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information
KBA Rapida 75
KBA-Grafitec s.r.o.
Opocenska 83, 518 19 Dobruska, Telephone 00420-494 672 371, Fax 00420-494 622 460
E-mail: office@kba-grafitec.cz, Internet: http://www.kba-grafitec.cz
KBA-Grafitec s.r.o.
Identification No.: ZTI_RA75_2008_A_3Q_EN (00)_V1 / 12.8.08
ZTI_RA75_2008_A_3Q_EN (00)_V1 / 12.8.08 KBA-Grafitec s.r.o. 2
Rapida 75 basic technical information
1. Introduction ............................................................................................................................ 5
1 Introduction
KBA Rapida 75 is available in two format classes. The standard equipped machine allows B2
format of 530 750 mm, optional equipment moves the machine into extended B2+ format of
605 x 750 mm.
The range of the RAPIDA 75 machines gives customers choice of designs and equipments.
With its versatility, the RAPIDA 75 covers wide application field in small, medium as well as
large printing shops for widest range of printed materials including the most demanding fine art
reproduction works.
The machines operate on the offset printing basis at which the positive image from the printing
form is transferred onto the offset roller blanket and then to the sheet transported by the
pressure roller of a double diameter, in all printing units successively.
Excellent register parameters of the machine at printing guarantee high-quality print of multi-
colour printed matters on all suitable types of paper.
Activation of printing pressures, inking unit control, engagement of ink rollers and other
functions are control system commanded.
All safety elements comply with the requirements of stringent safety regulations inc. CE
and GS standards.
A Machine control
C Machine drive
D Feeder
E Feeding head
F Ionization
G Conveyor
H Face lay
Z Side lay
I Pregripper
J Dampening unit
K Dampening aggregate
L Inking unit
M Form rollers
N Offset rollers
O Pressure rollers
Q Delivery
R Infrared drying
S Powdering device
U Central lubrication
The main machine control element consist in central touch screen display located on a turntable
console of the delivery. Most important functions of the machine can be controlled from this
place. Other control elements are positioned on the control panels of printing units and feeder.
They are used for direct control of functions of the respective part of the machine. The control
panels are easily accessible for the operator of the machine. Their face area with pushbuttons
is covered with a foil keyboard, which makes maintenance and cleaning of panels considerably
easier.
GS safety standard
The assembled sides of the printing units, feeders and deliveries form separate units. They may
be disjointed (for transportation).
The drive of all printing rollers and inking unit rollers is derived from outside positioned angular
gearing. The gearing is automatically central lubricated. The main electric motor drives the
transfer roller on a given printing unit (in the middle of the machine, according to total number
of printing units) with a belt and gear transmission and with co-engaging gears of another
printing unit. The main electric motor is equipped with a separately energized independent
brake that will stop the machine in case of activation any safety element.
3.1.5 Feeder
The feeder guarantees proper sheet loading in the machine. The feeder head (described
separately below) is its most important part. The working height of the pile is controlled with the
feeder head caliper and can be adjusted by height setting of the complete feeder head. The
feeder is adapted for palettes. The palette is to be positioned behind the board (the palette
trolley can be approached using the wedge supplied). Side feed of the complete board with
palette can be used for correction of inaccuracies in sheet pile alignment.
3.1.8 Ionization
3.1.9 Conveyor
Electro-mechanic
double sheet detection
Thrust pulleys
Sheets are transported on the bottom face lay that consists of a shaft with 8 stoppers. The shaft
with stops can be shifted in a small range in the printing direction and its right- and left-hand
parts can be deflected opposite to each other. This allows compensating minor face or diagonal
deflections when adjusting register.
All stops of the face lay are provided with a pulley that prevents in damage of the reverse side
of sheet when it is passing through the stops.
In the two stops of the face lay, there are optical barrier sensors for sheet detection on the face
lays and skewed sheets detection. Two pneumatic cylinders designated for safe catching and
blocking of the incorrectly loaded sheets so that they could not get in the first printing unit
operate in close cooperation with the system for sheet monitoring on the face lays.
Side alignment of the loaded sheets is provided with two vacuum side lays - for each direction
of side aligning. Adjustment of positions of both side lays can be made on the attended side
using the handle. Side lay adjustment can be carried out even during machine operation. The
lay design itself allows using one or more suction chambers, which has effect on the the force
of sheet pulling. Thanks to slots in all channels, jamming with paper dust is eliminated.
3.1.15 Pregripper
The machine is equipped with a lower swinging pregripper that will grip an aligned sheet when
at rest, then will accelerate it smoothly to the speed of the machine and hand it over in the
grippers of the subsequent transfer roller.
