mnu-1651-51 (x51121_e)

use

MNU-1651-10

hp indigo press ws2000for use also with:

Indigo Omnius WebStream 50

hp indigo press ws2000

user guide

© Hewlett-Packard Company 2002

All Rights Reserved. Reproduction, adaptation or translation without prior written permission is prohibited, except as allowed under the copyright laws.

The information furnished in this manual is for informational use only, is subject to change without notice, and should not be construed as a commitment by HP Indigo. All intellectual rights arising from, accruing to, and residing in this manual are the property of HP Indigo. HP Indigo assumes no responsibility or liability for any errors or inaccuracies that may appear in this manual.

Except as permitted by HP Indigo, nothing herein may be copied, reproduced or distributed in any form or any medium without the express written permission of HP Indigo.

HP Indigo, HP Indigo press, HP Indigo RIP, and HP Electroink are trademarks or registered trademarks of HP Indigo.

PostScript® is a trademark of Adobe Systems Incorporated.

Windows® is a U.S. registerd trademark of Microsoft Corp.

All other products or name brands are trademarks of their respective holders.

The HP Indigo press is a Class 1 Laser Product containing high voltage power supplies and laser light sources. There is no danger to persons or equipment when the system is operated in accordance with the directions provided by HP Indigo in this and other publications. All high voltage power supplies and laser sources are located behind protective covers. Warning labels are attached to each protective cover. Do not remove covers.

Publication number:MNU-1651-51Part number:5851-1120First Edition: April, 2002.

Hewlett-Packard Company11311 Chinden BoulevardBoise, Idaho 83714 U.S.A.

Contents
1 Preface
About this user guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Conventions used in this guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Presses supported . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2 Getting started

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14HP Indigo press ws2000 overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

A tour of the HP Indigo press ws2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15The print cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16A look inside the HP Indigo press ws2000 . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3 Safety

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20In this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Warning labels on the HP Indigo press ws2000. . . . . . . . . . . . . . . . . . . . . . 20Warning signs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Safety devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Material Safety Data Sheets (MSDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Fire extinguishing equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Eye wash stations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Heat insulating tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Electrical safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Emergency stop buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Inching button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Standby state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Maintenance safety and emergency procedures . . . . . . . . . . . . . . . . . . . . . . . . 25Emergency power cut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Door interlocks and their warning indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Flammable liquids and fumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Isopropyl alcohol (IPA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Handling and storing imaging oil, inks, and IPA . . . . . . . . . . . . . . . . . . . . . . 28Disposing of consumables and cleaning materials. . . . . . . . . . . . . . . . . . . . 29Additional information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4 HP Indigo press ws2000 basics

Navigating the HP Indigo press ws2000 interface . . . . . . . . . . . . . . . . . . . . . . . 32User levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Sequential windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Wizards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

HP Indigo online help suite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33About the online help suite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Reference guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Operation guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Help Topics window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Printing help topics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Related topics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

ENWW 3

5 The main windows

Using the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38The Schematic window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Managing jobs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42The Job Manager window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42The Loaded Jobs list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Customizing Job Properties field display . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Changing the order of the Print Queue. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Retained jobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Using the Job Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Job Editor functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Configuring the Hotfolder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Job imposition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

6 Operating the press

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Turning the press on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Turning the press off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Preparing the press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Printing jobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Second pass reinsertion jobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Job maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Editing job properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55The Job Properties window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Look-up tables (LUTs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Screening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Color match . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Image placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Repeat length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Advancing the system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Control pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Web Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Inching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Find Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Using the handwheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Angle indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Mechanical reset option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

7 Web transport system

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Threading procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Defining substrate type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Editing an existing substrate properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Selecting a threading mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Double S threading procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Pre-threading procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Threading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Setting repeat length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Correcting image skew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Straight path threading procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Pre-threading procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90Threading procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

4 ENWW

Centering the web . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105Setting repeat length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106Image deskew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Web replacement procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108Using the web pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109Setting substrate flow rate with the web pump . . . . . . . . . . . . . . . . . . . . . . . . . 110Troubleshooting web jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110Checking image placement accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111Test jobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Adjustment procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114Pressure rollers tension adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

