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HP Indigo press 3050, User Manual

The HP Indigo Press 3050 is a high-quality digital printing device. Ensure smooth functioning with our Troubleshooting Manual, available for free download at manualshive.com. This comprehensive manual offers expert guidance and step-by-step instructions to address any issues that may arise while operating the press.

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Contents

1 Preface

About this user guide  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Conventions used in this guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2 Getting started

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Digital offset color printing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Press specifications  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Printing rate  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
A tour of the press  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
HP Indigo press 3050 jobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

A look inside the press  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Print cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Starting up  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Charging and discharging the PIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Inking the PIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Transferring to the blanket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Printing the image. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3 Safety

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Warning signs and labels  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Warning labels on the press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Warning signs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Placement of warning labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Safety devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Material safety data sheets (MSDS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fire extinguishing equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Eye wash stations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Noise levels  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Heat insulating tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Electrical safety  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Emergency power shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Door interlocks and warning indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Maintenance safety and emergency procedures  . . . . . . . . . . . . . . . . . . . . . . . . 31

Standby status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Inching button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Inch-safe-service method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Machine lockout procedure  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Flammable liquids and fumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Isopropyl alcohol (IPA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
IPA contamination  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Handling and storing imaging oil, inks, and IPA . . . . . . . . . . . . . . . . . . . . . . 33
Disposing of consumables and cleaning materials. . . . . . . . . . . . . . . . . . . . 34
Additional information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4 HP Indigo press 3050 basics

The press interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Control panel  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Summary of Contents for Indigo press 3050

Page 1: ...HP Indigo press 3050 User guide English version ...

Page 2: ...hp indigo press 3050 user guide ...

Page 3: ...any form or any medium without the express written permission of HP HP HP Indigo Press HP Indigo Press RIP and HP ElectroInk are trademarks or registered trademarks of HP Adobe PostScript is a trademark of Adobe Systems Incorporated MS Windows and Windows are U S registered trademarks of Microsoft Corp All other products or name brands are trademarks of their respective holders The HP Indigo press...

Page 4: ...g signs 25 Placement of warning labels 26 Safety devices 26 Material safety data sheets MSDS 26 Fire extinguishing equipment 26 Eye wash stations 26 Noise levels 27 Heat insulating tools 27 Electrical safety 27 Emergency power shutdown 28 Door interlocks and warning indicators 29 Maintenance safety and emergency procedures 31 Standby status 31 Inching button 31 Inch safe service method 32 Machine ...

Page 5: ...b Editor 48 Job Editor functions 49 Accessing the Job Editor 49 Configuring the Hotfolder 49 Job imposition 51 6 Operating the press Turning the press on and off 54 Turning the press on 54 Turning the press off 54 Preparing the press 55 Printing jobs 56 Stage 1 Preparing the press 56 Stage 2 Proofing 56 Stage 3 Printing the full run 59 Divider between pages 60 Job maintenance 60 Editing job proper...

Page 6: ...up procedure 85 End of day routine 85 Weekly routines 85 Monthly routines 86 Mechanical system lubrication 86 Paper feed unit 88 Input Conveyor 92 Front section 93 Paper exit 95 Rear section 96 8 Handling ink Overview 100 Draining the ink tank 101 Replacing ink cans and rebuilding ink 102 Replacing ink cans 102 Rebuilding the ink in a tank 103 Adjusting ink density 105 Calibrating ink density wiza...

Page 7: ...rt control pads 152 Paper feed unit 152 Press 154 Adjusting the paper transport system 155 At your workstation 155 Paper path adjustments 156 Defining substrate type 157 Loading a substrate 158 Mounting a paper tray base plate 158 Loading a new substrate in the main tray 160 Loading a new substrate in the secondary tray 160 Adjusting the input tray 161 Before you begin 161 Adjusting paper tray gui...

Page 8: ...ing the cleaning station 206 Installing the cleaning station 208 Sponge roller replacement 208 15 Scorotron Overview 212 Scorotron maintenance procedures 212 Maintaining the scorotron 212 Replacing the scorotron corona 213 Replacing the damper 216 Maintaining the scorotron 217 16 Binary ink developer BID Overview 220 Replacing the BID 221 Diagnostics 221 Removing the BID unit 222 Installing the BI...

Page 9: ... solids air compressor 259 19 Chiller Overview 262 Chiller type 262 Warnings 262 Operating conditions 263 Control panel 264 Components of the control panel 264 Control thermostat 265 Maintenance 265 Weekly 265 Monthly 265 Yearly 265 Troubleshooting 266 Chiller timer 267 Setting the timer 268 20 Long term shutdown Long term shutdown 272 Initializing after a long term shutdown 272 21 Glossary A Part...

Page 10: ...he HP Indigo press 3050 This preface provides an overview of the user guide contents and explains conventions used in this guide This preface contains the following sections z About this user guide z Conventions used in this guide ...

Page 11: ...ion z Handling ink Describes replacement and maintenance of HP ElectroInk z Blanket Describes replacement and maintenance of the blanket z PIP Provides PIP replacement procedures z Paper transport Provides detailed instructions for adjustment and maintenance of the paper transport system z Impression drum Describes the impression paper replacement procedure z Imaging oil Provides maintenance and r...

Page 12: ...s appear in all capital letters for example Press the SHIFT key z Menu options are indicated in bold type for example On the File menu click New z Window names appear in italics for example After selecting the options in the Print window click OK z References to other sections in the guide appear in quotes for example See the Installation on page 37 ...

Page 13: ...12 Chapter 1 Preface ENWW ...

Page 14: ...ENWW 13 2Getting started This chapter contains the following sections z Overview z Press specifications z A look inside the press z Print cycle ...

Page 15: ... digital offset color printing transfers the inked image from the image carrier to a blanket and from the blanket to the substrate However unlike offset printing digital offset color printing creates a different image with each revolution without the use of film separations or printing plates The press is equipped with an embedded HP Indigo raster image processor RIP The HP Indigo embedded RIP ena...

Page 16: ...pot color Input formats The following input formats are supported z PostScript z Portable document format PDF z Encapsulated PostScript EPS z Tagged image format TIF z Joint photographic experts group JPG z HP Indigo s proprietary Job Layout format JLT Input job definition Press productivity PFU rate impressions hour Job type1 A4 pages hour Separations hour 8 000 A4 1 0 16 000 8 000 4 000 A4 1 0 8...

Page 17: ...document format PDF files are created The PostScript or PDF files are then transferred to the press The system consists of two subsystems the HP Indigo RIP and the press The RIP software reads the files from the pre press station converts them to bitmaps one per separation and then sends them to the press for printing Figure 2 1 HP Indigo press 3050 Figure 2 2 From pre press to the press Front Rea...

Page 18: ...Ink cans store concentrated solid inks Impression drum Applies counterpressure on printed sheet Scorotrons This is where the PIP is charged Ink tanks store heated inks BID units Apply ink to the PIP Cleaning station Cleans the PIP Paper feed unit Perfector Holds sheets between first and second side printing ITM Drum This is where the blanket is located Rotors Carry output sheets ...

Page 19: ...up To initiate the print cycle in the control panel click Print The drums start rotating and the support systems begin to work Charging and discharging the PIP The scorotron unit electrically charges the photo conductive imaging plate PIP as it rotates on the PIP drum The writing head laser beams selectively discharge the PIP A latent image forms on the PIP Figure 2 4 Control panel window Figure 2...

Page 20: ...The PIP discharged areas which are the image areas attract the ink particles The charged areas which are the non image areas repel the ink When the image on the PIP surface is inked the image is ready to be transferred to the blanket Figure 2 6 Discharging the PIP Figure 2 7 BID unit engaged to the PIP Laser beams 12 selectively discharging the PIP PIP drum Writing head PIP foil BID unit Ink reser...

Page 21: ...rinting the image With a substrate between them the impression drum presses against the ITM causing the melted ink image to solidify and adhere to the substrate The process is repeated for each separation usually four to form four colors on the printed substrate During each rotation of the ITM and the impression drums one color separation is transferred to the substrate Figure 2 8 Ink transfer fro...

Page 22: ...nted sheet towards the exit rotors and feeds in a new sheet For duplex jobs the perfector moves the sheet into the perfector tray and turns the sheet over for the second side printing Figure 2 10 Paper exit system Duplex conveyor Impression drum Perfector Rotors ...

Page 23: ...22 Chapter 2 Getting started ENWW ...

Page 24: ...contains the following sections z Overview z Warning signs and labels z Safety devices z Emergency power shutdown z Door interlocks and warning indicators z Maintenance safety and emergency procedures z Flammable liquids and fumes ...

Page 25: ...nvisible laser radiation may be present when doors are open and interlocks are defeated Avoid direct exposure to beam Laser Radiation The lasers in the press emit radiation in the invisible range The laser unit in the writing head is enclosed in a protective housing and permits exit of the beam only at the writing head window aperture to the PIP Do not insert or allow any reflective objects to be ...

Page 26: ...tomer engineers Do not climb into the paper input or paper exit bays for any reason Doing so could be dangerous Hot Surface Hazard WARNING Hot surface Can cause burns Do not touch Heat Hazards The blanket and ITM drum become very hot during normal operation of the press with temperatures up to 165 C 355 F Do not touch the ITM drum or its cover with bare hands Carelessness may cause burns Wear ther...

Page 27: ... Inside the paper exit bay Safety devices Material safety data sheets MSDS MSDS are supplied for consumables including the different HP ElectroInks imaging oil and the imaging agent adhesion promoters and adhesion promoter test fluids Keep the MSDS readily available in the work area Read and consult them for your personal protection Keep the MSDS in a protective plastic cover Fire extinguishing eq...

Page 28: ...ome very hot during normal operation of the press with temperatures up to 165 C 355 F Carelessness may cause burns Take the following precautions when you work near the ITM drum or when you are replacing the blanket z Wear insulated thermal gloves z Use needlenose pliers or another grasping instrument to remove and replace the blanket z Do not place hands on the moving blanket Use a tool to grip t...

Page 29: ...nd blanket and contaminate colors z Main supply disconnect switch The main supply disconnect switch is permanently connected to the press via a conduit A lockable disconnect device incorporated in the fixed wiring must be readily available It must be rated at 30amps 5000A C current interrupt capability This is an isolating device which can be locked in the Off position to avoid an unexpected start...

Page 30: ...3050 has interlocked doors that stop the machine and turn off electrical power to most system devices when the service doors are opened WARNING Access and use of bypass keys must be restricted to specifically trained personnel Do not disconnect or override any of these safety devices when operating the system The following doors and covers are interlocked z Upper Exit door z Rear door z Front door...

Page 31: ...n indicates that the door is open and the door that is open is indicated as Open in the Interlocks window Figure 3 5 The Interlocks window is shown under Diagnostics and Interlocks on the Interlocks tab Figure 3 3 Interlock doors front feed view Figure 3 4 Interlock doors rear exit view Front door Upper feed door Rear cover tray B door Lower feed door Reservoir door Rear cover tray A door Front co...

Page 32: ...m is unattended The unit automatically goes into Standby after it remains idle for more than 20 minutes Inching button Use the Inching button in maintenance procedures that require inching the drums If any interlocked doors are open the machine returns to the off state The Inching button located at the side of the door is enabled when the paper feed door or the paper exit door is opened Opening bo...

Page 33: ...nue inching the press stopping the press putting it into a safe state and servicing the press part until the job is complete Machine lockout procedure Health and safety regulations require that you use the following lockout procedure before performing maintenance procedures that do not require drum rotation Lockout means either locking an energy isolating device for example a fuse box to prevent t...