The pregripper is equipped with a device for pregripper grippers blocking in the open position.
This device prevents in gripping an incorrectly fed sheet with the grippers of the pregripper and
its subsequent transport in the machine.
As all the rollers with grippers, the pregripper uses stop boxes with special plastic filled grooves
on the surface filled with plastic. This allows precise sheet transport and eliminates paper dust
accumulation.
With multicolor machines (RA75-4 and higher) temperature of dampening solution can be set
within the range from 8 to 15C ( 46 to 59F) with recommended setting to 10C (50F), IPA
dosing can be set within the range of 0 to 15%.
RAPIDA 75-4
RAPIDA 75-2 RAPIDA 75-6
RAPIDA 75-5
Technotrans aggregate alpha.d 10 alpha.d 20 alpha.d 30
1x230V, 50Hz [kW / A] 0.9 / 6.3 2.2 / 10.8 -/-
Electric 1x230V, 60Hz [kW / A] 1.1 / 6.5 2.2 / 11.4 -/-
connection 3x400V, 50Hz [kW / A] -/- -/- 2.7 / 5.8
3x480V, 60Hz [kW / A] -/- -/- 3.3 / 6.2
Supply line protection (user provided) [ A] 10 16 10
[mm] 942 x 470 x 567 1,155 x 654 x 800
Dimensions - height x width x depth
[inch] 37.1 x 18.5 x 22.3 45.5 x 25.7 x 31.5
kg 105 225
Operational weight
lb 231 496
When printing on some types of paper that tend to dusting, dirt of variable character is released
from paper. This dirt mostly adheres to the printing plate and causes deterioration of printing.
Optional modified drive of dampening rollers is offered, which make slight speed difference
between the form roller and the dampening roller. In this way created relative movement (shear)
will remove all mechanical dirt from the printing plate very effectively. A slight increase of
dampening roller wear may occur within the mentioned option use, depending on setting of the
dampening unit rollers.
Inking unit is equipped with hollow rollers and therefore can Distribution phasing with respect
be additionally equipped with inking unit temperature to the form roller
stabilization system.
3.1.20 Distribution
Optional inking roller axial movement mechanism is available. It allows achieving the required
printing quality in case of some expensive jobs. Distribution setting is comfortable without use
of tools after cover opening.
3.1.22 alpha.c
.
RAPIDA 75-5
RAPIDA 75-2 RAPIDA 75-4
RAPIDA 75-6
Technotrans aggregate alpha.c 60 alpha.c 90 alpha.c 120
3x400V, 50Hz [kW / A] 8.2 / 16.5 9.6 / 19.5 11.5 / 23.9
3x480V, 60Hz [kW / A] 10.4 / 17.5 12.1 / 20.5 14.5 / 25.5
Supply line protection (user provided) [ A] 20 25 35
[mm] 1,300 x 1,400 x 700
Dimensions - height x width x depth
[inch] 51.2 x 55.1 x 27.6
kg 105 225
Operational weight
lb 231 496
3.1.23 Fluidos
Standard equipment of the machine includes the combicontrol.m while alcocontrol and
alcosmart AZR units are optional.
All printing rollers are cast iron castings or precise steel workpieces. Form and offset rollers are
provided with contact rolling shoulders that increase mutual rigidity. The printing rollers are
driven with angular gears on the external side of the unattended sides. The pressure rollers and
transfer drums between printing units have double diameter when compared with the form and
offset rollers.
The surface of the form rollers is coated with a special ceramic material that guarantees its long-
term service life and absolute immunity with respect to chemical agents. RAPIDA 75 press is
provided with the semi-automatic plate loading device as standard. The form rollers are
equipped with quick clamping bars with a rear expanding bar that allow easy printing plate
clamping and stretching. The clamping systems are designated for aluminium plates with
thickness of 0.2 to 0.3 mm.. The printing plate clamping process is semi-automatic; it is
controlled from the panel of the respective unit. All the roller control mechanisms are
pneumatic, for higher reliability. There are no electronic apparatuses in the roller. The form
rollers can be turned radially and shifted axially remotely from the control screen of the delivery
while the machine is running, which reduces time required for printing form setting in the
To accelerate machine register adjustment, the machines are provided with the BACHER
CONTROL 2000 register system for printing form setting. It is possible to order punchers and
installation and copying bars.
There are frequently cases when the motif has to be rotated during register adjustment. The
device for remotely controlled motif diagonal cocking positioned on the transfer roller allows
compensating machine register diagonal deviation during machine operation and even during
printing.
Principle of operation is as follows. The transfer roller flange is eccentric, turning it (using
the motor), the transfer roller axis deflection occurs, resulting in motif turning.