End-of-roll indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115End-of-roll sensor adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

8 Second pass printing

Second pass printing introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120Web motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123Eye-mark placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Inserting eye-mark on the HP Indigo press ws2000. . . . . . . . . . . . . . . . . . 124Simplex reinsertion with rewinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125Simplex reinsertion without rewinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126Duplex reinsertion with rewinding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127Duplex Reinsertion without rewinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Eye-mark placement and size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128Eye-mark size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129Eye-mark position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129Designing a duplex job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

How to design first and second pass jobs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130Designing a simplex job with rewind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131Designing a simplex job without rewind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133Designing a duplex job with rewind. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135Designing a duplex job without rewind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138HP Indigo press ws2000 operator instructions . . . . . . . . . . . . . . . . . . . . . . . . . 140QuarkXpress operator instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141Operator – setting the press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

First pass printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141Second pass printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142Eye-mark sensor calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144Simplex eye-mark calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146Duplex eye-mark sensor calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149Repeat Length Matching Verification wizard . . . . . . . . . . . . . . . . . . . . . . . 150

9 Job handling

Working with the HP Indigo RIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154Preparing to print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Preparing the press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154Preparing the job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154Selecting a print mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155Changing the machine state. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Printing the job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157Printing a proof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

ENWW 5

Pausing or stopping a print job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158Pausing a print job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158Switching between jobs during printing . . . . . . . . . . . . . . . . . . . . . . . . . . . 158Ending the current job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159Printing from a specified copy or spread number . . . . . . . . . . . . . . . . . . . . 159Stopping a job before the full run is printed . . . . . . . . . . . . . . . . . . . . . . . . 160Stopping the system in case of emergency . . . . . . . . . . . . . . . . . . . . . . . . 160

Handling image wetness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160Changing feed blanket fan mode on

presses not equipped with dripping prevention kit . . . . . . . . . . . . . . . . 161Changing feed blanket fan mode on

presses equipped with dripping prevention kit . . . . . . . . . . . . . . . . . . . 162

10 Handling consumables

Working with ink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166HP ElectroInk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166Imaging oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166Draining the ink tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166Refilling the ink tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167Replacing ink cans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169Changing the color of an ink tank using the Install Ink wizard . . . . . . . . . . 170Increasing ink conductivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171Decreasing ink conductivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171Viewing the ink log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Maintaining the blanket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172Replacing the blanket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172First transfer pressure adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175Viewing and modifying blanket temperature. . . . . . . . . . . . . . . . . . . . . . . . 176Viewing the blanket log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176Cleaning the blanket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177Blanket recovery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177Enabling/disabling automatic blanket cleaner page. . . . . . . . . . . . . . . . . . 178Correcting misregistrations (supervisor only) . . . . . . . . . . . . . . . . . . . . . . . 179

Maintaining the PIP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181Replacing the PIP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182Preparing the PIP for printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

Defining substrate type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189Maintaining the separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

Replacing the separator waste bag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191Maintaining the separator imaging oil level . . . . . . . . . . . . . . . . . . . . . . . . 191Adding separator imaging oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193Cleaning separator imaging oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

Maintaining the scorotron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193Stretching the corona . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193Advancing the corona. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

11 Operator routines

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196Practical tips for performing maintenance routines . . . . . . . . . . . . . . . . . . 196

Start of day routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197Power up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197Activate the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197Prepare the press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

6 ENWW

Perform color adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197End of day routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

Clean the blanket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198Clean the PIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198Clean the cleaning station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198Check the impression film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198Set the press position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198Clean the slit injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198Replace the plastic waste bag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198Cool the blanket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199Lubricate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199Empty the drain cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199Shut down the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

Weekly routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200Cleaning station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200Scorotron and dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201Developer drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201Slit Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201Electrometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201Developer station and catch tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202Reverse rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202Squeegee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202ITM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202Ink tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202Substrate feed rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203Driving belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203Final check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

Interlock check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203Interlock fault condition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

Long-term shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206Shutting down the press for a long period . . . . . . . . . . . . . . . . . . . . . . . . . 206Initializing the press after a long shut down . . . . . . . . . . . . . . . . . . . . . . . . 207

12 Maintaining the press

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210Cleaning the slit injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