Page 34: ...allow its use near an open flame or sources of electrical sparks Use IPA for cleaning specified parts only Clean with IPA only when the printing engine is idle When you use IPA wait two to three minutes after application to allow the IPA to evaporate before proceeding If you cannot tell if the IPA has evaporated use your finger to feel for wetness IPA contamination The inks used in the press are h...

Page 35: ...nd dispose of the consumables and cleaning materials that you use Consult with your local authorities to determine the waste disposal regulations for the following wastes z Cooler drain liquid waste and imaging oil z Imaging oil and ink z Empty HP ElectroInk containers z Blankets z PIPs z Cleaning wipes soaked in imaging oil z Lint free wipes or tissue paper contaminated with ink z Contaminated ch...

Page 36: ...ENWW 35 4HP Indigo press 3050 basics This chapter contains the following sections z The press interface z HP Indigo online help suite ...

Page 37: ...ifferent levels of users have different access to the press software By default you have access to all functions that are intended for performance by an operator No password is necessary Windows and sub windows The press helps you to perform complex procedures correctly When you start a complex procedure only the window that relates to the first steps of the procedure is accessible As you progress...

Page 38: ...options available from the windows The guides complement each other and can be opened simultaneously Reference guide The reference guide provides detailed information about the press windows Graphic representations of the windows accompany descriptive text When you want information on a specific area of the window place the mouse cursor on the area and click A pop up window opens You can access th...

Page 39: ...able from the press windows and wizards You can open operation guide topics by clicking Help Contents and Operation guide and then choosing the topic You can also open topics while viewing a reference guide window by clicking Related operation procedures or by clicking a link within the topic text Figure 4 3 Example of an operation guide help topic ...

Page 40: ...isplay Figure 4 4 The Help Topics window The Help Topics window also offers keyword and word search options Related topics To locate the buttons or fields that are described in the procedure open a related reference topic while reading the steps of a procedure To view all steps in a procedure performed using the window while reading about a window open a related operation procedure topic All relat...

Page 41: ...40 Chapter 4 HP Indigo press 3050 basics ENWW Figure 4 5 Related topics ...

Page 42: ...ENWW 41 5The main windows This chapter contains the following sections z Using the control panel z Managing jobs z Using the Job Editor ...

Page 43: ...entifies the system that needs attention and remains lit until the problem is solved z Machine state indicator z Print buttons z Current print job panel z Print mode selector Enables you to print jobs uninterruptedly in one continuous session or in steps one job at a time z Job Manager button Gives you access to the frequently used Job Manager window z Schematic animated indicator Click to display...

Page 44: ...operties z job name z number of copies to be printed and number copies printed the last field can be reset z number of sheets in the job z access to job properties some properties can be changed while the job is printing z the next job to be printed Print buttons The following print buttons are available z Print z Proof Before you print a job first print one copy z Sample Print one copy in the mid...

Page 45: ...dicator The Schematic window appears with the present state of the press indicated If the press is unable to change from Standby state to Ready state the problem subsystems are highlighted in the schematic A glance at the Schematic window provides a quick diagnostic of the press Note When the cursor is moved over the Schematic window it appears as an arrow or a hand When the cursor is over a non l...

Page 46: ... z In the Schematic window click the subsystem A window appears z Use the toolbar or the control panel menu Figure 5 5 Schematic window Writing Head Perfector PIP drum Exit tray Ink cans Impression drum Scorotrons Ink tanks BID units Cleaning station Output rotors Imaging oil filter ITM drum Paper feed unit ...

Page 47: ...ign a specific job definition The Job Manager window Access the Job Manager window using one of the following methods z On the control panel click the Job Manager button located on the lower right side of the panel or z On the System menu click Job Manager The Job Manager window consists of the menu bar the Print Queue and the Loaded Jobs list Jobs in the Print Queue are press ready jobs Jobs prin...

Page 48: ...order of the Print Queue The Print Queue displays all jobs to be printed in the order that they will be printed You cannot sort jobs in the Print Queue because the job order reflects the printing order Use one of the following methods to change the order of items in the Print Queue z Select a job z On the Queue menu click Move Up or Move Down z On the positioning toolbar click the Move Up or Move ...

Page 49: ...ys z On the Job menu click Retain List z On the toolbar button click the Retained Jobs Archiving Export or import one or more jobs at the same time Exporting a job 1 In the Loaded Jobs list select the relevant job 2 On the Job menu click Export 3 Choose a destination Importing an archived job 1 On the Job menu click Import 2 Select the required job The imported job appears in the Loaded Jobs list ...

Page 50: ...lick the Job menu and then select Job Editor z Click the Job Editor toolbar button z From the Job Properties window click Job Editor Configuring the Hotfolder The press Hotfolder automates job management for the following purposes z Automatic load of image files Image files that are placed in the press Hotfolder are automatically loaded into the system as jobs Once loaded the jobs are displayed in...

Page 51: ...procedure to configure the press Hotfolder 1 From the control panel click the Options menu and then select Hot Folder 2 Click the Hot Folder tab and then define the Hotfolder path Figure 5 9 Hot Folder Parameters window Figure 5 10 Defining Hotfolder path ...

Page 52: ...Tools menu and then click Imposition The Imposition window allows you to perform job imposition by selecting a signature file template that defines the number and layout of spreads to fit on a printed page The Job Editor creates a new job based on the selected template giving it the name of the original job plus the name of the signature For more information see the Help Topic Performing Job Impos...

Page 53: ...52 Chapter 5 The main windows ENWW ...

Page 54: ...ENWW 53 6Operating the press This chapter contains the following sections z Turning the press on and off z Printing jobs z Job maintenance z Service operations z Calibrating the press colors ...

Page 55: ...t side of the press The press is now in Standby state Turning the press off 1 On the control panel click the System menu and then select Shutdown The Shutdown window appears 2 Select an option and click OK Wait for the computer to completely shut down which may take a few minutes and then turn off the main circuit breaker at the rear of the machine The system is now shut down Figure 6 1 Main circu...

Page 56: ...ture ink concentration and ink conductivity as they move from stage to stage towards printing condition You will be prompted to replenish consumables such as ink substrate blanket and the PIP But most routine procedures such as applying cleaner page and adjusting color levels are automated unless you configure the machine to ask for operator confirmation 7 Jobs are generally prepared at remote des...

Page 57: ...best way to organize your Print Queue because priorities change daily But the system is flexible enough to let you customize the Print Queue every day in accordance with your needs and preferences Stage 1 Preparing the press 1 Set the Print Queue 2 Set the Loaded Job list 3 Make certain the job properties number of copies print range and screen ruling are defined as required Modify the properties ...

Page 58: ...the image should be centered on the narrow axis and 10 mm 0 39 inches from the leading edge If necessary open the Job Properties window click the Image Placement tab and make corrections Figure 6 6 Image Placement tab simplex job Figure 6 7 Image placement on the sheet Leading edge 10mm 39 inches Image is centered on the horizontal axis X X x x ...

Page 59: ...egistration If registration is off open the Job Properties window click the Image Placement tab Make corrections Figure 6 8 Image Placement tab duplex job Figure 6 9 Front to back registration Front crossmarks aligned with backside crossmarks Front side leading edge Back side leading edge ...

Page 60: ...actual full run print one proof immediately before the beginning of the full run print to make certain it matches the approved proof Stage 3 Printing the full run 1 If the control panel print mode selector is set on Continuous the job is unloaded at the end of the print run and the next job in the Print Queue starts the print process If the control panel print mode selector is set on Step the next...

Page 61: ... The press will discard save save for a limited period of time or archive jobs that have been printed Define what is to be done with a job after printing in the Job Properties window On the General tab in the After Print Retain For section type or select the period of time you need to retain a print job After that period of time the job is deleted automatically from the disk Retrieve a retained jo...

Page 62: ...es collation duplexing or simplexing mirroring tumbling and rotating the job z Color Control Allows you to change a job s color look up table LUT z Color Order and Screening Allows screen ruling changes z Color Match Lets you alter color brightness z Image Placement Allows you to change the location of images within the job z Substrates Lets you define a substrate to be used for printing the selec...

Page 63: ...ing from linear to Chromalin with Chromalin applying the biggest dot gain You can also create your own LUT or set a customized LUT as the default To create your own LUT click Job Properties and select the Color Control tab It is possible to modify the entire LUT or change selected points When finished click Apply and Close Note LUT changes will only apply to the selected job Figure 6 14 Different ...

Page 64: ...ned machine calibration HP Indigo supplies the following screen rulings z Sequin an average of 144 lines per inch lpi z HDI 160 an average of 160 lpi z HDI 175 an average of 175 lpi z HDI 180 an average of 180 lpi z HDI set 2 an average of 250 lpi You can print a separation several times to enhance density HP Indigo supplies you with alternative color order to support transparency printing Inks do...

Page 65: ... density value for the 100 percent dot and for the 50 percent dot for each ink individually you can do this while printing The system readjusts itself to the new values immediately The next sheet is printed with the new values Those values are saved as part of the job properties for future runs Image placement Adjust image placement in relation to the top left corner of the sheet The simplex side ...

Page 66: ... dynamic data read during the print process You may use a ready made annotation template or create a new template 1 To create an annotation template click Options Press Configuration and select Annotation Marks Figure 6 17 Annotation Marks tab Figure 6 18 Press Configuration window Template Manager button Select a ready made annotation template ...

Page 67: ...lick the Template Manager button in Figure 6 18 to open the annotation window Figure 6 19 3 The toolbar in Figure 6 19 is used to create the following annotations text color bars date time Figure 6 19 Job Editor window tool bar usage Tool bar ...

Page 68: ... off power to the subsystems There are two control pads on the press one next to the feed conveyor and the other next to the paper exit tray The feed conveyor contains an Inching button The exit side control pad contains a light switch that controls the exit side light an Inching button an Elevator Up button and an Elevator Down button Figure 6 20 Job Editor window tool bar usage Figure 6 21 Contr...

Page 69: ...the direction of the button arrows to restart power To start the system after an emergency stop click Get Ready on the control panel Inching button The Inching button advances the machine at slow speed Press and hold it to move the machine forward Release it and the machine stops Paper Feed button The Paper Feed button is a toggle button that activates the paper feeding system The button when pres...

Page 70: ...w by clicking Consumables Substrate and Sample Tray Handwheel The handwheel manually advances the machine forward It is located behind the front door and is generally used when it is inconvenient to use the control pads To operate the handwheel push it in and turn it counterclockwise Figure 6 23 Sample tray button Figure 6 24 Handwheel Sample tray button Sample tray Forward motion counterclockwise...

Page 71: ...uspension of imaging oil and solid pigment particles The concentration of the ink ink density decreases as part of the pigment adheres to the printed substrate The system adds solid pigment to the ink tank automatically whenever pigment concentration drops below the desired level The concentrated ink is pumped from the ink can to the ink tank A pop up message will appear when the can is empty To r...

Page 72: ...etails refer to the Paper transport chapter chapter 11 Blanket maintenance The function of the blanket is to entirely remove the ink from the PIP and to transfer it to the substrate The blanket has two characteristics the ability to attract all the ink from the PIP and to transfer it to the substrate All the ink must be attracted and then transferred Cleaning the blanket The cleaner page option an...

Page 73: ...nsation as a function of the PIP s age let the system know when you replace a PIP On the control panel click the Consumables menu and select PIP Enter the information in the PIP Replacement section The PIP must be replaced when the system is unable to write an image on the PIP and erase it or when there are scratches or physical defects on the PIP surface To prolong PIP longevity handle it with ca...

