Leibinger RAPID Series Manual

Technical information
The new LEIBINGER RAPID printer series
Version 1.4

Table of content
Page 3 of 31
Table of content
1Introduction .............................................................................................................4
2Technical data ..........................................................................................................5
2.1 Overview ..........................................................................................................5
2.2 Font - Font height – Font width – Stroke distance – Speed ......................................6
3Features and applications ...........................................................................................7
3.1 Overview about features and applications ..............................................................7
3.2 Printing speed and the quality of printouts .............................................................8
3.3 Print samples ...................................................................................................11
3.3.1 Print samples RAPID Wire .........................................................................11
3.3.2 Print samples: RAPID Highspeed in comparison with RAPID Universal..............11
3.3.3 Print samples: RAPID Universal in comparison with JET3up – 2D codes ..........12
3.3.4 Print sample: RAPID Universal with 70000-00031 ink ...................................12
3.3.5 Print sample: RAPID Wire and Rapid Highspeed cabel printouts.......................13
4Available inks .........................................................................................................14
4.1 Different ink ranges for different printers .............................................................14
5RAPID Wire and Highspeed: The print head ventilation .................................................15
5.1 Basics about the functionality ............................................................................15
5.2 Technical details ..............................................................................................16
6Information about encoders ......................................................................................17
6.1 Basics.............................................................................................................17
6.2 The resolution and the output frequency of the encoder.........................................17
6.3 The specifications of the encoder input of the printer ............................................18
6.4 Recommendations regarding the encoder / Printer combination for high-speed
applications ...............................................................................................................19
6.5 Example for an encoder / printer combination .......................................................19
7Appendix ...............................................................................................................20
7.1 Hydraulic settings and printout parameters...........................................................20
7.1.1 Ink selection............................................................................................20
7.1.2 Print modes.............................................................................................22
7.1.2.1 Available print modes for the RAPID Universal ............................................22
7.1.2.2 Available print modes for the Rapid Highspeed............................................23
7.1.2.3 Available print modes for the Rapid Wire....................................................24
7.2 Print head adjustment: RAPID Wire and Highspeed ................................................25
7.2.1 Adjustment of the ink jet...........................................................................25
7.2.2 Adjustment of the drop production unit .......................................................28
7.2.3 Adjusting the distance between ink jet and ink drop voltage detector ..............31

Introduction
Page 4 of 31
1Introduction
The new high-speed printer series Rapid is designed for all print jobs for which the current
version of the JET3up is not fast enough.
This document provides:
oTechnical data
oDifferences between the features and the possible applications of the available types of
RAPID
oOverview on the available inks
oImportant information about recommended encoders
oOverview on the differences regarding the spare parts
Important Information
There are several significant differences between the JET3up and the printers of the RAPID series.
The differences affect parts of the printer as well as service procedures.
It is highly recommended thoroughly checking the manuals and the
accessories catalogue for the differences between the JET3up and the
JET3 RAPID series.
The following list gives an overview about the parts that are different for the RAPID series in
comparison to the JET3up:
oController board
oParts of the Printhead (please see details in accessories catalog)
oInk valve (VV)
Regarding service and adjustment procedures the main differences are:
oHydraulic settings
oInk jet adjustments
The differences are described in the manuals that come together with the printers.
There are extracts of the manuals in the addendum of this document.

Technical data
Page 5 of 31
2Technical data
There are three types of the RAPID available:
•RAPID Universal
•RAPID Highspeed
•RAPID Wire
2.1 Overview
Type RAPID Wire
RAPID Highspeed
RAPID Universal
Maximum
printing
speed
1000 m/min 800 m/min Up to 30% faster than
the JET3up
Characters
per
second*
5830
128 kHz oscillator
3x7 tower font
5600
128 kHz oscillator
5x5 font
4635
128 kHz oscillator
7x5 font
Oscillator
frequency
128 / 115 kHz
128 / 115 kHz
128 / 115 kHz
Nozzle size
50 µm / 55 µm
Please see ink list in the
appendix for details
50 µm / 55 µm
Please see ink list in the
appendix for details
50 µm / 55 µm
Please see ink list in the
appendix for details
Available
fonts
3x7 tower
4x5
5x5
7x5*
3x7 tower
4x5
5x5
7x5*
Same fonts as JET3up
Up to 32 dots
Print head
dimensions
Available
inks
Please see appendix for a
detailed ink list
Please see appendix for a
detailed ink list
Please see appendix for
a detailed ink list
Possible
substrates
Please see ink list in the
appendix for details
about substrates
Please see ink list in the
appendix for details about
substrates
Please see ink list in the
appendix for details
about substrates
Pressured
air required
Yes. 20 l/min
Yes. 20 l/min
No. Optional available.
*The characters per second value depends on the font and the oscillator frequency. Based on
a standardized printout. The 128 kHz oscillator is not available for each ink/font combination!
**Only available with 50 µm nozzle
43
mm
43
mm
43
mm
217 mm
217 mm
212 mm