Light cleaning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210Full cleaning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Maintaining the cleaning station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214Removing the cleaning station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214Cleaning the wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215Replacing the wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215Reinstalling the cleaning station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

Maintaining the developer station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216Short cleaning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216Full cleaning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217Replacing the wiper blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Cleaning the imaging ink pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219Cleaning the separator clean sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221Cleaning the squeegee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222Cleaning the electrometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

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Maintaining the reverse rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224Cleaning the reverse rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224Replacing the wetting blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226Replacing the reverse roller blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227Reassembling the reverse roller unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

Maintaining the scorotron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229Maintaining the PIP underlayer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

Removing the PIP underlayer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231Installing the PIP underlayer jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233Mounting the PIP underlayer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234Running a test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237Performing troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Mounting the impression film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238Web Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239Lubricating the press. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240Lubricating the front section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241Lubrication points behind the front upper door . . . . . . . . . . . . . . . . . . . . . . 242Lubricating the substrate input section . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242Lubricating the substrate exit section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243Lubricating the rear section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

13 Accessories

Imaging products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248Additional imaging products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249Additional parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250Disposable parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

14 Glossary

A Service and support

Index

8 ENWW

Preface

Welcome to the HP Indigo press ws2000. This preface provides an overview of the user guide contents and explains conventions used in this guide.

This preface contains the following sections:

● About this user guide

● Conventions used in this guide

● Presses supported

ENWW 9

About this user guide

This user guide assumes that you are familiar with the basic Windows environment and that you have basic Windows skills such as using a mouse and choosing menu items. If you do not, please see the Windows documentation that came with the computer.

The user guide contains the following information:

● Preface: Provides an overview of the user guide contents and explains conventions used in this guide.

● Getting started: Describes the workflow of the HP Indigo press ws2000 and the print cycle.

● Safety: Provides important safety information for using the HP Indigo press ws2000.

● HP Indigo press ws2000 basics: Presents the HP Indigo press ws2000 user interface and the help system.

● The main windows: Discusses the control panel, the Job Manager window, and the Job Editor.

● Operating the press: Explains HP Indigo press ws2000 basic operations.

● Web transport system: Describes threading procedures, web replacement and adjustment procedures, how check for image placement accuracy, and how to troubleshoot web jams.

● Second pass printing: Explains the purpose of, and describes the procedures for using, the eye-mark system, to assure proper placement of second pass images.

● Job handling: Discusses details of the print cycle.

● Handling consumables: Details replacement and maintenance of such consumables as imaging ink, the blanket, and impression film.

● Operator routines: Presents routine procedures for correct maintenance of the HP Indigo press ws2000.

● Maintaining the press: Describes maintenance procedures in detail.

● Accessories: Lists HP Indigo press ws2000 accessories, their part numbers, and sources.

● Glossary: Provides definitions of terms used throughout the HP Indigo press ws2000 documentation set.

● Service and support: Provides HP Indigo service and support contact information.

Conventions used in this guide

This guide uses the following documentation conventions:

● Keyboard keys to press appear in all uppercase, for example: Press the SHIFT key.

● Menu options are indicated in bold type, for example: Choose New from the File menu.

● Window names appear in italics. For example: Enter the following information in the Modify window.

● Options that you need to select in dialog boxes and dialog box names appear in bold type, for example: After selecting the options in the Print dialog box, click OK.

● References to other sections in the guide appear in quotes, for example: See “Installation” section on page 22.

10 Chapter 1 Preface ENWW

Presses supported

This guide applies to the following Indigo and HP Indigo presses:

Indigo press HP Indigo press

WebStream 50 HP Indigo press ws2000

ENWW Presses supported 11

12 Chapter 1 Preface ENWW

Getting started

This chapter contains the following sections:

● Introduction

● HP Indigo press ws2000 overview

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Introduction

This chapter is a general introduction to the press. It is intentionally basic and will help you become acquainted with the machine, its various features, some of the more common operator functions and the routines you will most often be performing. Read it before you start working with the press. It will put you well on your way to understand the HP Indigo press ws2000 and how it operates.

