5.4.2 Suction pump ................................................................................................65
6.5.4.3 Viscosity control ............................................................................................66
6.5.4.4 Leak detection...............................................................................................67
6.5.5 Print head.............................................................................................................67
6.5.5.1 Drop production unit with oscillator ...............................................................69
6.5.5.2 Deflector unit.................................................................................................69
6.5.5.3 Nozzle plate...................................................................................................70
6.5.5.4 Nozzle seal with gutter..................................................................................70
7. Data entry/programming..................................................................................................71
7.1 General.........................................................................................................................71
7.2 Text administration.......................................................................................................71
7.2.1 Text entry.............................................................................................................72
7.2.1.1 Bold print.......................................................................................................73
7.2.2 Font parameters...................................................................................................75
7.2.3 Text editor............................................................................................................78
7.2.4 Graphics entry/graphics selection........................................................................78
7.2.5 Graphics editor.....................................................................................................79
7.2.6 Shift code input ....................................................................................................80
7.2.7 Barcode input.......................................................................................................82
7.2.7.1 Barcode information......................................................................................82
7.2.7.2 Barcode selection..........................................................................................84
7.2.7.3 Barcode parameter........................................................................................85
7.3 Job administration ........................................................................................................86
7.3.1 Opening job..........................................................................................................86
7.3.2 Factory setting & default jobs...............................................................................87

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7.3.3 Deleting jobs ........................................................................................................88
7.3.4 Storing and listing jobs.........................................................................................89
7.4 User-/ Password administration....................................................................................90
7.4.1 Password levels (User groups) and user rights ...................................................90
7.4.2 Call up password administration..........................................................................91
7.4.3 Activate user administration (first password input)...............................................91
7.4.4 User change and password change.....................................................................92
7.4.4.1 Login as supervisor or advanced operator....................................................93
7.4.4.2 Change passwords........................................................................................93
7.4.4.3 Logoff as supervisor or advanced operator...................................................95
7.4.5 Password forgotten..............................................................................................96
7.4.6 Deactivate user-/password administration...........................................................96
7.5 Print start parameters...................................................................................................98
7.5.1 Print delay and print repetition .............................................................................98
7.5.2 Printgo distance...................................................................................................99
7.5.3 Droplet flight time.................................................................................................99
7.5.4 Print Go and Print Go Gate................................................................................100
7.5.5 Meter go function ...............................................................................................101
7.5.6 Pre-defined print stop.........................................................................................103
7.6 Function parameters...................................................................................................104
7.6.1 Expiration time and shift times...........................................................................104
7.6.2 Replacements and text sources.........................................................................105
7.6.2.1 Printing with the function “ex. text”..............................................................105
7.6.3 Reset counters...................................................................................................107
7.6.4 Counter settings.................................................................................................108
7.6.5 Counter programming........................................................................................109
7.6.6 Mode normal and reflected ................................................................................111
7.7 Service/test/system parameters .................................................................................112
7.7.1 Direct start and time/date...................................................................................112
7.7.2 Monitoring functions (Control functions).............................................................113
7.7.2.1 Printgo- and strokego monitoring................................................................113
7.7.3 Encoder..............................................................................................................114
7.7.4 Encoder parameters...........................................................................................114
7.7.5 Job change ........................................................................................................115
7.7.5.1 Printing with the function “external job selection”........................................115
7.7.6 Service/test- and diagnosis functions.................................................................117