Page 74: ...nfluence the rate of PIP deterioration The color adjust procedure fine tunes the compensation process for each PIP The color adjust procedure is performed automatically every 8 000 impressions unless overridden by the operator The color adjust procedure is triggered automatically when you turn the machine on after a break of several hours and after PIP replacement Performing custom color adjustmen...

Page 75: ... opens Follow the online help instructions Calibrating the machine LUT The machine LUT generation will calibrate 15 points on the machine LUT curve The automatic machine LUT is operated via a wizard The machine LUT generation wizard automatically calibrates the machine LUT without the need for an external densitometer The machine LUT is performed for a particular screen ink and substrate Figure 6 ...

Page 76: ...he Machine LUT Validation window is printed to an accuracy within 5 percent Substrate related parameters Different substrates may produce different color results The ability to perform machine LUT generation and color adjustment for each substrate increases the color accuracy for different substrates Color adjustments may be performed on most substrates including some with a matte finish Figure 6 ...

Page 77: ... it appears the same to the human eye Therefore the press should adjust to a lower density on a matte substrate than on a glossy substrate It is possible to define the optical density for each substrate by selecting the correct substrate gloss level z Matte 0 gloss 12 represents a group of uncoated and highly matted substrates z Semi gloss 12 gloss 25 represents a group of high quality matte and s...

Page 78: ...results may not be suitable for use Therefore verify print quality before performing the machine LUT Make sure the following items are checked for best results z the first transfer is adjusted properly z the substrate you are using is well defined type and thickness z no print quality defects exist such as voids streaks or stains You should avoid performing a machine LUT on a blanket having less t...

Page 79: ...substrate types z Perform a machine LUT for all screens used Note It is important to assign all of the substrates used to those that were performed with a machine LUT Normal accuracy workflow For a normal accuracy workflow perform the following z Do not perform a machine LUT but instead use the default LUT z If Color Adjust fails check that the consumables such as blanket PIP are in good condition...

Page 80: ...chine LUT that is calibrated according to the last machine LUT calibration performed Figure 6 32 Last Machine LUT Generation Results window Enables LUT generation for inks separately or together Time of calibration Allows the use of default LUT curves for all inks for a selected screen Last machine LUT generation ...

Page 81: ...n The Color Adjustment and Calibration Wizard Manager opens 2 In the Inline Densitometer Calibration section click Quick The Quick Densitometer Calibration Wizard opens 3 Press F1 the online help opens Figure 6 33 Last Machine LUT Validation Results window Figure 6 34 Color Adjustment and Calibration Wizard Manager The number of impressions performed since the last validation Date and time for the...

Page 82: ... calibration has not calibrated the densitometer 1 On the Adjustments menu select Color Adjustment and Calibration The Color Adjustment and Calibration Wizard Manager opens 2 On the Inline Densitometer Calibration section click Full The Full Densitometer Calibration Wizard opens 3 Press F1 The online help opens Follow the online help instructions Figure 6 35 Color Adjustment and Calibration Wizard...

Page 83: ...82 Chapter 6 Operating the press ENWW ...

Page 84: ...ENWW 83 7Operator routines This chapter contains the following sections z Overview z Start of day routine z End of day routine z Weekly routines z Monthly routines z Mechanical system lubrication ...

Page 85: ...ut the ink thoroughly and replace with new ink Whenever you use IPA wait two to three minutes before you proceed to allow the IPA to completely evaporate If you cannot make a visual check use your finger to feel for any dampness Water contamination The inks used in the press are highly sensitive to water contamination The press cooling system uses water Take special precautions not to contaminate ...

Page 86: ...ect placement dirt and creases or tears If necessary replace the impression paper 5 Set the press to Standby 6 Shut down the press Weekly routines Perform the following procedures at the end of every week 1 Perform the end of day routine 2 Rinse the imaging oil squeezer bottle using imaging oil 3 Perform weekly maintenance on the chiller see Maintenance on page 265 4 Clean the PTE protective cover...

Page 87: ...aining the scorotron on page 217 2 Clean the ink pumps for the four process colors CMYK See Cleaning the ink pump on page 109 3 Clean the imaging oil clean sensor See Imaging oil cleanness sensor on page 199 4 Perform monthly maintenance on the chiller see Maintenance on page 265 Mechanical system lubrication Weekly lubrication of the mechanical system is essential to its proper operation Componen...

Page 88: ...ease is to be applied Use the following lubricating oils and greases z grease mechanic lubrication grease z gear oil sep 32 or equivalent lubrication oil z grease BG 87 Molykote or equivalent for main drum gear lubrication only PIP ITM and impression drums Note Do not over apply lubricants A number of lubrication points are protected by spring bearings To lubricate these points you must apply pres...

Page 89: ...ine are covered either with doors or with guards The following figures illustrate all the lubrication points in the paper feed unit behind both front and rear covers Figure 7 2 Input tray chain inside front and rear Figure 7 3 Lift chains button outside front and rear walls G O O O ...

Page 90: ...hanical system lubrication 89 Figure 7 4 Elevator motor gear use the grease on the outer front cover Figure 7 5 Suction fingers bar inner rear wall Figure 7 6 Suction fingers bar inner front wall G O O O O O O ...

Page 91: ...90 Chapter 7 Operator routines ENWW Figure 7 7 Inner front wall O O O O ...

Page 92: ...ENWW Mechanical system lubrication 91 Figure 7 8 Paper feed unit motor outer rear wall Figure 7 9 Cams behind three cam wheel For cams located behind three cam wheel see Figure 7 9 G O O O ...

Page 93: ...he input conveyor side jogger and static side guide The following figures illustrate all the lubrication points in the conveyor on the front and rear sides Figure 7 10 Stack centering screw inside rear and front walls Figure 7 11 Rear side jogger O G O O O O O O O ...

Page 94: ...on All moving parts in the machine are covered either with doors or with guards The following figures illustrate all the lubrication points in the front behind the ink concentrate cans Figure 7 12 Front static guide Figure 7 13 Front of press O O O O ...

Page 95: ...94 Chapter 7 Operator routines ENWW Figure 7 14 Front scorotron lubrication points Figure 7 15 PIP drum gear Figure 7 16 Paper input side O O O O G ITM drum O O O O ...

Page 96: ...g this procedure To access the paper exit bay see Accessing the impression drum area on page 175 Figure 7 17 Impression drum gear G Note BG 87 Molykote or equivalent grease is used for the PIP ITM and impression drums G G Figure 7 18 Paper exit inner rear wall O Use a flathead screwdriver to remove the cap ...

Page 97: ... Rear section Open the rear press door WARNING Turn off the Power Enable switch before performing this procedure Figure 7 19 Rear fly wheel and belt Figure 7 20 Rear scorotron bridge O O O Impression engage motor see Figure 7 21 O O O O ...

Page 98: ...cal system lubrication 97 WARNING Ensure that all equipment tools and materials are removed from the unit and that all doors are closed before operating the machine Figure 7 21 Rear impression engage motor O O O O ...

Page 99: ...98 Chapter 7 Operator routines ENWW ...

Page 100: ... This chapter contains the following sections z Overview z Draining the ink tank z Replacing ink cans and rebuilding ink z Adjusting ink density z Adjusting ink conductivity z Viewing the ink can log z Cleaning the ink pump ...

Page 101: ... areas z temperature determines adherence of ink capacity to the substrate z ink tank levels When the ink characteristics approach the specification limit the press system displays a warning message If you ignore the warning and the ink characteristics slip outside the limits the press changes to the Standby state The press ink system is a semi closed system The press system creates ink in the ink...

Page 102: ...o drain the ink tank 1 On the control panel click Get Ready to allow the ink pumps to rotate This ensures that no sediment is formed at the bottom of the ink tank 2 On the control panel click Standby The system changes to the Standby state 3 Press an Emergency Stop button 4 Open the ink cabinet door 5 Place the empty container close to the ink container 6 On the right side of the ink tank locate t...

Page 103: ... closed before operating the press Replacing ink cans and rebuilding ink Replacing ink cans Replace an ink can when an ink concentrate can is empty as indicated by the system warning indicator on the control panel or when you want to change the color of ink in an ink tank Ink can replacement can be performed while the press is printing Use the following procedure to replace an ink can 1 Open the i...

Page 104: ...To update your system on the control panel click the Consumables menu and then select Ink Cans The Ink Cans window opens 8 If the Replace Cans tab is not selected click the Replace Cans tab The ink cans status displays either OK or Empty 9 Click the ink can that you replaced An image of the selected ink can appears on the screen 10 In the Ink Cans window click Replace The impression counter resets...

Page 105: ... Inks Properties window opens 8 Verify that the required ink pump is on If it is not in the Inks Properties window click Ink Pump to turn the ink pump on 9 Open the ink cabinet door 10 Remove the plug from the top of the ink tank Add 2 ml 0 07 oz of imaging agent and wait two minutes 11 In the Inks Properties window monitor the conductivity until the conductivity reading stabilizes 12 Add 0 5 ml 0...

Page 106: ... is constantly monitored by the press Whenever the ink density falls below the nominal value the ink cans inject a dose of solid ink into the tank The system waits to let the ink tank density stabilize and then re checks the ink density A warning message is displayed when the ink density rises above the density set point If the ink density continues to increase and reaches 2 5 the press changes to...

Page 107: ...0 clean the pump and density sensor and then check the density again See Cleaning the ink pump on page 109 If the problem persists call your HP Indigo service center Adjusting ink conductivity The ink conductivity in the ink tanks should be between 90 to 100 pmho cm at a working temperature of 30 C 1 86 F 1 Conductivity control is automated Check the imaging agent container weekly and refill it if...

Page 108: ...e imaging agent access door on the right side of the ink cabinet 2 Fill the imaging agent bottle shown in Figure 8 11 through the imaging agent access door 3 Close the imaging agent access door Decreasing ink conductivity Use the following procedure to decrease ink conductivity when prompted by the system 1 Press an Emergency Stop button 2 On the control panel click the Diagnostics menu and select...

Page 109: ...elect Ink 6 Monitor ink conductivity level 7 Click Pump 8 Fill the ink tank with imaging oil 9 Check the ink conductivity again Note If ink conductivity keeps rising above 110 pmho cm call your HP Indigo service center Viewing the ink can log Use the ink log to track ink can replacements and the number of impressions for each replaced ink can Accessing the ink log 1 In the control panel click the ...

Page 110: ... ink pump unit z wash basin z fine cleaning brush z density sensor cleaning paper z gloves Perform the following procedure to clean the ink pump 1 On the control panel click Standby 2 Press an Emergency Stop button 3 Loosen the locking knob on the top plate of the ink tank Press the quick coupling air hose connector ring to disconnect the air hose from the ink concentrate can holder Figure 8 13 In...

Page 111: ...Take out the ink can 5 Pull the unit by the front handle until it comes free and lift it out Figure 8 15 6 Place the unit in the wash basin or in a plastic lined tray Note Don t remove the filter from the pump The plastic holder may break Figure 8 15 Ink pump removal ...

Page 112: ...the ink waste 9 Clean the magnets using imaging oil 10 Take a single sheet of density meter cleaning paper from the plastic wallet Fold the paper along the perforated line to form a cleaning wedge Figure 8 16 Ink pump O ring Magnets Conductivity sensor Filter Level sensor Pump motor housing TCU board Ink concentrate inlet Impeller ink outlet Impeller housing ...

Page 113: ...d on the pump unit Remove the paper 12 Clean the sensor with imaging oil Note Do not use the same paper twice 13 Reinstall the ink pump unit into the ink tank 14 Push in and tighten the release knob 15 Connect the air hose to the quick coupling connection on the ink concentrate can Figure 8 17 Density sensor cleaning Density sensor ...