Technical data
Page 6 of 31
2.2 Font - Font height – Font width – Stroke distance – Speed
RAPID Wire
Font Height [mm] Recommended
character width [mm]
Recommended stroke
distance [mm]
Speed [m/min]
drop frequency
115 kHz 128 kHz
3x7
1,5 – 2,0
2,0 - 4,0
0,30 – 0,58
521 - 988
580 - 1100
4x5*
1,5 – 2,0
1,4 – 2,5
0,25 – 0,52
341 - 719
380 - 800
7x5** 2,0 – 2,2 1,4 – 2,5 0,25 – 0,52 216 - 449 240 - 500
RAPID Highspeed
Font Height [mm] Recommended
character width [mm]
Recommended stroke
distance [mm]
Speed [m/min]
drop frequency
115 kHz 128 kHz
3x7
1,5 – 2,4
2,0 – 4,0
0,3 – 0,58
521 - 988
580 - 1100
4x5*
0,9 – 2,4
0,9 – 2,5
0,2 – 0,52
234 - 719
260 - 800
7x5**
2,2 – 2,6
1,4 – 2,5
0,25 – 0,52
216 - 449
240 - 500
*there is also a 5x5 font available. With the 5x5 the maximum speed is a bit lower
**Only available with 50 µm nozzle
RAPID Universal
Same fonts as JET3up with print styles up to 32 dots. Recommended printing distance: 15mm.

Features and applications
Page 7 of 31
3Features and applications
The three types of printers of the RAPID series provide different features and they are designed
for different kinds of applications.
3.1 Overview about features and applications
Type RAPID Wire
RAPID Highspeed
RAPID Universal
Features •1000 m/min
maximum printing
speed in high quality
•A special print head
provides a very short
distance between
print head and
substrate.
•There are several
approved inks
especially for cable
applications available
•
Up to 800 m/min
maximum printing
speed in high quality
•There are several
approved inks
available for various
applications and
substrates
•
Up to 30% faster
than the JET3up
•There is a broad
range of approved
inks available for
various applications
and substrates
•There are the same
fonts available as for
the JET3up
Applications •Cable/wire marking
and printing
•High speed printing
on substrates that
are adapted to the
special print head
•High speed printing
with a maximum
print height of
2,5 mm.
•JET3up applications
that require higher
production speeds
especially if there is a
2- or 3-line print out
required. E.g. filling
systems or bottling
plants.
Restrictions •There is a smaller
range of approved
inks available than
for the JET3up
•There are only three
fonts available:
o3x7 tower
o4x5
o5x5
o7x5*
•The diameter of the
substrate must not
be larger than 5 mm.
•There is a smaller
range of approved
inks available than
for the JET3up
•There are only four
fonts available:
o3x7 tower
o4x5
o5x5
o7x5*
•The recommended
distance between
print head and
substrate is 5 mm.
Shorter distances
bear the risk of
contaminating the
print head, larger
distances may have a
negative effect on
the quality of the
printouts.
•There is a smaller
range of approved
inks available than
for the JET3up
•For optimal results
the recommended
distance between
print head and
substrate 15 mm.
Shorter distances
bear the risk of
contaminating the
print head, larger
distances may have a
negative effect on
the quality of the
printouts.
*Only available with 50 µm nozzle