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7.7.6.1 Summary graph (oscillator voltage curve)...................................................117
7.7.6.2 Motor test ....................................................................................................118
7.7.6.3 Charging voltage test/Piezo test..................................................................119
7.7.6.4 Software information ...................................................................................120
7.7.6.5 Permanent bleeding....................................................................................120
7.7.6.6 Hydraulic test & parameters........................................................................121
7.7.6.7 Touch screen calibration.............................................................................123
7.7.6.8 Service interval............................................................................................124
8. Trouble shooting............................................................................................................125
8.1 General.......................................................................................................................125
8.2 Error notification .........................................................................................................125
8.3 Error messages..........................................................................................................126
8.4 Other causes of errors................................................................................................129
9. Equipping/maintenance.................................................................................................130
9.1 Equipping/operation....................................................................................................130
9.1.1 Refilling of ink and solvent.................................................................................130
9.2 Guarantee...................................................................................................................132
9.3 Service/maintenance..................................................................................................132
9.3.1 Daily servicing work ...........................................................................................132
9.3.2 Weekly servicing work........................................................................................132
9.3.2.1 Lubrication...................................................................................................132
9.3.2.2 Nozzle sealing.............................................................................................133
9.3.3 Annual servicing work........................................................................................135
9.3.3.1 Filter replacement and ink change..............................................................136
9.3.4 Other servicing work ..........................................................................................139
9.3.4.1 Adjusting the ink jet in the gutter.................................................................139
9.3.4.2 Replacement of the main pump ..................................................................140
9.3.4.3 Replacement of the battery and fuse ..........................................................142
9.3.5 Servicing work with more difficult operating conditions......................................143
9.4 Cleaning .....................................................................................................................144
9.4.1 Daily cleaning work............................................................................................144
9.4.1.1 Cleaning the print head...............................................................................144
9.4.1.2 Cleaning the deflector unit and gutter .........................................................145
9.4.2 Weekly cleaning work ........................................................................................146
9.4.2.1 Cleaning of the spindle and guides of the nozzle seal................................146
9.4.3 Other cleaning work...........................................................................................147

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9.4.3.1 Cleaning the nozzle.....................................................................................147
9.4.3.2 Cleaning the suction pump..........................................................................149
9.5 Further maintenance measures (Service intervals)....................................................151
9.6 Taking out of operation...............................................................................................152
9.7 Dismantling/disposal...................................................................................................152
10. Replacement parts.......................................................................................................153
10.1 Replacement parts electronics .................................................................................153
10.2 Replacement parts hydraulics ..................................................................................153
10.3 Replacement parts print head SK2...........................................................................154
10.4 Special tools.............................................................................................................154
10.5 Cleaning/servicing accessories ................................................................................155
10.6 Periphery..................................................................................................................155
10.7 Data entry devices....................................................................................................156
11. Consumables................................................................................................................157
12. Appendix.......................................................................................................................158
12.1 Hydraulics diagram...................................................................................................158
12.2 Interface layout plan.................................................................................................159
12.3 Calculation of the print speed...................................................................................161
12.4 Fonts.........................................................................................................................164
12.5 List of graphics .........................................................................................................166
12.6 Technical drawings...................................................................................................167
List of keywords/Index.......................................................................................................169
List of illustrations.............................................................................................................175

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Release 3.00 Leibinger-Jet 2 se
1.2 Group directory
The group directory serves as a guide through the device manual at hand to be able to find
specific subject areas quickly.
Group Directory Page
1 Overview .........................................................................................................1
Table of contents.............................................................................................1
Group directory................................................................................................7
Menu level index..............................................................................................8
Publisher........................................................................................................10
Introduction....................................................................................................12
2 Safety.............................................................................................................1
4
3 Accident prevention.....................................................................................2
5
4 Technical data ..............................................................................................28
5 Transport/start up ........................................................................................32
6 Operation ......................................................................................................43
Construction/Structure...................................................................................43
Functional principle........................................................................................44
Operating procedures/-elements...................................................................47
Interfaces.......................................................................................................57
Description of the device...............................................................................59
7 Data Entry .....................................................................................................71
8 Trouble shooting/malfunctions.................................................................12
5
9 Equipping/maintenance.............................................................................130
10 Replacement parts.....................................................................................153
11 Consumables..............................................................................................157
12 Appendix.....................................................................................................158
Hydraulics diagram......................................................................................158
Interface layout plan....................................................................................159
Calculation of the print speed......................................................................161
Fonts............................................................................................................164
List of graphics ............................................................................................166
Technical drawings......................................................................................167
Index............................................................................................................169
List of illustrations.....................................................................................17
5