Page 114: ...9Blanket This chapter contains the following sections z Overview z Replacing the blanket z Cleaning the blanket z Shifting separations z ITM temperature sensor z First pressure adjustment z Removing the ITM hood ...

Page 115: ... and remove all paper shreds as soon as they are detected Replacing the blanket Replace the blanket when it is damaged or if parts of the image are missing on the printed output Before beginning this procedure make sure to have the following items z new blanket z thermal gloves z needlenose pliers Removing the old blanket WARNING The ITM drum is very hot and may cause injury if treated carelessly ...

Page 116: ...he ITM drum until the leading edge of the blanket is in view Note Do not use a sharp object to peel off the blanket since this could scratch the ITM drum WARNING The ITM drum can be very hot and cause burns Figure 9 2 ITM hood maintenance position Figure 9 3 Leading edge of blanket ITM hood ITM drum Blanket leading edge ...

Page 117: ...nd the ITM drum on the rear side above the metal fastener bar Peel the blanket from the drum Note Do not use a sharp object to peel off the blanket because this can scratch the ITM drum Figure 9 4 Leading edge of blanket Figure 9 5 Gently pull off the leading edge of blanket ITM drum Blanket leading edge Metal width behind the blanket Outside metal clamp Cut here Side view BLANKET REMOVALB1 ...

Page 118: ...nket so that the adhesive side faces out Press an Emergency Stop button b Press the sticky side of the blanket to the bare ITM to pick up adhesive residue c Clean the ITM drum surface that is accessible d Release the Emergency Stop button Press the Inching button to advance the drum until a new section of the drum is accessible e Repeat this procedure until the ITM drum is free of adhesive residue...

Page 119: ... advance the machine so that the ITM slot is in view 2 On the control panel click the Consumables menu and select Blanket The Blanket window opens 3 Click Imp Engage The impression drum engages with the ITM drum 4 Place the new blanket adhesive side up on the work table Remove the plastic covering from the adhesive side Figure 9 8 Blanket window Replace Blanket tab Figure 9 9 Remove plastic coveri...

Page 120: ...pped under the blanket 7 Check for evenness of the blanket by advancing the ITM drum an additional revolution while pressing it with a lint free wipe soaked in imaging oil 8 Close the ITM hood and then close the service doors 9 On the control panel click the Consumables menu and select Blanket The Blanket window opens 10 Click the Replace Blanket tab 11 In the Serial No field type the new serial n...

Page 121: ...just first pressure See First pressure adjustment on page 128 16 Perform the color adjust procedure 17 Perform the print cleaner procedure Cleaning the blanket Even though the blanket transfers all the ink from the PIP to the substrate a small amount of residue can remain on the blanket This is primarily a result of blanket aging Before beginning the procedure make sure to have the following items...

Page 122: ...l soiled soak the lint free wipe in imaging oil and rub the blanket until the ink residue and other contamination are removed Continue until the wipe no longer picks up residue 4 Perform the print cleaner procedure using the Print Cleaner wizard See the following section Recovering the blanket surface on page 122 Figure 9 13 Fold the pad four times ...

Page 123: ... Press an Emergency Stop button WARNING The blanket is very hot and may cause injury if handled carelessly Access the blanket area with care Avoid imaging oil vapors 2 Immediately remove any jammed paper from the machine Use a blanket scraper if needed 3 If any paper remains on the blanket remove it carefully while the blanket is still hot If this does not work soak a folded lint free wipe in clea...

Page 124: ...g oil The blanket is clean when you rub it with a clean lint free wipe and the wipe does not appear tinted 11 Close the blanket hood and click Get Ready Note If the Print Cleaner wizard s Paper Jam Handling mode fails change the first paper type Use paper thicker than 150 microns for the Print Cleaner function 12 Resume printing Monitor the print quality of several prints after a paper jam Full bl...

Page 125: ...ob check box Figure 9 17 The cleaner page is automatically printed every 1000 impressions The procedure is performed automatically unless you bypass the cleaner page option You can bypass the cleaner page option if the substrate is costly and you do not want to use it to clean the blanket When the cleaner page option is enabled a cleaner page is automatically generated during a long cold start at ...

Page 126: ...te The Substrate window opens 2 Click the Replace Substrate tab 3 Select the Bypass Cleaner Page check box 4 Click OK 5 Click Close Enabling the automatic cleaner page option 1 On the control panel click the Consumable menu and then select Blanket The Blanket window opens 2 Click the Cleaner Page tab 3 Click to clear the Bypass Cleaner Page check box 4 In the No of Pages field select the number of...

Page 127: ... in the available field for simplex printing Alternatively select the value by sliding the lever or using the spin buttons 5 Click Apply to accept the changes and leave the window open or click OK to accept the changes and close the window For duplex printing 1 On the control panel click Pause The press changes to the Pause state 2 On the Consumables menu click Blanket The Blanket window opens 3 C...

Page 128: ... procedure only when the ITM drum has cooled to room temperature Perform the following procedure weekly 1 On the control panel click Standby The press changes to the Standby state 2 Open the upper feed door 3 Lift the ITM hood 4 Using lint free wipes soaked in IPA clean the ITM area that comes into contact with the ITM thermal fuse Use a blunt plastic knife to scrape off the dry ink 5 Using the in...

Page 129: ...heet is numbered one through nine The PIP to ITM pressure varies from one sheet to the next The press prints the first sheet with minimum pressure and the ninth sheet with maximum pressure The job image consists of two columns of six triangles each One column is on the left side of the sheet and the other is on the right side The system makes identical transfer pressure adjustments to each drum si...

Page 130: ...fer Calibration window opens 2 Click Print The First Transfer Calibration prints nine sheets 3 Analyze the printed sheets Examine each column separately and identify the first print in which at least three triangles are composed out of the printed fragments 4 In the First Transfer Calibration enter the print number in the correct column The print number appears in each triangle 5 If you cannot ide...

Page 131: ...130 Chapter 9 Blanket ENWW 6 Click Next Figure 9 22 First transfer Wizard define the correct pressure here Rear Front ...

Page 132: ...he illustrations are prints taken during a First Transfer Calibration procedure In the samples nine sheets of the First Transfer Calibration job were printed Figure 9 24 through Figure 9 27 show sheets number 4 to number 6 Figure 9 23 Calibration completed Figure 9 24 Spread 4 incorrect front pressure Figure 9 25 Spread 5 correct front pressure ...

Page 133: ...2 Removing the ITM hood Perform the following procedure to remove the ITM hood and allow access to the cleaning station replace the PIP or allow access for maintenance procedures 1 Turn the press off by pressing an Emergency Stop button 2 Open the front door and the upper feed door Figure 9 26 Spread 6 correct rear pressure Figure 9 27 Spread 7 too much pressure ...

Page 134: ...rd Lift the input paper conveyor 4 Using your right hand hold the ITM hood upper bar Using your left hand release the ITM lock and pull the ITM hood Figure 9 28 Press doors and conveyor Figure 9 29 ITM hood Input conveyor Upper feed door Front door ITM hood ITM latch ITM hood lock ITM hood knob ITM hood upper bar ...

Page 135: ...134 Chapter 9 Blanket ENWW 5 Remove the left side front first and then the right side rear 6 Install the ITM hood by reversing the steps above Figure 9 30 Removing the ITM hood ITM hood Hood upper bar ...

Page 136: ...ENWW 135 10PIP This chapter contains the following sections z Overview z Replacing the PIP ...

Page 137: ...ng procedure to replace the PIP when it is damaged or aged Before you replace the PIP make sure you have the following items z PIP pack one unit or seven units z Plastic squeeze bottle with 500 ml 16 9 oz of imaging oil The spout of the bottle should be at a 45 angle with a nozzle size 1 5 to 2 0 mm 0 06 to 0 08 inch z Lint free wipes z Chemical resistant gloves Removing the old PIP To remove the ...

Page 138: ...c Lock the lever by rotating it away from you Make sure the lever studs at both ends are inserted into their sockets Figure 10 1 Scorotron bridge lever working position Figure 10 2 Scorotron bridge lever maintenance position Scorotron bridge lever at working position Lever studs in machine wall Rotate lever towards you to loosen it Lever studs in machine wall Scorotron bridge lever at maintenance ...

Page 139: ... 8 Open the front door 9 Remove the cleaning station blade Figure 10 3 Front door Figure 10 4 Remove cleaning station blade behind front door Front door Work table Emergency Stop button Cleaning station blade holder Handwheel ...

Page 140: ... pad press the Inching button to advance the press until the PIP trailing edge is in view See Inch safe service method on page 32 12 Unlock the PIP latch Figure 10 5 Clean the cleaning station blade Figure 10 6 Input control pad Inching button Figure 10 7 PIP holder Cleaning station blade PIP latch To release pull lever To lock push lever PIP holder slot ...

Page 141: ... the package only when you are ready to install it After the package is open be careful not to place the cartridge on a dirty surface If you do so accidentally clean the cartridge thoroughly with a lint free wipe soaked in imaging oil CAUTION Perform this procedure under dim lighting conditions to protect the PIP Use the following procedure to install the new PIP do not omit any steps 1 Verify tha...

Page 142: ...lders If the shoulders are not parallel remove the PIP and reinsert it properly 8 Hold the PIP away from the drum Using the squeezer bottle apply imaging oil generously to cover the entire visible section of the PIP underlayer Moving the nozzle from side to side squirt the imaging oil on the top section of the drum Make sure that a continuous layer of fluid forms Apply imaging oil liberally Drops ...

Page 143: ...14 Reinstall the cleaning station blade Mount the cleaning station blade groove on the rail 15 Push the blade all the way in Make sure that the cleaning station blade is inserted all the way If the blade is not in place the press displays the following message when you try to change the press to the Ready state Blade is not in place or unlocked 16 Close all doors Figure 10 12 Place PIP trailing ed...

Page 144: ...l to remove the adhesive from the drum surface Keep the drum wet with imaging oil CAUTION Make sure that no glue residue falls into the machine Take care not to damage the PIP drum surface 8 When all the glue has been removed wipe the drum with the lint free wipe soaked in imaging oil 9 Carefully wipe and clean the PIP drum thoroughly using a lint free wipe soaked in IPA While holding the wet lint...

Page 145: ...the PIP underlayer installation jig 15 Install the jig with sleeves at the cleaning station position via the slots on the side walls Figure 10 14 Drying the PIP holder slit Figure 10 15 PIP underlayer installation jig Figure 10 16 Mounting the PIP underlayer installation jig PIP drum PIP groove Cleaning paper Sleeves PIP drum PIP underlayer installation jig ...

Page 146: ...should then insert the PIP underlayer mounting strip entirely in the PIP holder slit including the metal retaining strip c A second person should rotate the handwheel counterclockwise until the roll has completely wrapped around the drum The roll should pass between the jig and the PIP drum Make sure that the strip is inserted completely along the width of the PIP underlayer Note Verify that the P...

Page 147: ...jig top edge to about 10 cm from the end h One person should hold the PIP underlayer unrolled straight i A second person should rotate the handwheel very slowly clockwise to apply the PIP underlayer to the entire drum surface The layer should pass between the drum surface and the jig Turn the drum one complete rotation Figure 10 19 Mounting the PIP underlayer Figure 10 20 Installing the PIP underl...