The total control range of the diagonal register on each printing unit is 0.12 mm (0.005). Within
the operational range, the printing forms must be copied precisely. The required precision of
mutual position of the printing image with respect to the centring holes in the face direction must
be within tolerance of 0.1mm (0.003). Control of the diagonal cocking is possible from either
the ErgoTronic remote control desk touch screen display or from the delivery panel touch
screen display.
In case of semi-automatic printing form loading, only the first of the steps listed above has to
be carried out manually. The other steps are carried out automatically without operator's
intervention. Select the semi-automatic loading mode and the numbers of the printing units
where this operation will take place using the touch screen in the automatic loading menu. Then
operator can continue with the preselected printing units to load the form.
The procedure of printing form removal is also programmed semi-automatically in a similar way.
The device allows clamping both new and used printing forms with thickness of 0.2 to 0.3 mm
(0.008 to 0.012).
Before clamping, the printing form rear edge is to be bent by the angle determined. Use delivery
included bending device to the purpose.
The device indicates loss of sheet in the machine (its absence on the pressure roller). In case
that sheet absence on the pressure roller is detected, the machine will disengage the pressure
rollers from pressure and stop sheet loading. The device is suitable for printing on thin paper
where there is a risk of sheet sticking on the offset roller and its subsequent tearing out of the
pressure roller grippers.
The transfer drums between the printing units are of a double diameter and provided with two
gripper systems. Each gripper system is provided with 12 grippers and is removable from the
machine without drum removal. The seating areas of the roller grippers are coarsened and
provided with a tungsten carbide coat that provides gripper holding force. The seating flats of
the stops (boxes) are provided with special grooves with plastic coat resistant to choking with
paper dust.
3.1.35 Delivery
The discharging drum of the delivery is standard shipped without optional guiding sheets. Upon
a request the SuperBlue system is also available to complete the delivery discharging drum.
The delivery allows the printed sheet palette bothsided balancing . A palette trolley with fork
spacing 535 mm (21) max is required to do so.
Powdering device
Sheet guiding through the machine is carried out mostly with chrome-plated sheets shaped
according to paper path, adjustable segments and with blowing in some places in order to
prevent in sheet damage.
There are smooth chrome-plated sheets over the pressure rollers in the standard variant; these
sheets together with standard chrome-plated guiding sheets on the transfer drums (see 3.1.33)
create the most suitable solution in order to prevent in damage of prints. The solution is
recommended for printing on all standard types of paper and paper with higher square weights.
Upon wish, it is possible to substitute smooth guiding sheets above the pressure rollers with
chrome-plated wires. The guiding wires are side adjustable and for that reason, they can be
positioned so as to guide sheet in its unprinted part. Moreover, this solution allows easier
access to the pressure roller e.g. during washing it. If the machine is equipped with guiding
wires over the pressure rollers, guiding sheets over the pressure rollers are not supplied.
After achieving the specified machine speed programmed in the machine control system, the
lubrication system will deliver the required quantity of lubricant in the places where it is
necessary. Besides this, there are places on the machine which have to be lubricated in
intervals given by the Maintenance Manual or a lubrication schedule.
The air distribution system provides main machine functions in the area of the feeder, delivery
and complementarily also in the printing units in the path of sheet passage. A dry rotary
compressor is a source of pressure and vacuum air in the feeder area.
Low-pressure blowers positioned under the delivery and controlled with frequency converters
from the delivery touch screen are used as a source of air in the delivery.
Pneumatic elements allow control of machine functions both with the automatic system and
machine control with pushbuttons from control panels and control screen.
The pneumatic circuit is driven by a dedicated compressor. The compressor is also available
as noise-damped.
As standard the machine comes with blowing hose useful eg. for machine maintenance and
cleaning.
If the printing shop is equipped with a compressed air central distribution system, the printing
press can be installed without this source, however, it should be provided with air regulation
and filtration system. Pressure in the pneumatic distribution system is 0.6 MPa (87 psi).
The automatic washing devices are controlled using the touch screen display positioned on the
delivery panel. The main functions of the washing devices are pneumatic controlled. The
washing cycle takes place automatically after preselecting a washing program. Washing
program setting can be done on the touch screen after recalling a respective washing menu.
Three levels of washing intensity presets depending on the level of soiling, a choice of washing
using a cleaning agent or cleaning agent with water and a selection of printing unit to wash are
available.
Functions of the washing devices are monitored and potential defects are indicated on the
screen. It is possible to use cleaning agents on the basis of both mineral and vegetable oils (for
environment friendly cleaning agents) for washing.