Group 1 Menu level index Page 8
Release 3.00 Leibinger-Jet 2 se
1.3 Menu level index
The menu level index guides you through the manual on hand in order to facilitate the search
for the required information about the individual menu functions.
Group Chapter Menu level no. Page
7 7.1 Menu level 1...........................................................................71
7 7.2 Menu level 2...........................................................................71
7 7.2.1 Menu level 3, 9, 15, 18...........................................................72
7 7.2.1 Menu level 50, 51, 52, 60.......................................................73
7 7.2.2 Menu level 3, 11.....................................................................75
7 7.2.2 Menu level 12.........................................................................76
7 7.2.4 Menu level 50 (graphics entry).............................................78
7 7.2.5 Menu level 3, 10, 19...............................................................79
7 7.2.7.2 Menu level 3, 9, 17.................................................................84
7 7.2.7.3 Menu level 3, 22.....................................................................85
7 7.3.1 Menu level 5, 45.....................................................................86
7 7.3.3 Menu level 5, 47, 49...............................................................88
7 7.3.4 Menu level 5, 46, 50...............................................................89
7 7.4 Menu level 2, 7.......................................................................90
7 7.5.1 Menu level 2, 4.......................................................................98
7 7.5.5 Menu level 4, 8, 1 (meter go function) ...............................101
7 7.5.6 Menu level 4, (pre-defined print stop) ...............................103
7 7.6 Menu level 2, 6, 41, 44.........................................................104
7 7.6.2 Menu level 6, 13...................................................................105
7 7.6.4 Menu level 6, 42 (counter settings)....................................108
7 7.6.5 Menu level 60 (counter programming) ..............................109
7 7.7 Menu level 2.........................................................................112
7 7.7.2 Menu level 8, 31...................................................................113
7 7.7.3 Menu level 8, 14...................................................................114
7 7.7.6.1 Menu level 16, 25.................................................................117
7 7.7.6.2 Menu level 16, 37.................................................................118
7 7.7.6.3 Menu level 16, 38, 39...........................................................119
7 7.7.6.4 Menu level 16, 35.................................................................120
7 7.7.6.5 Menu level 16, 34.................................................................120
7 7.7.6.6 Menu level 16, 29.................................................................121
7 7.7.6.6 Menu level 43.......................................................................122

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Release 3.00 Leibinger-Jet 2 se
7 7.7.6.7 Menu level 16, 59................................................................123
7 7.7.6.8 Menu level 16, 64................................................................124

Group 1 Publisher Page 10
Release 3.00 Leibinger-Jet 2 se
1.4 Publisher
For questions regarding the operation and running of the LEIBINGER-JET 2 as well as in
service case please contact the listed dealer address.
Dealer address
Paul Leibinger GmbH & Co. KG
Special factories for numbering machines
Daimlerstraße 14
D-78532 Tuttlingen
Federal Republic of Germany
Phone [phone]
Fax [phone]
E-mail: [email protected]
Service hotline phone [phone]
Service hotline fax [phone]
Service hotline e-mail: [email protected]
American Branch Office
Paul Leibinger
Numbering Machine L.P.
221 Wilson Avenue
Norwalk, CT 06854 USA
Phone [phone]
Fax [phone]
email: [email protected]

Group 1 Publisher Page 11
Release 3.00 Leibinger-Jet 2 se
We reserve all rights, in particular the right to translate, distribute and reproduce. No part of
this manual must be reproduced or distributed and stored through the use of electronic data
processing systems or made accessible to third parties in any form (redrawn, photocopied,
microfilmed or through any other process) without the written consent of the publisher.
We reserve the right to make alterations to the scope of delivery at any time in the form of
technology, hardware, software as well as the corresponding materials (and manual extracts)
as a result of innovative further development of our devices.
Texts, illustrations and technical drawings have been compiled with the greatest of care.
Nevertheless errors cannot be excluded. Consequently no guarantee can be assumed for
the correctness of the content of this manual and no claims can be asserted against Paul
Leibinger GmbH & Co. KG.
We shall be grateful for information regarding possible printing errors as well as for
suggestions for the further optimisation of the device manual.
Authoritative for the scope of delivery is not the manual but rather the written order
confirmation.