Page 148: ...s down from the PIP underlayer center outward toward the edges 20 Turn the handwheel and firmly press down the side edges of the PIP underlayer Make sure that the layer surface is smooth and completely attached to the drum 21 Visually inspect the PIP underlayer on the drum Look carefully for air bubbles or other particle adhesions causing bumps in the PIP underlayer 22 Remove the jig 23 Install ne...

Page 149: ...u must use it give a specific reason for the PIP replacement Note Precise descriptions of the PIP replacement cause helps the service personnel properly maintain the press 5 Click Replace to reset the counter and accept the information The system performs the automatic color adjust procedure 6 Click Close Viewing the PIP log View the PIP log to keep track of PIP replacement and the number of impre...

Page 150: ...g a substrate z Adjusting the input tray z Adjusting the double feed sensor z Adjusting the conveyor belts z Adjusting the front static guide and rear jogger z Testing the substrate transport system z Sample tray configuration z Accessing the impression drum area z Clearing paper jams z Maintaining the paper transport system z Removing paper jammed under cleaning station z Removing paper shreds un...

Page 151: ... paper stack until it has reached room temperature Maintain 40 to 60 percent relative humidity in both the storage room and in the printing room Paper specifications Allowable substrates simplex and duplex Substrate size Substrate type Weight coated glossy paper 90 to 350 g m2 60 lb text to 130 lb cover coated matte papers 90 to 350 g m2 60 lb text to 130 lb cover uncoated papers 80 to 300 g m2 55...

Page 152: ...will cause paper jams Sheet size When using a new paper stack verify that the sheet size is identical to the size defined in the substrate list Make sure that the size of the sheets used in the main tray and the secondary tray are identical Paper transport subsystems Paper feed unit The paper feed unit consists of the paper elevator a set of blowers suction fingers and sheet separators The main fu...

Page 153: ...r the sheet and feeding it for duplex printing Exit unit The exit unit stacks the printed sheets The output of the paper stack allows the paper to feed to the post printing process such as binding or trimming Paper transport control pads The press is equipped with several control pads to adjust the paper transport system The following sections are in the order of the paper transport system Paper f...

Page 154: ...nit z move the paper elevator up and down z unlock the side walls when loading a new substrate You can move the elevator in continuous mode by pressing the Elevator Cont button while pressing the Elevator Up or the Elevator Down buttons To stop the elevator press either the Elevator Up or the Elevator Down buttons again The up motion stops automatically as the paper stack reaches the pre set heigh...

Page 155: ... paper feed unit only Press Use the following control pads to enable the Inching and Paper Feed buttons z input control pad on the feed side of the press z exit control pad Input control pad Use the input control pad to inch the press and paper feed unit Figure 11 5 Blower suction flow rate control pad Figure 11 6 Double feed sensor control pad Figure 11 7 Input control pad Trailing edge blower Si...

Page 156: ...vements z light the exit area z inch press and paper feed unit z lift the paper tray z lower the paper tray Adjusting the paper transport system At your workstation You can control the paper transport system through the press software interface Figure 11 8 Exit control pad Light switch Inching Lift up Lift down ...

Page 157: ...sport subsystems in the order they appear in this guide beginning with the input paper tray and ending with the exit tray z define substrate type z load substrate z adjust the input tray z adjust the double feed sensor z adjust the conveyor belts z adjust the rear jogger z adjust the front static guide z test the substrate transport system Paper feed unit and conveyor adjustments z input tray guid...

Page 158: ... a substrate define the type of substrate on the press The system uses this information to automatically adjust pressures and fine tune colors 1 On the control panel click the Consumables menu and then select Substrate The Substrate window opens 2 Click the Substrate tab 3 Click List to open the pre defined paper type list 4 Under the appropriate tray click Select Substrate 5 If the substrate does...

Page 159: ...he Substrate tab Click Apply to apply the change 10 Perform the appropriate hardware adjustments in order to load the new substrate Loading a substrate Adjust the paper transport system to ensure smooth paper feeding and ejection Adjust the paper transport system whenever you replace the substrate with a substrate of a different weight or size Mounting a paper tray base plate The press is supplied...

Page 160: ...crews 5 Slide the screws to fit the new base plate size 6 Insert the new paper tray base plate 7 Lock the butterfly screws Figure 11 12 Paper tray base plate Figure 11 13 Paper tray base underside Figure 11 14 Paper tray base Trailing edge Butterfly screws Trailing edge Slide butterfly screws to adjust to base plate size Trailing edge ...

Page 161: ...ding edge guides 7 Align the stack horizontally and vertically 8 Place the stack exactly in the middle of the tray between the side guides The distance from either the wall rear or front to the sheet margin must be equal 9 If necessary fan the stack again 10 Adjust the input tray Loading a new substrate in the secondary tray Note Load a substrate in the secondary tray after you have loaded a subst...

Page 162: ...guides The distance from either the wall rear or front to the sheet margin must be equal 10 If necessary fan the stack again 11 Adjust the input tray Adjusting the input tray Adjust the transport system to ensure smooth feeding and ejection of the substrate You should adjust the substrate transport system whenever you load a substrate of a different weight or size Before you begin Checking sheet s...

Page 163: ...tside the paper format 2 Disable the suction by pulling the valve up Adjusting paper tray guides 1 Close the stack centering knob until the side guides touch the stack Figure 11 15 2 On the control pad press the Elevator Up button together with the Elevator Cont button The elevator stops when it reaches the correct height Figure 11 17 Sheet separator Figure 11 18 Suction fingers valves Sheet separ...

Page 164: ... the substrate with a new substrate of different weight or size Fine tune the suction blower flow rate while the press is transporting paper Increase the flow rate when printing on heavy substrate or on substrate with a rough surface Use the following procedure to increase the flow rate 1 On the control panel click the Consumables menu and then select Substrate andTransport 2 Set the following tra...

Page 165: ...r stack Verify that the guides keep the top sheet from curling over its leading edge Take extra care when printing on light paper stock 1 Release the top paper guides set screws 2 Slide the top paper guides to the desired location Place rear and front guides at the same distance from the sheet margins 3 Lock the top paper guides set screws Adjusting the double feed sensor The double feed sensor en...

Page 166: ...sor flips 6 Press the Inching Forward button to release the folded sheet 7 Turn the double feed sensor counterclockwise two additional clicks 8 On the feed control pad press the Paper Feed button 9 Press the Inching Forward button 10 Watch a sheet being fed into the double feed sensor If the sensor activates the double feed preventor bar turn the double feed adjustment screw one click clockwise Fi...

Page 167: ... belts evenly across the sheet width to ensure a smooth transport Use the following procedure to adjust the conveyor belts 1 Lift up the ITM hood 2 Release the conveyor latch Lift the conveyor handle Figure 11 23 Conveyor belts Figure 11 24 ITM Hood PIS28A Steel strip Conveyors belts Rear jogger Front static guide Conveyor handle Conveyor latch Ball drive frame Ball drive cover ITM hood ITM hood l...

Page 168: ... other 5 Return the conveyor table to its working position 6 Push the conveyor latch down to secure it 7 Place the steel strips on top of the two external belts Adjusting the first friction wheels 1 Move the two friction wheels over the two central belts Figure 11 26 Figure 11 25 Conveyor belt holders conveyor underside Figure 11 26 Align belts with belt knobs overview Turn knob to adjust belt pla...

Page 169: ...teps below show how to adjust the front static guide to align substrate in the press 1 Lift up the secondary conveyor of the Paper Feed Unit 2 Open the ball drive cover and lift up the ball drive frame 3 Open the guide knob on the front static guide and move the front static guide all the way to the front of the press Figure 11 27 Front static guide and rear jogger Figure 11 28 Front static guide ...

Page 170: ... Forward button until the rear jogger moves closest to the front of the press 11 Make sure that the paper crease is aligned with the zero mark on the scale and that the paper is parallel to the paper width scale 12 Adjust the side knob for the rear jogger so that the jogger is parallel to the paper 13 Open the guide knob on the rear jogger and move the jogger until it touches the paper Make sure t...

Page 171: ...30 lb cover stock paper 17 Adjust the side knob for the front static guide so that the flat spring is parallel to the paper 18 Repeat steps 6 through 8 19 When the paper is aligned with the scale the rear jogger is closest to the front and touches the paper move the front static guide until its flat spring is pushed 2 mm 0 078 inch by the edge of the paper 20 Lock the front static guide knob Figur...

Page 172: ... parameters such as glossy are unimportant 25 Push the tray B Paper Feed button and the Inching Forward button to advance the creased paper 26 When the creased paper is under the feed rollers of the Paper Feed Unit push the Paper Feed button again to stop the vacuum 27 From the exit side of the Paper Feed Unit press the Inching Forward button until the creased paper arrives at the front static gui...

Page 173: ...ly manner click Stop 5 Readjust the exit tray 6 Click Run Inspect the sheet stacking in the exit tray 7 Repeat the procedure until you are satisfied with the paper transport system performance 8 Click Stop Front to back registration 1 Select a duplex job with registration marks and print five copies Note The back side side 2 is the upper side of the printed sheet as it lays on the exit tray 2 On t...

Page 174: ... centers the image in relation to the sheet Select the Joined check box to shift the image so that both sides of the sheet are parallel 7 Click OK and print another copy Check your setting Note The image placement settings are job dependent If all duplex jobs require image placement adjustments use the Image Placement wizard Figure 11 34 Image Placement tab Figure 11 35 Image movement in relation ...

Page 175: ...e tray maximum capacity z One copy will print one copy from the printed job z Number of sheets will print only the defined number of sheets z Duplication will print to both the main and sample trays In this mode a few prints may pass before the duplicated page arrives at the sample tray Select to print more than one copy to the sample tray Select Single duplicated sheet to produce a single duplica...

Page 176: ... the impression drum area Some maintenance procedures are performed at the impression drum area Use the following procedure to access the impression drum 1 Press an Emergency Stop button 2 Open the door below the input conveyor 3 Press the duplex conveyor cover to release its latch Lower the duplex conveyor The impression drum is accessible Figure 11 37 Multiple copies proofing Select to proof mor...

Page 177: ...overing the blanket surface on page 121 4 Perform the appropriate procedure according to the following warning message Paper Misfeed or TRN_PIS_feed_timing When this message appears access the input area pull jammed paper out gently and remove all shreds Check the paper input feeding mechanism This message also appears when there is insufficient vacuum with the result that no paper has been fed in...

Page 178: ...ing the machine Maintaining the paper transport system The procedures described below should be performed routinely to ensure a smooth paper flow Perform the following procedures weekly as part of the weekly maintenance procedures and when encountering repeated paper jams Cleaning the paper path sensors All sensors verifying the presence of paper along the paper path are optical sensors The sensor...

Page 179: ...lex conveyor feed sensor Figure 11 42 Exit side sensor locations shown with grid removed Intermediate rotor jam sensor Duplex conveyor jam sensor Perfector jam sensor 2 Perfector jam sensor 1 Exit tray sensor Sample tray sensor Grippersensors upper lower Skew and encoder sensors TWISTER 358 Sensor Intermediate rotor jam sensor Sample tray sensor Exit tray sensor ...

Page 180: ...ENWW Maintaining the paper transport system 179 Figure 11 43 Perfector jam sensors Figure 11 44 Intermediate rotor jam sensor Figure 11 45 Exit tray sensor Jam sensor behind this plate Rotor Sensor ...

Page 181: ...Chapter 11 Paper transport ENWW Figure 11 46 Sample tray sensor Figure 11 47 Encoder and skew sensors Figure 11 48 Gripper sensors Sensor Encoder sensor Skew sensor Upper gripper sensor Lower gripper sensor ...