The device for inking unit automatic washer is designated for quick washing inking unit rollers
from ink, dust or other dirt.
Collection pan for wiped dirt, cleaning agent and water wiped
off
Washing is performed at abt. 7,000 rph.
Bar with nozzles from which cleaning agent and water is Automatic washer
applied on the surface of the offset blanket for offset blanket,
The body with the textile belt wiping the offset roller
surface.
The body is removable from the machine; it is locked in the machine using pins and pawls.
Replacement of the used contaminated textile belt by a new one can be carried out after washer
removal from the machine. Washing takes place at minimum machine speed.
Use of densitometer with polarization filter is more usual in European countries. Densitometer
without polarization filter is mostly used in the USA.
TECHKON DENSITRONIC
Simple, manually controlled apparatus Sophisticated, fully automatic apparatus
Allowing control strips measuring only, removed
Allowing both, control strips and point
from bracket it operates as a manual
measuring on a sheet
densitometer
Sheet is held by vacuum on the travel path
Sheet is free during measuring
during measuring
Background area colour - black, exactly
Background area colour - matching the panel
consistent with the ISO 12647 standard for
colour (grey)
colour measuring
The control strip must be positioned with high The measuring head is able to correct
precision in parallel with sheet edge imprecisions in control strip positioning
Automatic calibration. White and black
Calibration using calibration card
calibrated before every measuring.
Servo mechanism for zone control is provided with a mechanical stop preventing in
blade damage in case of potential failure of the electronic system;
Calibration module - intuitive control for resetting of ink duct opening, eg. if worn.
Control panel
1. Mechanical part
2. Electric part
CIP4 integration is an important element for improvement of quality of production together with
reduction of costs (Cooperation for Integration of Processes in Prepress, Press and Postpress).
CIP4 is a name of organization (www.cip4.org) established from a free association of
companies known as CIP3. CIP4 brings technology for automation of the printing job
processing management with emphasis upon interconnection of all production stages from
customer service up to shipment. KBA-Grafitec company is a member of the CIP4 organization;
PPF and JDF standards have been defined within CIP4.
PPF format (Print Production Format) is an international standard used for data description in
the process of printing job processing. PPF file contains detailed data on the job (such as job
name and author, customer, times and terms, previews of individual colour separations,
transfer functions, definitions of register marks and densitometric fields or data for finishing
operations). Most information enters the PPF file in the prepress stage, then data become
available for next production steps, reducing data entering repeatedly. The archived PPF files
can be used again in case of job repeating.
JDF (Job Definition Format) is a new universal standard independent of the platform and able
to interconnect various stages of the printing job production process and to it related operations
perfectly. It is based on experience and knowledge from already existing technologies
developed under the auspices of CIP4. In order to guarantee full compatibility, it includes also
PPF standards based on CIP3 and PJTF (Portable Job Ticket Format) by Adobe.
Using JDF, it is possible to describe a job from the first steps when it is discussed with the
customer up to packing and shipment to the customer. We meet also the term JMF (Job
Messaging Format) in association with JMF. JMF holds a function of a standard communication
language among various devices of your printing shop or between these devices and your MIS
Management Information System. The term MIS means an economic and planning system of
the printing shop. However, in order such interconnection could operate and we could utilize
the potential offered by JMF, it is necessary to use such devices and applications that
understand JMF messages and are able to receive and dispatch them and to respond them in
an adequate way. The MIS system generates so called job tickets (messages containing
working tasks) and sends them to the respective devices. Individual devices inform the MIS
system back on the current status of their task during working tasks (job tickets) processing.
The ErgoTronic system allows utilizing data in CIP4 formats for quick presetting of the printing
press for a printing job so that information on the printing job from a selected JDF/JMF or PPF
file (previews of individual colour separations, transfer functions, etc.) are processed with the
ErgoTronic system and subsequently used for presetting individual ink ducts and colour
ductors.
The ErgoTronic system allows in association with the standards defined by CIP4:
printing press presetting (ink ducts, ductors) on the basis of digital pre-press data
obtained from CIP4 technology
printing press setting using CIP4 technology for standard process colours (CMYK) as
well as special customer's colours
modification of presetting obtained from CIP4 data before proper setting of ink ducts
and ductors
machine presetting for printing both face and reverse sides according to CIP4 data
definition
automatic printing job centring
automatic trimming in case that preview exceeds printing area
printing press presetting according to factory predefined or user correction curves
The ErgoTronic system can be incorporated into both a system using PPF files and JDF
workflow system:
PPF files are complemented with previews of individual colour separations (or potentially
generated) simultaneously with data creating for the CTP system.