Group 1 Introduction Page 12
Release 3.00 Leibinger-Jet 2 se
1.5 Introduction
We are pleased that you have decided in favour of a LEIBINGER-JET 2 device and welcome
you as one of our customers.
You now own a LEIBINGER-JET 2 device that has been developed and constructed on the
basis of many years of experience and using the latest Leibinger technology. This results in a
high degree of quality and the renowned Leibinger reliability.
This manual shows you the fundamental advantages of the Leibinger Jet system
manufactured by us, such as for example the fully automatic working, low maintenance etc..
The manual must be read thoroughly prior to to first start up in order to
ensure that no damage to the device and/or endangering of the operating
personnel results from a defective electrical connection and/or from
incorrect operation.
Please pay particular attention to the safety instructions of the groups
Safety instructions and accident prevention when handling
consumables (ink and solvent).
Our devices are subjected to a quality control in our plant prior to delivery. If despite this the
device or parts of it should be damaged or their function disturbed please advise us of this as
fast as possible.
The guarantee conditions can be seen from the confirmation of order. The warranty
presupposes that the device or the installation is operated correctly in accordance with the
available guarantee manual and any possible additional manuals and descriptions prepared
by us.
It is only through the use of inks and solvents from Paul Leibinger GmbH & Co. KG that
optimum operating characteristics can be achieved. Should other inks and solvents be
used all guarantee claims will expire.
Product liability!
No alterations whatsoever must be carried out on the entire
LEIBINGER-JET 2 device. No liability will be accepted for damage or
dangers resulting from inadmissible alterations.
Caution – risk of explosion!
The device must not be operated in rooms where there is a risk of
explosion!

Group 1 Introduction Page 13
Release 3.00 Leibinger-Jet 2 se
1.6 Document information
The instruction Release 3.00 of 17th February 2006 is valid for Leibinger-Jet 2 se machines
from the software-version V40.1.00.00.

Group 2 Safety instructions Page 14
Release 3.00 Leibinger-Jet 2 se
2. Safety
2.1 Scope of risks
The high performance printer LEIBINGER- JET 2 has been built in accordance with state-of-
the-art standards and recognized safety requirements and has been equipped with protective
devices.
Operational and safety checks of the installation were carried out before it left the factory. In
case of improper handling or misuse, however, there are dangers for
! the health of the operating staff
! the LEIBINGER-JET 2 and other real assets of the plant operator
! the efficient operation of the high performance printer
All persons entrusted with the putting into service, the operation, the maintenance and the
overhauling of the high performance printer must
! have the necessary qualification and
! strictly comply with this operating manual.
YOUR safety matters!
2.2 Safety instructions and recommendations
This operating manual use the following SYMBOLS with DANGER WARNINGS:
Indicates impending electrical danger!
Failure to observe this instruction can lead to serious injuries or to death!
Indicates a dangerous situation through pressurised media!
Failure to observe this instruction can cause injuries!
Indicates a dangerous situation!
Failure to observe this instruction can lead to material damage or to
injuries!

Group 2 Safety instructions Page 15
Release 3.00 Leibinger-Jet 2 se
Indicates a dangerous situation!
Failure to observe this instruction can cause serious hand injuries!
Indicates a dangerous situation through flammable materials!
Failure to observe this instruction can lead to material damage, to serious
burns or to death!
Indicates a dangerous situation through irritating
materials!
Failure to observe this instruction can lead to poisoning
and to irritation of the eyes, the skin as well as of the
respiratory organs!
Indicates the necessity of personal protective
clothing!
Sufficient protective equipment must be worn. Failure to
observe this instruction can lead to injury!
Indicates the necessity of observing the device
manual and other instructions!
Failure to observe this instruction can lead to material
damage, the loss of guarantee and to injury!
Indicates service activities!
This work must only be carried out by trained personnel or by Leibinger
service technicians!

Group 2 Safety instructions Page 16
Release 3.00 Leibinger-Jet 2 se
Indicates important user information
for safe and effective working.
Indicates recommendations for use
and other useful pieces of information.