Page 182: ...em Clean the following rollers z paper feed rollers paper input side z paper exit roller access through paper exit bay Replacing the sheet separators on the Paper Feed Unit The sheet separators ensure that only the top sheet is picked up by the suction fingers from the paper feed tray If a sheet separator is twisted use the following procedure 1 Press an Emergency Stop button Figure 11 49 Paper in...

Page 183: ...the sheet separator locking screw 7 Pull the sheet separator out 8 Install a new sheet separator in the sheet separator bracket Figure 11 51 Sheet separators above the paper feed tray Figure 11 52 Sheet separator assembly Figure 11 53 Sheet separator Suction fingers Sheet separator bracket Feed roller Sheet separator bracket locking knob Sheet separator protruding tongue Sheet separator locking Al...

Page 184: ...between the PIP drum and the cleaning station A paper sheet is jammed between the cleaning station and the PIP when one or more of the following situations occur z The sheet is not found in the exit tray rotors perfector duplex unit or on the blanket z The cleaning station drips imaging oil z The PIP is scratched Remove the cleaning station using the following procedure Figure 11 54 Sheet separato...

Page 185: ...aper conveyor 4 Remove the ITM hood See Removing the ITM hood on page 131 5 Stand facing the front door hold the cleaning station blade knob and remove the blade Figure 11 56 Press doors Figure 11 57 Remove the cleaning station blade behind the front door Front door Upper feed door Input conveyor Cleaning station blade knob Handwheel ITM hood lock ...

Page 186: ...along the groove on the press inside walls 8 Remove the paper sheet that is jammed between the cleaning station and the PIP drum Install the cleaning station using the following procedure Figure 11 58 Cleaning station connector Figure 11 59 Remove the cleaning station Cleaning station connector Cleaning station imaging oil inlet ITM drum PIP drum Cleaning station groove Cleaning station latch Clea...

Page 187: ...lade see Figure 11 57 6 Release the Emergency Stop button and resume work Removing paper shreds under the air knife When a sheet is torn during a paper jam you must take the paper shreds out of the press Loose paper shreds between the drums can cause unexpected problems When you suspect that you have not removed the whole sheet after a paper jam check the space between the air knife and the PIP us...

Page 188: ... latch and pull the unit out 7 You can now access the PIP Remove any loose paper shreds 8 Re install the air knife by following the steps above in reverse order 9 Release the Emergency Stop button Figure 11 61 Air knife Figure 11 62 PIP air knife nip Number 5 electrical connection Number 4 air hoses Air knife latch PIP surface check this area for paper shreds Impression drum ...

Page 189: ...188 Chapter 11 Paper transport ENWW ...

Page 190: ...ENWW 189 12Impression drum This chapter contains the following sections z Overview z Replacing the impression paper ...

Page 191: ...esult the impression paper can crawl towards the trailing edge When inspecting the impression paper pay extra attention to the leading edge area and for symptoms of ripping near the grippers window Replace the impression paper when it is dirty or damaged or has moved more than 2 mm 0 08 inch from the lower side of the grippers window on the impression drum see Figure 12 2 Note Replace the impressi...

Page 192: ...ssion paper holder and pull out the old impression paper Dispose of the old impression paper 4 Advance the drums using the handwheel and check the impression drum for cleanliness Pay special attention to the leading and trailing edges If necessary use a lint free wipe and IPA to clean the impression drum 5 Using the handwheel bring the impression paper holder into view 195 to 200 Figure 12 1 Gripp...

Page 193: ...le in the indicator slot of the impression paper holder Using a 3 mm Allen key tighten the two screws shown Fasten the screws Hold the paper in place while you fasten the screws 10 Rotate the impression drum so that the impression paper wraps around it 11 Lock the duplex tray into place 12 Lower and lock the conveyor 13 Lock the ITM hood in place 14 Close all doors 15 Release the Emergency Stop bu...

Page 194: ...ENWW 193 13Imaging oil This chapter contains the following sections z Overview z Imaging oil filters z Imaging oil cleanness sensor ...

Page 195: ... become too dirty to filter the imaging oil The imaging oil filter assembly has an optical sensor that checks imaging oil purity Clean this sensor periodically to keep it in good working order Imaging oil filters The imaging oil system is a semi closed system While printing some imaging oil evaporates The press system automatically compensates by adding imaging oil to the ink tanks The imaging oil...

Page 196: ...ge appears there is enough imaging oil left in the tank for an additional day s work Wait for the end of the day or the end of the print job before you refill the imaging oil Before you refill the imaging oil tank you should have a full imaging oil container available Refill the imaging oil tank at the end of the day before performing the end of day routine Use the following procedure to refill th...

Page 197: ...l is too dirty replace immediately param1 The press can continue printing for several hours after you receive this message Wait for the next break before replacing the filters To replace the filter you must refill the imaging oil reservoir which can lower imaging oil temperature and hinder production while you wait for the imaging oil to reach the proper temperature Before you perform this procedu...

Page 198: ...or over the filter 5 To loosen the filter turn the filter extractor clockwise 6 To release the filter hold it with both hands to avoid spillage and then turn it clockwise The filter weights about 3 kg 7 lb 7 Remove the second filter Figure 13 5 Filter extractor Figure 13 6 Lock the filter extractor over filter Figure 13 7 Unattached filter Remove first mount second Remove second mount first Rubber...

Page 199: ...ure the rubber gasket is in place 10 Close the rear press door and the blower cabinet 11 Release the Emergency Stop button 12 On the control panel click Get Ready 13 Once the press is in motion the imaging oil filters fill up The press system prompts you to add imaging oil Add imaging oil immediately Do not wait for the end of the day 14 Verify that imaging oil does not drip from the filters Figur...

Page 200: ...Perform the following procedure monthly 1 Press an Emergency Stop button 2 Open the rear press door 3 The imaging oil cleanness sensor is located inside the imaging oil tank and may be accessed by removing its mounting bracket Figure 13 9 Access door to the imaging oil cleanness sensor Figure 13 10 Cleanness sensor mounting bracket view from rear door Blower cabinet Rear press door Imaging oil cle...

Page 201: ...ou and lift it up 5 Clean both sensor faces on the printed circuit board 6 Reinstall the cleanness sensor assembly and tighten its mounting screw 7 Release the Emergency Stop button Figure 13 11 Removing the cleanness sensor mounting bracket Figure 13 12 Cleaning the cleanness sensor Mounting screw Sensor faces Cotton swab ...

Page 202: ...ENWW 201 14Cleaning station This chapter contains the following sections z Overview z Cleaning the cleaning station blade z Rotating and replacing the cleaning station blade z Sponge roller replacement ...

Page 203: ...ade You should clean the cleaning station blade periodically and replace it when it is damaged Cleaning the cleaning station blade Before performing this procedure you should have the following items z imaging oil z lint free wipes Clean the cleaning station blade at the end of each day Use the following procedure to clean the cleaning station blade 1 Change the press to the Standby state 2 Press ...

Page 204: ...aning station blade holder 5 Clean the wiper with a lint free wipe soaked in imaging oil Figure 14 2 Remove the cleaning station blade behind the front door Figure 14 3 Wipe the cleaning station blade Cleaning station blade holder Handwheel Cleaning station blade ...

Page 205: ...ely inserted 8 Close all the doors 9 Release the Emergency Stop button Rotating and replacing the cleaning station blade Rotate and replace the cleaning station blade when ink streaks appear on the printed output Before performing this procedure you should have a cleaning station blade 1 Change the press to the Standby state 2 Press an Emergency Stop button 3 Open the front door see Figure 14 1 4 ...

Page 206: ...r For example if edge 1 was in use turn to 2 and so on If edge 4 was in use replace the wiper Install the blade into the holder making sure that you do not angle the blade while pushing it into position Figure 14 5 Remove cleaning station blade Figure 14 6 Cleaning station blade section Cleaning station blade Press here to remove or insert a cleaning station blade Blade edge number Cleaning statio...

Page 207: ... and lift the input paper conveyor 4 Remove the ITM hood See Removing the ITM hood on page 132 5 Stand facing the press front door hold the cleaning station blade knob and remove the blade Figure 14 7 Press doors Figure 14 8 Remove the cleaning station blade behind the front door Front door Upper feed door Input conveyor Cleaning station blade holder Handwheel ...

Page 208: ...station latch and pull out the cleaning station Slide the cleaning station along the groove on the press inside walls Figure 14 9 Cleaning station connector Figure 14 10 Remove the cleaning station Cleaning station connector Cleaning station imaging oil inlet ITM drum PIP drum Cleaning station groove Cleaning station latch Cleaning station ...

Page 209: ...station 4 Replace the ITM hood Insert the side facing the rear wall first 5 Lock the ITM hood 6 Replace the cleaning station blade See Figure 14 4 7 Release the Emergency Stop button 8 Resume work Sponge roller replacement 1 Remove the cleaning station see Removing the cleaning station on page 206 Figure 14 11 Cleaning station facing the PIP Cleaning station studs Figure 14 12 Sponge roller assemb...

Page 210: ...ew sponge roller a Slide the roller into the housing assembly right side first Figure 14 13 Timing belt 3 mm Allen screw and front locking plate Figure 14 14 Fitting sponge roller into the housing Front locking plate Timing belt 3 mm Allen screw Sponge roller housing Right end cap Left end cap Slot Slots on sponge roller Fit sponge roller into right end cap ...

Page 211: ... timing belt Note When putting the timing belt on the pulleys turn the pulleys until the belt lies in the middle of the pulley Figure 14 16 7 Re install the cleaning station See Installing the cleaning station on page 208 Figure 14 15 Fitting sponge roller into the housing Push roller as indicated to fit it into the left end cap Figure 14 16 Putting the timing belt on the pulleys Make sure the tim...

Page 212: ...ENWW 211 15Scorotron This chapter contains the following sections z Overview z Scorotron maintenance procedures ...

Page 213: ...the bridge to access the PIP Scorotron maintenance procedures Maintaining the scorotron To remove the scorotron open the front door press the scorotron latch and pull the scorotron out To replace the scorotron unit push the scorotron in until it clicks into place The system does not send any message to notify if the scorotron is not inserted completely but it does send the following error message ...

Page 214: ... automatically to expose new wire after 4500 to 6000 impressions Before performing this procedure make sure you have the following items z Corona bobbin with wire z Empty PVC bobbin z Two corona grids z Scorotron dumpers z Phillips screwdriver Use the following procedure to replace the scorotron corona 1 Open the front door 2 Remove the scorotron unit by pressing the scorotron latch and pulling th...

Page 215: ...ng the corona wire loop from the idler pulley at the other end of the unit 8 Replace the damper see Replacing the damper on page 216 CAUTION Watch out for corona wire integrity Mishandling it may break the wire 9 Thread the wire into the empty PVC bobbin shaft hole and return it by the second hole Secure by knotting Loop the wire around the bobbin a few turns to ensure that it is secured 10 Mount ...

Page 216: ...5 Rotate the plastic gear by hand to tighten the wire and ensure free movement The spring loaded idler pulley retracts 16 Return the grids to their slots by sliding each on its rails hooking up the first on the inner end and then pressing the latch and hooking up the outer end Return the grid to its previous position The grid side that formally faced out should be mounted face out 17 Insert the sc...

Page 217: ...e the Phillips screw removing the damper clamp and the damper 5 Discard the damper 6 Install the new damper in the same orientation as the old one 7 Place the clamp on top of the damper and secure it with the Phillips screw 8 Reassemble the scorotron unit in reverse order Install the unit and lock it Figure 15 7 Scorotron dampers Figure 15 8 Scorotron damper Damper clamp Phillips screw Damper ...