There are two ways to transfer PPF files into ErgoTronic system:
The ErgoTronic system is incorporated in the local computer network together with the other
devices supporting JDF standard. RIP generates JDF ticket for the ErgoTronic system together
with creating data for CTP. The JDF ticket contains previews of individual colour separations
similarly like PPF file in the case described above. The ErgoTronic will receive the JDF ticket
pertaining to it and allow its processing. During printing job processing, the ErgoTronic system
enables to send reverse information on the status of the printing job in the JDF ticket generator.
The ErgoTronic system is incorporated in the local computer network together with the other
devices supporting JDF standard. Then ErgoTronic remains waiting for a message sent by JDF
ticket generator of the MIS system. The JDF ticket contains previews of individual colour
separations (similarly like PPF file). The ErgoTronic will receive the JDF ticket pertaining to it
and allow its processing. During printing job processing, the ErgoTronic system enables to send
reverse information on the status of the printing job in the JDF ticket generator.
Environmental benefits:
Less waste thanks to quicker printing press and finishing machines and from this fact
resulting lower consumption
Support of CTP systems and from this fact resulting elimination of chemical agents
for film developing.
Tool for complex description and monitoring of a printing job in broader context
Perfect job definition
Support of all production processes
Better control over printing shop production flow
Mean for more effective planning and economic assessment
In accordance with the current trends in improving printed matters, a lacquering device for full-
value powerful in-line lacquering has been developed. This device represents an option for the
machines of the RAPIDA 75 series and is designated for high-quality area and partial
lacquering with dispersion lacquer.
The benefits of the machine equipped with the lacquering unit consist above all in higher
efficiency of job processing. Powdering can be reduced to minimum. The job can be dispatched
for next processing almost immediately after printing and lacquering.
Resistance of the printed sheets against doubling and mechanical damage. The lacquered
sheets are considerably more resistant to water and the printed colours better resist to fading
out as a result of sunshine. Impressive visual and utility effects can be achieved by use of highly
gloss, pearl or metallic lacquers.
lacquering unit; it is used to transfer uniform film of dispersion lacquer on the sheet
even at maximum printing speed
lacquer circulation system; its main function consists in providing lacquer supply in
the lacquering unit
Powerful IR and hot air drying; it is used for perfect drying lacquered sheets even at
maximum printing speed
Extended delivery; it extends drying path and is used for positioning of powerful
drying units
1) Lacquering unit
2) Lacquer circulation
system
3) Drying
4) Extended delivery
Lacquering unit
1) Transfer drum
2) Pressure roller
3) Raster roller
4) Chamber doctor
blade
Lacquer quantity transferred on paper is determined with raster roller raster density. A standard
printing shop specializing in a certain segment of printed matters will usually have 2 to 3 raster
rollers with different raster values. The raster value of the raster roller is stated using a number
that indicates number of lines per 1 cm (1 inch) of length. In case that raster roller relief is not
represented with depressions, but with a spiral micro-groove (Haschur), LR marking follows
after the number specifying the raster value. It applies generally that the rollers marked with LR
transfer higher quantity of lacquer at the same raster value and the lacquered surface has
better quality from the viewpoint of visual perception, however, such roller is a little bit more
expensive when compared with the roller with depressions. Common available rollers have
raster value ranging between 60 and 120 l/cm (152305 l/inch).
Basic features of several raster rollers are listed in the table below. However, the values are
only approximate. They will differ between various manufacturers of raster rollers and depend,
among other, also on the type of lacquer used.
The standard variant of the lacquering unit is fitted with the raster roller with raster density of
100 l/cm (254 l/inch). Raster roller of this kind is to perform appropriate thickness lacquer
coating to avoid printed sheets deterioration.
Replacement of the raster roller in the lacquering unit represents an easy, manual and short
task for the machine operator. It is necessary to pay increased attention when handling the
raster roller. Its operational surface is hard, however simultaneously also very brittle. Any
damage of roller surface will be subsequently apparent on the lacquered area. The raster roller
weight parameter is then important from this viewpoint. The weight of the roller made of
aluminium alloy is approximately 25 kg (55.1 lb) and weight of steel roller is approximately 75
kg (165.3 lb). However, the aluminium alloy roller is approximately by 10 to 15% more
expensive.
The lacquering unit allows area or partial lacquering. Use of a lacquering blanket that is
clamped on the lacquering roller is the simplest and also the most cost effective alternative of
area lacquering. The area for lacquer transfer is to be created by lacquering blanket padding.