Group 2 Safety instructions Page 17
Release 3.00 Leibinger-Jet 2 se
2.3 Intended use
The high performance printer LEIBINGER-JET 2 serves exclusively the contact-free marking,
inscribing and coding of surfaces using the continuous ink jet process.
The high performance printer can be used on the most varying materials (e.g. metal,
synthetic material, glass, paper, wood, pressed materials, rubber etc.) with both, smooth as
well as uneven, rough and stepped surfaces.
The intended use of this device also includes the observance of all
instructions in this manual.
Using the installation for other purposes is considered contrary to
its intended use!
For safety reasons conversions and alterations are only admissible
following consultation with the manufacturer. Repairs to the device must
only be carried out with original replacement parts.
The manufacturer shall not be liable for damage resulting from use for
other than the intended purpose or misuse.
2.4 Sources of danger
Protective devices must neither be removed nor put out of operation.
Defects discovered must be rectified immediately.
Mains connection!
The device has no mains switch and must only be connected to a plug
socket in the direct vicinity of the place of setting up!
Installation of the device
The device must be installed in a well ventilated room only and must be
kept away from any source of heat, flame or sparks, e.g. radiant heater,
etc.
Installation of the print head
The operating staff must not be exposed to danger due to the installation
of the device in a production plant. Moving products under the print head
may cause risk of crushing/cutting. The instructions of the machines
directive must be strictly adhered to

Group 2 Safety instructions Page 18
Release 3.00 Leibinger-Jet 2 se
Caution – risk of explosion!
Risk of explosion in the event of incorrect replacement of the battery.
Replace only with an identical battery or with an equal value battery type
in accordance with the recommendations of the manufacturer! The
instructions of the battery manufacturer must be observed when disposing
of the battery!
Caution – risk of explosion!
The device must not be operated in rooms where there is a risk of
explosion!
Attention – risk of injury!
Your fingers could get caught between the frictional wheel and the
production line. Keep your hands outside the danger area.
Dangerous electrical voltage!
Contact causes serious damage through an electric shock! Disconnect the
device from the mains supply prior to opening. Remove mains plug!
Dangerous electrical voltage!
Contact causes serious damage through an electric shock! The print head
must close automatically. Work on the head must only be carried out in a
closed state!
Dangerous electrical voltage!
Parts of the device are still under voltage after blowing the protecting
device! Disconnect the device from the main supply prior to opening.
Remove mains plug!
Dangerous electrical voltage!
Measurement under voltage has carried out only by electrical experts!

Group 2 Safety instructions Page 19
Release 3.00 Leibinger-Jet 2 se
Risk of crushing/piercing!
During the closing movement of the print head your fingers could get
caught between deflector unit or nozzle plate and gutter or during the
opening movement between housing and gutter. Keep your hands outside
of the danger area!
Risk of crushing/piercing!
During the closing movement of the print head your fingers could get
caught between deflector unit or nozzle plate and gutter or during the
opening movement between housing and gutter. Only carry out cleaning
and service work with the machine placed idle. Remove mains plug!
The content is under pressure even if the device has been
disconnected from the mains supply!
Ink under pressure can spray out. Prior to opening disconnect the device
from the mains supply and let off the pressure!
Risk of fire!
Combustible gases and liquids cause serious burns. Sources of ignition
must be kept away from the print head!
Dangerous material in the machine!
Danger of serious damage through burns, skin irriation and poisoning!
Warning!
Read and understand the device manual before using this machine.
Incorrect operation can lead to injury or damage to the device!

Group 2 Safety instructions Page 20
Release 3.00 Leibinger-Jet 2 se
Dangerous material in the machine!
Read the safety leaflets and the regulations on personal safety
equipment!
Risk of injury!
Spraying of ink into the eyes can cause blindness. Prior to the opening of
the device eye protection must be put on!
Risk of injury!
Ink escapes from the head aperture. Spraying of ink into the eyes can
cause blindness. Eye protection is necessary!
Risk of injury!
Upon contact the contents causes skin irritation. Protective equipment is
necessary!