Page 218: ...NG IPA should be used to clean specified parts only Cleaning may be carried out only when the printing engine is idle It is essential that all parts be completely dry before you reinstall them in the machine and resume printing 3 Using a cotton swab and IPA clean the unit grids and inside shield 4 Pay special attention to the cleaning of parts 4 5 6 and 7 in Figure 15 5 5 Test the damper part 4 in...

Page 219: ...218 Chapter 15 Scorotron ENWW ...

Page 220: ...ng sections z Overview z Replacing the BID z Reusing the BID unit z Adjusting the BID to the PIP pressure z Adjusting the BID engage and disengage angle z Press long term shutdown maintenance z Bellows position z BID troubleshooting z BID Washer z Cleaning the ink tank ...

Page 221: ... Each BID participates in the generation of a different separation although the units are identical There are seven BID stations numbered from 1 to 7 Starting from bottom right to top left the BIDs are orange or other spot color 1 cyan 2 magenta 3 yellow 4 black 5 violet or other spot color 6 and spot color 7 Figure 16 1 BID stations PIP drum ITM drum 1 Orange or other spot color 5 Black 3 Magenta...

Page 222: ...erformed before removing a suspect BID from the press Use this wizard to check BID units for correct flow rate proper mechanical movement Positive Developer Not Rotating correct BID biases and for open and short circuits The BID wizard is automatic and will either indicate that the BID is okay or show a specific error message To perform BID diagnostics perform the following 1 On the control panel ...

Page 223: ...k parameters are adjusted 6 After the test is completed the results will show in the status bars The test may take a few minutes z When finished click Close Removing the BID unit 1 On the control panel click Standby Figure 16 3 BID Diagnostic Wizard Inks Preparation window Figure 16 4 BID Diagnostic Wizard BID Diagnostic window Click here Test results appear in status bars ...

Page 224: ...y BID Units tab 4 Click the BID unit s to be replaced 5 Click the Dry arrow 6 Click Close 7 Press an Emergency Stop button 8 Open the front door Figure 16 5 BID Units window Figure 16 6 Open the front door Click here to start the manual BID cleaning procedure Select this check box to dry clean the Black BID for example ...

Page 225: ...latch to the right c Hold the ink supply assembly and pull it out 10 Insert the ink stopper into the BID 11 Release the BID latch 12 Hold the BID handle and pull it out Figure 16 7 BID ink coupling Figure 16 8 BID station and BID ink stopper Ink supply latch Set screw Ink outlet Ink inlet BID latch press here to release BID Ink stopper BID housing BID handle ...

Page 226: ...ff the adhesive tape Do not leave paper fibers on the developer CAUTION Use only your fingers to remove the protective paper sheet 3 Insert a 3 mm Allen key into the developer gear slot and turn clockwise 4 Keep rotating the developer until you have removed the protective cover completely Figure 16 9 BID stand Figure 16 10 New BID Figure 16 11 Removing the developer protective cover BID stand Deve...

Page 227: ...D and may be scratched by the BID pins 6 The BID should be inserted gently and parallel to it s housing Make sure that the BID rail and pins fit into the housing slots There are three slots that correspond to the rail the pin on the right side of the BID and the pin on the left side 7 Make sure that the BID is inserted all the way If the latch is unlocked the following error message appears when t...

Page 228: ...nting Registering BID replacement 1 Release the Emergency Stop button 2 In the control panel click the Consumable menu and then select BID Units The BID Units window opens 3 Click the Replace BID Unit tab 4 Select the relevant BID unit and click Replace The Replace BID Unit window opens 5 In the Serial No field type the new BID serial number Figure 16 14 BID Units window Figure 16 15 Replace BID U...

Page 229: ...eplacement 7 Click OK 8 Click Get Ready 9 Perform the Custom Color Adjust wizard and include the Velectrode calibration procedure 10 Return old BIDs to HP Indigo in accordance with the information provided below The BID Return form which came in the BID package should be completed and mailed back to HP Indigo Returning the BID Please perform the following procedure to return the old BID 1 Remove t...

Page 230: ...en you replace an ink Storing the BID unit 1 Perform the BID removal procedure See Removing the BID unit on page 222 2 Place the BID unit on the BID stand and use a 3 mm Allen key to rotate the developer roller clockwise as viewed from the front of the BID unit 3 If a BID washer is available use it to clean the BID If not use a lint free wipe soaked in imaging oil to wipe the surface of the develo...

Page 231: ...ge area resume working If the replaced BID ink does not fully cover the image area readjust the BID to the PIP gap 4 Turn the press to Off 5 Press an Emergency Stop button 6 Each BID unit is equipped with a rear and a front adjustment engage screw To access the front BID engage screws open the paper exit door 7 Rotate the BID engage screw clockwise all the way 8 Rotate the BID screw three revoluti...

Page 232: ...t disengage from the PIP drum contact your customer engineer 14 If full ink coverage is not achieved check that the ink bellows is straight before repeating the last step See Bellows position on page 239 If you do not obtain full ink coverage of the image and the BID engage screw is turned clockwise all the way contact your customer engineer Figure 16 20 BID window Figure 16 21 BID units Check BID...

Page 233: ...he image trailing edge to be at 447 mm 17 6 inches of the sheet s leading edge Perform a BID engage disengage calibration when the following situations occur z When a full printed image is not obtained on the leading edge or the trailing edge z When a single inkless patch appears in the 25 mm 1 inch strip of the sheet s leading edge See Correcting an inkless spot on the leading edge on page 237 Pr...

Page 234: ... edge is uneven select the Engage check leading edge check box If the trailing edge is uneven select the Disengage check trailing edge check box If both Leading and Trailing edge are uneven select both check boxes 3 On the control panel click Get Ready 4 After the press reaches the Ready state click Next The second step of the wizard opens Figure 16 23 Select correction type Figure 16 24 Calibrate...

Page 235: ...sheet center Note A different test job is printed for the calibration of BID engagement at the leading edge and BID disengagement at the trailing edge If both the Leading Edge and Trailing Edge check boxes were selected the wizard handles the leading edge first and then the trailing edge Figure 16 25 Analyzing the leading edge Figure 16 26 Setting BID engage value In the Analyze window enter the h...

Page 236: ...hortest bar The lower value is for the bar edge which is closest to the sheet center 8 Click Print Two copies of the BID engage calibration verification job are printed Figure 16 27 Analyzing the trailing edge Do not enter this value In the Analyze window enter the higher value of the adjusted BID Enter this value ...

Page 237: ... correct engage calibration for all the BID units 10 The BID engage calibration completion message appears Click Finish Figure 16 28 BID engage calibration verification job Figure 16 29 A successful completion message Color bars of the same length 437mm are an indication to a well adjusted BID engage disengage 437mm 17 2 inches ...

Page 238: ...missing color 5 Analyze the print and note the value of the shorter bar of the missing color Add 3 to the read value 6 In the Analyze window enter the sum value in the appropriate color field 7 Click Print Two copies of the BID engage calibration verification are printed 8 Click Finish 9 Print the CATP job and inspect it If the inkless spot has not disappeared repeat steps 1 through 4 10 In the An...

Page 239: ...nit See Removing the BID unit on page 222 2 Place the BID unit on the BID stand 3 Use a 3 mm Allen key to rotate the BID developer roller Rotate the roller clockwise as viewed from the front of the BID unit 4 If a BID washer is available use it to clean BID units before a long term shutdown If a BID washer is not available use a lint free wipe soaked in imaging oil to wipe the surfaces of the deve...

Page 240: ...t be achieved if the ink bellows is not straight If you do not obtain full ink coverage of the image and the BID engage screw is turned clockwise all the way contact your customer engineer BID troubleshooting Use this section to troubleshoot BID problems All the procedures detailed below are for an Operator authorization level Follow the workflow exactly Figure 16 32 Correct Figure 16 33 Incorrect...

Page 241: ... the ink outlet bellows is not twisted z Use the Ink Flow wizard to check the ink flow rate z Check that the ink catch tray is assembled z Run the BID diagnostic wizard and verify that the BID motor is rotating Developer surface damage Cracks or cuts on the developer roller z Most mechanical defects are caused by improper BID handling especially when inserting and removing the BID BID roller grind...

Page 242: ... roller Non uniform 133 mm 5 24 inches band z Remove the BID Clean the developer unit and squeegee with imaging oil and a lint free wipe z Otherwise replace the BID Burned strip Thin straight horizontal line 133 mm 5 24 inches band z Call customer engineer z Replace the BID Problem Reason for replacement Symptoms and solutions Resultant image LEADING EDGE FEED DIRECTION 133 mm 5 24 inches 133 mm 5...

Page 243: ...ections are kinked before performing Ink Flow Calibration wizard z Perform the Ink Flow Calibration wizard to recalibrate the ink flow rate z Check for a clogged pump waste around the filter or a bad pump that decreases the flow rate If problems continue after BID replacement check the flow Low flow rate can also cause the following problems z Developer not rotating z Streaks z H V error message H...

Page 244: ...mer service Note Some print quality problems may not be BID related To isolate the problem make sure that all process parameters are set at the correct values and all process subsystems are adjusted and calibrated It is recommended to print in a single color to see if the problem is in the color or in all colors ...

Page 245: ...n the black BID before removing it 1 Remove the black BID and place it on the BID stand or on the specially designed BID holder provided with new BID units Make sure that the BID is positioned facing you with the BID motor to the right 2 Clean the BID developer roller using imaging oil on a lint free wipe Then thoroughly dry the roller with a lint free wipe 3 Remove the adhesive strip from the BID...

Page 246: ...per roller 6 Use a 3 mm Allen key to rotate the BID developer roller one rotation towards you Wipe waste from the roller as you rotate it 7 Rotate the developer roller two more times wiping off any waste 8 Rotate the developer roller until the BID cleaning foil s adhesive strip is exposed on the roller Figure 16 36 BID cleaning foil Figure 16 37 Rotating the developer roller ...

Page 247: ...ils Perform the following procedures only when required to troubleshoot the BIDs Checking ink flow The purpose of this procedure is to verify ink flow rate The verification process consists of two stages checking that the ink pump is on and setting the ink pump flow rate Checking the ink pump 1 In the control panel click Adjustments and Ink Flow Calibration to start the wizard 2 Select a color the...

Page 248: ...valve will shorten the flow time and closing the flow valve with lengthen it 6 The wizard will instruct you how to open or close the valve 7 Open the ink cabinet door 8 Check the required ink tank When the ink pump is on you can see the ink stirring If the pump is not on call your customer engineer 9 Close the ink cabinet door Figure 16 40 Ink Flow Calibration Adjust Ink Flow window Figure 16 41 I...

Page 249: ...brated ink densitometer It is important to build a solid color for calibration Make sure you have a sufficient amount of solids present in the ink 1 On the control panel click the Adjustment menu and then select Calibrate Density The Calibrate Density wizard opens 2 Press the F1 key The online help opens 3 Follow the procedure described in the Help window Adjusting ink conductivity 1 On the contro...

Page 250: ...engaged and disengaged using the window shown below Do not use this window for testing other BID functions but rather use the BID Diagnostic Wizard 1 Change the press status to Ready 2 On the Diagnostics menu select BID The BID window opens 3 Click Close BID Washer The BID Washer should be used by customers who ordered the ink mixing system Refer to the BID Washer user guide for more information C...

Page 251: ...scratch it 3 Connect hoses to the BID simulator 4 Latch the BID simulator into place 5 The fast ink replacement filter is attached as shown in Figure 16 45 6 The BID ink pump is activated and is allowed to run for ten minutes Figure 16 44 Fast ink replacement filter Figure 16 45 Attaching external filter Filter ...