The pads are calibrated papers of the corresponding dimensions and thickness that are
mounted to the lacquering roller body in a simple way. For a precisely demarcated area or for
partial lacquering, is is suitable to use so called "stripping" blanket. This blanket is designated
for manual cutting or for machine cutting using a cutting plotter. The places that should not
transfer lacquer will be stripped manually after preliminary cutting. This will create lacquering
relief formed with height differentiated areas on the lacquering blanket. The lacquering blankets
are offered by all reputable suppliers of offset blankets.
In order to achieve register between the printed and lacquered images, the lacquering roller is
equipped with a device for fine adjustment of the axial and peripheral register within the range
of 2mm (0.08). This device can be used even if the machine is in operation and is controlled
manually. The surface of the lacquering roller can also be turned by 50 mm (2") in the direction
from collection edge. This operation is carried out manually and only in the machine is idle.
The complete system includes also a set of suction and discharging tubes that are positioned
in the tank with lacquer and in waste tank during lacquering unit operation. If the operational
mode of the lacquer circulation pump is changed (lacquering - discharging - washing), it is not
necessary to remove these tubes from the tanks. The lacquer circulation pump requires
compressed air supply for its operation. This supply is represented by a compressor that is
included in the delivery and is powered from the printing press itself. The compressed air circuit
includes also an air drier that is also included in the delivery.
3.2.3.3 Drying
Drying of a lacquer coat during the sheets travel is a vital part of the process.
Dispersion lacquers contain a considerable share of water that must be removed from the
lacquered sheet surface before its unloading in pile. A powerful drying system is used for this
purpose. Two components participate on dispersion lacquer drying - IR radiation and hot air.
The task of IR radiation is lacquer heating in order to release water in ambient atmosphere. In
this way created moisture is absorbed with hot air that is subsequently discharged from the area
of the delivery. Gaseous products arising during drying that would annoyed the operator of the
machine with odour are discharged simultaneously with moist air from the area of the loader.
Two disengaging cartridges installed in the area of the delivery are source of both drying
components. The first cartridge contains 3 IR radiators and 3 hot air units. The consequent
cartridge contain 4 sources of hot air.
Of course the IR as well as the hot air output is continuously controllable and adjustable for any
combination of printed materials.
The drying system contains a box positioned close to the delivery. Cables and abundantly
dimensioned air hoses lead out to the delivery. The box contains drying system control and two
powerful blowers - one for air supply in hot air radiators and the other one for moist air
exhaustion from the area of the delivery. Waste air can then be discharged directly in
atmosphere.
There is a touch display on the front wall of the drying system box; this touch screen is used for
control of the drying system. Besides the possibility of mutually independent adjustment of
output of IR radiators and hot air supplies, it is possible to save various settings of the drying
system for different printed materials and different printing conditions using the display. This
function can then be used by the operator for quick setting of drying parameters for repeating
jobs by reading the saved data with the control system and immediate carrying out the required
setting-up.
The drying system can be used also for drying of non-lacquered prints. Hot air drying remains
off and the output of the IR radiators is reduced adequately. It is advantageous to save such
setting of the drying system and to use it repeatedly. The drying system is a product of GRAFIX
GmbH (www.grafix-online.de).
Dispersion lacquer drying is energy highly demanding and this should be considered for electric
supply design to the printing press - see the table below.
The extended delivery of the printing press is also a part of equipment for powerful lacquering
with dispersion lacquer. It was created by inserting extension in the horizontal part of the
existing high delivery. The extension length is 1,410 mm (55.5"), adapted to facilitate insertion
and connection of drying system cartridges. The selected concept of extension itself and its
covering allows simple and comfortable handling the drying system cartridges. The extension
includes also sheet guide that allows influencing sheet passage. The sheet guide consists of a
chrome-plated steel sheet with holes through which it is possible to supply compressed air
under passing sheets or to exhaust air under sheets. Moist air is exhausted from the area
between the lower and upper branches of the chain track with two tubes of a large diameter.
Some parameters of lacquering unit periphery devices are listed in the table below.
45 Central lubrication x x x x
46 Becker 40, 80 compressor x x x x
47 Compressor hose for blowing x x x x
48 Benches on non-attended side x x x x
1 Starter Kit x x x x
16 Bacher puncher x x x x
17 Bacher copying bar x x x x
18 Bacher installation bar x x x x
31 CIP4 interface x x x x
32 ErgoTronic InkControl x - - -
33 Densitometr TECHKON k ErgoTronic x x x x
34 DENSITRONIC x x x x
35 Without Ergo Tronic - x x x
36 Ergo Tronic x - - -
KBA-Grafitec s.r.o.
Opocenska 83, 518 19 Dobruska, Telephone 00420-494 672 371, Fax 00420-494 622 460
e-Mail: office@kba-grafitec.cz, Internet: http://www.kba-grafitec.cz
KBA-Grafitec s.r.o.