Features and applications
Page 8 of 31
3.2 Printing speed and the quality of printouts
Each printer type of the RAPID series could be used for production speeds up to 1000 m/min.
However, the quality of the printouts would not be acceptable using the wrong printer for a
certain speed.
Therefore, it is important to know which type of printer to select for which speed.
RAPID Wire
The RAPID Wire comes with a special print head that allows a nearly zero distance between print
head and substrate. This makes it possible to work at the highest speeds.
The print head of the RAPID wire is designed especially for printing on wires. Nevertheless, the
print head may also be used for all other kind of products as long as they fit to the special design
of the print head.
Due to this design, the print head should only be used for substrates with a diameter smaller
than 5 mm. For substrates with a larger diameter or thickness, it is recommended using the
RAPID Highspeed or the RAPID Universal.
The print head of the RAPID Wire: designed for wire printing at high speeds
The illustrations show the special print head of the RAPID Wire printer with wires of different
diameters. It is important to get the wire, respectively the print head, in a position that
provides good print out results.
The closer the substrate is positioned to the outlet of the print head the better will be the
quality of the print out at high speeds.
It has also to be considered that the diameter of the wire affects the position of the print out
on the cable.
5 mm
5 mm
Wire diameter = 4 mm
Wire diameter = 2 mm
43 mm
217 mm

Features and applications
Page 9 of 31
Rapid Highspeed
The RAPID Highspeed comes with the same print head technology as the RAPID Wire but with a
different head cover. The headcover of the RAPID Highspeed is designed for high-speed
applications that:
•require a larger distance between print head and head cover
•whereby the recommended distance is 5 mm
•and/or for substrates that are not suitable for the RAPID Wire print head
With the special design, it is possible to mount the print head in a slightly inclined position. This
will prevent the printer from becoming contaminated by bursting ink drops.
Due to the larger distance between print head and substrate, the operation speed of the RAPID
Highspeed is a bit lower than with the RAPID Wire.
Whereby the difference is not based on technical restrictions but on the quality of the printouts.
Which means that the RAPID Highspeed may be operated at the same speed as the RAPID Wire
but the quality of the print outs are not expected to be as good as they are with the RAPID Wire.
The print head of the RAPID Highspeed: The slightly angled surface allows an optimized
mounting of the print head.
Ink drops that hit the surface of a substrate
tend to burst in smaller drops and not all
drops are absorbed by the substrate.
When the print head is mounted vertically, the
bursting ink drops may lead to a faster
contamination of the print head.
With the angled surface of the outlet side of
the print head, it is possible to mount the
print head in a slightly inclined position.
The ink drops will not hit the substrate at a
90° angle. Therefore, the bursting ink drops
will take a direction away from the outlet,
which will lead to less contamination of the
print head.
Generally: the distance between print head and substrate should not be below 5 mm in order
to avoid the contamination of the print head by rebounding ink drops. A larger distance may
have negative effects on the quality of the printouts.
Recommended: 5 mm
Recommended: 5 mm
43 mm
217 mm

Features and applications
Page 10 of 31
RAPID Universal
The RAPID Universal comes with the same print head as the JET3up. The main difference to the
JET3up is the higher oscillator frequency of the RAPID Universal.
With an oscillator, frequency of up to 128 kHz the RAPID Universal allows a 30% faster
operating speed than the JET3up with a 96 kHz oscillator frequency.
The RAPID Universal provides also the same fonts as the JET3up. Therefore, the higher
operating speed is available not only for a special range of high-speed fonts but for the whole
range of fonts.
If, for instance, a print job for the JET3up with a 32 dot high quality font allows a printing speed
of 30 meter/minute, it will be possible to print the same job with the RAPID Universal at a speed
of around 40 m/min.
In order to reach a good quality for the print outs at the faster speeds the recommended distance
between print head and substrate is 15 mm.
The print head of the RAPID Universal: From the dimensions, the print head is equivalent to
the SK6 print head of the JET3up.
The print head works with the same range of fonts as the JET3up. Due to the higher operating
speeds, the recommended distance between print head and substrate is 15 mm.
Shorter distances bear the risk of contaminating the print head; larger distances may have a
negative effect on the quality of the printouts.
Recommended:15 mm
43 mm
212 mm