Page 252: ... appears Put the system in standby then sequentially step through each of the functions indicated at the top of the window performing the necessary operations for each one Stepping is done via the Next button Finally click the Next button until the Cleaning Cycle tab is highlighted in yellow and the Cleaning Cycle menu appears Figure 16 46 Ink Installation Manager Ink replacement window Figure 16 ...

Page 253: ...ng to activate the BID pump 4 After cleaning out the tank the BID simulator is removed and an ink stopper is placed over it See illustration below Figure 16 48 Ink Removing Cleaning Cycle window Figure 16 49 BID station and BID ink stopper BID latch press here to release BID Ink stopper BID housing BID handle ...

Page 254: ...ENWW 253 17Pre transfer erase PTE This chapter contains the following sections z Overview z Cleaning the PTE cover ...

Page 255: ...nd paper dust Cleaning the PTE cover Clean the PTE cover weekly or whenever it is dirty Ink drops on the PTE cover hinder the full PIP discharge This results in light or dark strips running in the process direction Examine the strips with a magnifying glass you can notice that the screen dots seem splattered The screen dots should be round Use the following procedure to clean the PTE cover 1 Press...

Page 256: ...3 Pull the plastic tab below the PIP 4 Clean the PTE cover using a lint free wipe If necessary use IPA 5 Replace the PTE cover 6 Close the front door 7 Release the Emergency Stop button Figure 17 2 PTE cover PTE cover Air knife hoses ...

Page 257: ...256 Chapter 17 Pre transfer erase PTE ENWW ...

Page 258: ...EN 257 18Blower cabinet This chapter contains the following sections z Overview z Draining the cooler waste z Draining the solids air compressor ...

Page 259: ... the drain cooler door 2 Pull out the drain cooler hose 3 Place a drain waste container next to the drain cooler door For safety procedures see Disposing of consumables and cleaning materials on page 34 4 Open the tab by aligning it with the hose 5 Drain the cooler waste into the waste container 6 Set the tab to a perpendicular position to stop the flow 7 Close the drain cooler door Figure 18 1 Dr...

Page 260: ...orm this procedure make sure that you have a 200 ml 7 oz or more plastic waste container 1 Press an Emergency Stop button 2 Open the blower cabinet 3 Open the blower cabinet rear door 4 Insert the drain tube outlet into the plastic waste container 5 Turn the compressor drain valve counterclockwise Figure 18 3 Press rear Figure 18 4 Solids compressor drain valve Blower cabinet Compressor drain valv...

Page 261: ... 18 Blower cabinet EN 6 Water flows into the waste container Leave the valve open for about one minute 7 Turn the compressor drain valve counterclockwise 8 Remove the plastic waste container 9 Close all the doors ...

Page 262: ...ENWW 261 19Chiller This chapter contains the following sections z Overview z Warnings z Operating conditions z Control panel z Maintenance z Troubleshooting z Chiller timer ...

Page 263: ...enance instructions Chiller type HP Indigo presses are equipped with the following chiller z ultrafilter ultracool mini 0140 HP Indigo 50 60 Hz Manufacturers can modify chiller models or model names Contact the chiller manufacturer for details Contact your local HP Indigo service center for specific inspection and maintenance procedures for the chiller Note For Orion chillers used in Japan refer t...

Page 264: ...ir Nominal 25 C 77 F Minimum 15 C 5 F 2 Maximum 50 C 122 F 2For ambient temperatures below 5 C 40 F it is necessary to add ethylene glycol to the water of the circuit The required ethylene glycol concentration is obtained according to the following chart The ethylene glycol percentage of the total mixture by weight is given in the chart If any water is added to the mixture the concentration of eth...

Page 265: ...ter level in the tank is too low This condition causes the ultracool unit to stop 8 Low flow temperature control indicator This flow control can stop the compressor when there is no water circulation through the external water circuit In this case some flow still circulates inside the chiller The temperature control can also stop the compressor when you try to reach water temperatures below 7 C 45...

Page 266: ...at the water temperature indicated on the control thermostat is approximately at the setpoint 2 Verify the pressure of the pump 3 Verify the water level in the tank 4 Verify the state of the water filter if the pressure drop exceeds 0 5 bar 8 psi change the filter element Monthly 1 With the unit disconnected the main power switch is off clean the condenser with a blast of compressed air from the i...

Page 267: ...y running the chiller with the application stopped The motor fan is not working Check the motor fan fuses If the problem persists contact your HP Indigo service center Alarm due to low pressure of the refrigerant Gas leakage Contact your HP Indigo service center The low pressure safety switch SLP automatically resets itself when the pressure returns to normal Water level alarm Water leakage Check ...

Page 268: ...This ensures that the chiller is turned off only at the end of the workday The chiller timer is located behind the electronics cabinet below the Main Power switch Default Cause Solution Restart procedure The control thermostat displays the following codes LO The temperature has been below the setpoint for some minutes If the compressor is stopped the water temperature will rise to normal eventuall...

Page 269: ...tart Programming 1 To start a program entry press the Prog button The day arrow indicates Monday ON is displayed on the right side of the display panel 2 Use the d button to select the desired day You can program one day at a time or to program the whole week select 1 7 The arrow above the selected day flashes 3 Press the h button to set the hour 4 Press the m button to set the minute 5 You have p...

Page 270: ...Summer or winter time 1 To change from winter time to summer time press the d and the h buttons at the same time 2 To change from summer time to winter time press the d and m buttons at the same time Programming a holiday Use the holiday program to interrupt the automatic program from 1 to 45 days 1 Press the h button A two digit figure is displayed This figure indicates the number of days the aut...

Page 271: ...270 Chapter 19 Chiller ENWW ...

Page 272: ...ENWW 271 20Long term shutdown This chapter contains the following section z Long term shutdown ...

Page 273: ...by pressing two front pin latches Lower the container and pull it towards you to lift it out of its back slot Disconnect the two water pipes between the tank and the ink cabinet 4 Clean the ink tanks and reinstall them 5 Install the pumps 6 Refill the ink tanks with 3 8 liters of imaging oil Do not rebuild ink 7 For BID maintenance prior to a long term press shutdown see Press long term shutdown m...

Page 274: ...nt separation although the units are identical Chiller The press uses a water chiller to regulate ink and press temperature cleaning station A wetting sponge wiper unit that cleans the PIP between printing cycles CMYK The four process colors used in printing cyan magenta yellow and black collation In digital press work the sequential printing of signatures copy One printed unit of a publication de...

Page 275: ...ing plate or blanket cylinder intermediate rotor A rotor that transfers paper from the perfector to the exit rotor ITM the intermediate transfer media drum The drum around which the blanket is wrapped It transfers the image from the PIP to the substrate job The entire publication to be printed laser beam The acronym for light amplification by stimulated emission by radiation The laser is an intens...

Page 276: ...om a series of four or more separations in order to produce intermediate colors shades and tones Pre Transfer Erase PTE The PTE lamp discharges the PIP to enable the recording of a new image that is the next separation register In printing and image assembly the exact fitting of two or more images ensuring exact alignment with each other raster image processor RIP The part of an output device that...

Page 277: ...eakdown of color images to CMYK sheet A single physical sheet of paper complete with one or more pages printed on one side simplex or both sides duplex signature A single physical sheet of paper composed of several imposed pages simplex One sided printing spread One side of the printing sheet writing head An HP Indigo press subsystem composed of laser diodes that defines the image on the PIP Term ...

Page 278: ...EN 277 AParts and supplies This appendix contains the following sections z Imaging products z Operator maintenance parts z Special tools and jigs z Supplies ...

Page 279: ...Magenta 10 cans MPS 3133 43 HP ElectroInk Yellow 10 cans MPS 3134 43 HP ElectroInk Orange 10 cans MPS 3135 43 HP ElectroInk Green 10 cans MPS 3121 43 HP ElectroInk Violet 10 cans MPS 3136 43 HP ElectroInk Rhodamine Red 10 cans MPS 3122 43 HP ElectroInk Bright Yellow 10 cans MPS 3123 43 HP ElectroInk Reflex Blue 10 cans MPS 3124 43 HP ElectroInk Transparent1 10 cans MPS 3125 43 HP imaging oil 4 bot...

Page 280: ...14 01 Cleaning station wiper length 2 mm 0 08 inch MPT 1515 01 PIP underlayer MCH 1490 41 Sheet separator MCC 2248 01 Suction finger nipple MCC 2247 01 BID stand MJX 2910 01 Allen key 3 mm for impression paper holder MTZ 0013 03 Suction cups for rotors and perfector set of 36 MKT 1060 01 Density sensor cleaner MJX 0221 51 Description Part number PIP underlayer installation jig MJX 1336 51 PIP unde...

Page 281: ...mber Supplier IPA 1 liter MCH 0027 01 Available at any pharmacy Disposable gloves nitrile MCH 0116 51 Available at any pharmacy Gloves heat resistant MTS 0003 01 Synthetic cleaning wipes lint free MTS 0009 03 Global Logistic 21902 985 Texwipe TX1009 Alpha wipe or equivalent Cotton swabs MTS 0007 01 Available at any pharmacy Cleaner liquid organic for removing ink stains from cloth MCH 0115 51 Glob...

Page 282: ... replacing 71 114 transfer to 20 blower cabinet 257 blower suction control pad 153 buttons emergency stop 68 inching 31 68 paper feed 68 print 43 sample tray 69 C cabinet blower 257 Calibration machine LUT 74 calibration full densitometer 81 ink density 248 inline densitometer 80 press colors 72 81 charging and discharging the PIP 18 checking ink flow 246 ink pump 246 chiller 261 269 control panel...

Page 283: ... sensor 199 filters 194 filters replacing 196 refilling tank 195 replacing oil filters 196 replenishment 70 imaging products list 278 importing archived job 48 imposition job 51 impression drum 189 area accessing 175 impression paper maintenance 72 replacing 72 190 inching button 31 68 inch safe service method 32 indicators door interlocks and warning indicators 29 initializing after long term shu...

Page 284: ... system 177 subsystems 151 paper tray guides adjusting 162 performing custom color adjust 73 full densitometer calibration 81 inline densitometer calibration 80 photo imaging plate PIP 135 148 PIP adjusting BID to PIP pressure 230 charging and discharging 18 inking 19 installing new 140 maintenance 72 removing old 136 replacing 136 viewing log 148 placement image 64 position bellows 239 power cuto...

Page 285: ...ex printing shifting separations 125 solids air compressor draining 259 sorting jobs 47 special tools and jigs 279 specifications color 15 paper 150 press 14 sponge roller replacement 208 standby state 31 start of day routines 84 start up print cycle 18 storing BID unit 229 substrate loading 158 substrate related parameters 75 transport system testing 171 treatment list 280 type defining 157 sucti...

Page 286: ...go Division 550 King Street Littleton MA 01460 USA Tel 1 978 506 7425 Fax 1 978 506 7417 International Hewlett Packard Company Indigo Division Limburglaan 5 6221 SH Maastricht The Netherlands Tel 31 43 356 5656 Fax 31 43 356 5600 Israel Hewlett Packard Company Indigo Division Kiryat Weizmann P O Box 150 Rehovot 76101 Israel Tel 972 8 938 1818 Fax 972 8 938 1338 ...

Page 287: ...286 Appendix B Service and support ENWW ...

Page 288: ...reorder P N CA294 01131 Copyright 2005 Hewlett Packard Company This is an HP Indigo digital print Printed in Israel www hp com go indigo ...

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