Ident. slo: ZTI_RA75_2008_A_3Q_EN (01)_V1 / 22.8.08
Rapida 75 Basic technical information
The machine is shipped in partial assemblies. Packing and shipping to the contracted
arrangement also available.
RAPIDA 75-2
RAPIDA 75-4
RAPIDA 75-5
RAPIDA 75-6
RAPIDA 75-6L
Types of packing:
On skids
Skids are suitable for intrastate truck transport directly to the customer with transport time within
two days. Parts of the machine are fixed to the skids with cross section of 100x200 mm. The
main parts of the machine on skids are anchored to the truck body using anchoring prisms and
covered with PE foil. Protection against corrosion is provided by application of preservation oil
only.
On floors
Crate floor is compliant with European international truck direct transportation within the total
transport period of twenty days. The main parts of the machine are fixed to the floor skids. After
inserting siccative, the front part of the machine is covered with foam PE and top part of PE
packing and packing is sealed. Contact with marine aerosol is not recommended.
In crates
Crates are used for European, Euro-Asian and overseas combined transport with consequent
direct transport within total transport time of 100 days. Packing in crates can be selected
according to the method of protection against corrosion:
European packing with the main machine parts protected by PE packing and
siccative. Accessories and removable parts are protected only with oil. The protection
period is 3 months for Europe-like climate environment. Contact with marine aerosol
is not recommended.
Overseas packing with multi-layer PE-AL-PET protection and siccative with
protection of all elements in crates. The machine is protected for the period of one
year for Europe-like climate environment. Marine transport and storage in harsh
climatic conditions shorten the storage period.
It is necessary to provide sufficient area for machine unpacking, i.e. to allow access of lifting
mechanisms or other lifting systems.
It is advisable to have abundant space available. It is also necessary to remember that the
distance between the place of unpacking and place of erection should be as short as possible
and this area should be provided with relatively even and solid floor (road) on which it is
possible to transport machine parts in the final installation place. The following illustrations
apply to handling the unpacked machine parts using a crane.
1. The lifter is intended for lifting of printing unit series 74 and 66 only.
2. Before each use of the lifting equipment, check whether individual parts and welds are in
perfect conditions.
3. Carry out installation of the lifting equipment in accordance with the attached diagram.
4. After putting on the ropes, install struts (minimum rope length - 4 metres).
8. Any defects detected during operation must be reported to the crane operator.
9. According to CSN 27 0144 standard, only the laboratory for testing lifting means is
authorized to carry out any repairs and modifications of the lifting device.
10. Every 6 months, the lifter should be inspected and tested by a competent authorized
body.
11. According to CSN 27 0144 standard, records of the results of tests, inspections and
repairs should be maintained.
12. The personnel who use the lifting device must be familiarized in a demonstrable way with
its use by the crane operator.
13. Welds should be made in the second qualification grade in accordance with CSN 05
1305.
RAPIDA 75-2
RAPIDA 75-4
RAPIDA 75-5
RAPIDA 75-6
RAPIDA 75-6L
2) lifting rod 3) strut 4) support 5) support
6) jamb 7) jamb 8) jamb 9) jamb
10) fitting 11) washer 12) M12x30 bolt - modification
13) M12x80 bolt - modification
RAPIDA 75-2
RAPIDA 75-4
RAPIDA 75-5
RAPIDA 75-6
RAPIDA 75-6L
It is necessary to select a suitable place for final positioning of the printing press. It should
positioned so as it would not be positioned in place exposed to intensive sunshine, in the
proximity of heaters of places of more intensive air circulation. Unsuitable positioning causes
frequently printing problems. Virtually the same applies to printing shop environment like to a
paper warehouse, i.e. temperature range of 20C 4C (68F 7F) with relative humidity of
55 to 70%. Environment dustiness should be maintained as low as possible. Machine
positioning in the recommended minimum area is illustrated in the figures below.
RAPIDA 75-2
RAPIDA 75-4
RAPIDA 75-4L
RAPIDA 75-5
RAPIDA 75-5L
RAPIDA 75-6
RAPIDA 75-6+L
The figures above illustrate auxiliary systems of the printing press that are identified with letters.
These systems are listed in the table below according to these letters together with data for the
installation.
RAP IDA 75-4 Ba sic m a chine RAP IDA 75-5 Ba sic m a chine
w ith (Gra fix drye r ha s se pa ra te w ith (Gra fix drye r ha s se pa ra te
la cque ring unit pow e r supply) (38 kV A) la cque ring unit pow e r supply) (41 kV A)
P ower s upply P ower s upply
V oltage Current V oltage Current
line protec tion line protec tion
208 V /60 Hz 100 A 100 A 208 V /60 Hz 113 A 125 A
220 V /60 Hz 100 A 100 A 220 V /60 Hz 107 A 125 A
240 V /60 Hz 91 A 100 A 240 V /60 Hz 98 A 100 A
380 V /50 Hz 58 A 63 A 380 V /50 Hz 62 A 63 A
400 V /50 Hz 55 A 63 A 400 V /50 Hz 59 A 63 A
415 V /50 Hz 53 A 63 A 415 V /50 Hz 57 A 63 A
440 V /50 Hz 50 A 63 A 440 V /50 Hz 54 A 63 A
480 V /60 Hz 55 A 63 A 480 V /60 Hz 59 A 63 A
Pay adequate attention to the floor before machine installation. The floor should be horizontally
levelled and made of concrete in the best case. Gradient should not exceed 0.5 cm/m (0.06
mm/ft), however, it should not be higher than 2 cm (0.8") across the length of the machine.
The machine is supported by steel feet of 110 mm ( 4.3") diameter. Their layout is apparent
from the following figures and figures of machine working space. Floor total load capacity for
the machine feet should be at least 3,500 kg/m2 (730.7 PSF).
Dimensions of foundation for individual types of machines are illustrated in the following figure
and table. Reinforced structure of the foundation feet is made of B25 concrete and steel
reinforcement mesh SZ 8/100 x 8/150.
1) Floor
2) Foundation - B25
concrete
3) Sand-and-gravel
layer
4) Natural soil
5) Flexible dilatation
It is necessary to pay maximum attention to high-quality construction of the concrete floor under
the machine.
If the machine is installed on the floor that is not integral (paving), is uneven unacceptably or
which breaks with time, the manufacturer of the machine bears no responsibility for consequent
poor printing quality.
RAPIDA 75-2
The machine weight is 9,700 kg (21,400 lbs). Operational weight with paper in the feeder and
delivery is 10,900 kg (24.034 lb). The machine seats on the floor with 18 adjustable feet.
RAPIDA 75-4
The machine weight is 16,200 kg (35,720 lbs). Operational weight with paper in the feeder and
delivery is 17,400 kg (38.400 lb). The machine seats on the floor with 26 adjustable feet.
RAPIDA 75-4L
The weight of the four-colour machine with lacquering unit is 20,200 kg (44,540 lbs).
Operational weight with paper in the feeder and delivery is 21,400 kg (47.200 lb). The machine
seats on the floor with 34 adjustable feet.
RAPIDA 75-5
The machine weight is 19,500 kg (43,000 lbs). Operational weight with paper in the feeder and
delivery is 20,700 kg (20,706.49 kg). The machine seats on the floor with 30 adjustable feet.
RAPIDA 75-5L
The weight of the five-colour machine with lacquering unit is 23,500 kg (51,820 lbs).
Operational weight with paper in the feeder and delivery is 24,700 kg (24,702.64 kg). The
machine seats on the floor with 38 adjustable feet.
RAPIDA 75-6
The machine weight is 22,700 kg (50,050 lbs). Operational weight with paper in the feeder and
delivery is 23,900 kg (52,698 lbs). The machine seats on the floor with 34 adjustable feet.
RAPIDA 75-6L
The weight of the six-colour machine with lacquering unit is 26,700 kg (58,900 lbs).Operational
weight with paper in the feeder and delivery is 27,900 kg (61,520 lbs). The machine seats on
the floor with 42 adjustable feet.
For machine transport in the printing shop, it is necessary to take into consideretation the
required minimum door dimensions that are listed in the table below.
The switchboard can be removed if necessary. If it is necessary to remove the handles of the
lacquering unit register, both removal and reassembly should be carried in the "0" position.
If there is a central compressed air distribution system in the production premises, you can use
it after reducing the machine input prossure to 0.7 MPa (100 psi) for machine control. The
compressor for pneumatic distribution lines is not required then. Because of relatively high
noisiness of the compressors, it is not necessary to position them close to the machine. The
compressor for pneumatic installation can be positioned outside of the machine, namely within
the distance of up to 20 m (65). The compressor for pneumatic system should be positioned
within 6 m (20').
Maximum printing area . . . . . . . . . . . . . 510 x 735 (585 x 735) mm (20 x 29) (23.03 x 29)
KBA-Grafitec s.r.o.
KBA-Grafitec s.r.o.
Opocenska 83
518 19 Dobruska, Ceska republika
Telephone+49/351 833-0
Fax +49/351 833-1001
Web www.kba-print.de, e-mail office@kba-planeta.de