HP Indigo press ws2000 overview

The HP Indigo press ws2000 is a web-fed digital offset color press that incorporates the patented HP ElectroInk liquid ink technology and high speed electronic imaging to produce fully-finished, high quality color printing jobs. The HP Indigo press ws2000 features a new, intuitive and friendly user interface, provides diagnostic windows that take the guessing out of printing, accepts very large files and simplifies the entire process of archiving.

The HP Indigo press ws2000 enables you to print on a variety of substrates that are both thicker and stiffer than paper. With its ground-breaking one-shot technology, the press transfers all separations of the image onto the blanket — one separation per revolution — and then, in only one revolution, transfers the entire image to the substrate.

The HP Indigo press ws2000 comes equipped with an embedded raster image processor (RIP), the HP Indigo RIP. The embedded RIP enables you to process PostScript or portable document format (PDF) format files at your press station. It is fast, offers proofing and previewing capabilities, and supports limited editing capabilities. It RIPs jobs immediately upon arrival at the station.

14 Chapter 2 Getting started ENWW

A tour of the HP Indigo press ws2000

The HP Indigo press ws2000 is divided into four basic sections — the front, rear, web input side and web output side.

Figure 2-1. Schematic indicator window

Figure 2-2. The HP Indigo press ws2000

This is the schematic of the HP Indigo press ws2000 you will be working with on screen (front view)

Rear

Input

Output

Front

ENWW HP Indigo press ws2000 overview 15

HP Indigo press ws2000 jobs begin at desktop publishing stations unrelated to and often at a distance from the press. There, text and graphics are designed and integrated, pages impositioned, and PostScript and/or PDF print files created. The print files are then transferred to the system.

The system consists of an HP Indigo RIP and an HP Indigo press ws2000. The HP Indigo RIP reads the files from the pre-press station, converts them to bitmaps, one per separation, and then sends them to the HP Indigo press ws2000 for printing.

The print cycleOnce the job is in the Print Queue on the press, the press can begin the print cycle. Printing a job using the press takes six steps:

1 starting a print job

2 charging and discharging the PIP

3 inking the PIP

4 removing excess ink

5 transferring the image to the blanket

6 printing the image

Some of these steps require operator intervention, while others occur automatically.

Starting-up

Clicking the Print button on the control panel of the press starts the print cycle. The drums start rotating.

Charging and discharging the PIP

The scorotron unit electrically charges the photo imaging plate (PIP) as it rotates on the PIP drum. The writing head laser beam selectively discharges the PIP and an image is formed on the PIP.

Figure 2-3. From pre-press to the HP Indigo press ws2000

Figure 2-4. Print buttons


Inking the PIP

Injectors spray HP ElectroInk of the required color into the gap between the positively-charged PIP drum and the negatively-charged developer drum. The particles are attracted either to the developer drum or to the PIP. The image areas attract the ink particles and the non-image areas repel them. This inks the image on the PIP.

Removing excess ink

The electrically-charged developer drum rotates in a direction unsynchronized to the PIP drum, collecting the excess ink from the PIP-developer drum gap. Wiper blades remove the ink from the developer drum to a catch tray, where it is drained to its appropriate ink tank.

The reverse roller cleans off any excess ink particles that may have been attracted to the non-image areas on the PIP.

The image is now ready to be transferred to the blanket.

Transferring the image to the blanket

The PIP comes in contact with the intermediate transfer media (ITM) drum, which is covered by the blanket. The positively charged blanket attracts the inked image, and the image is transferred from the PIP to the blanket (this is the first transfer).

The ITM blanket is hot and melts the ink particles into a thin, molten film.

Printing the image

After the last transfer of the last separation, the image is transferred from the blanket to the substrate (this is the second transfer), using one-shot technology. There are generally either four or six separations.

With a substrate between them, the impression drum now presses against the ITM, while the substrate moves in the direction of the process, causing the melted ink image to solidify and adhere to the substrate.

The web handling system moves the web for printing at a rate which allows it to perform a second transfer, and then it moves back to control the gap between the printed images on the substrate.

The transport system then moves the printed substrate towards the exit roller.

ENWW HP Indigo press ws2000 overview 17

A look inside the HP Indigo press ws2000When you look inside the HP Indigo press ws2000, you will see the following:

1 Catch tray — collects excess ink for recycling2 Developer drum — forms an electric field that attracts excess (non-image) ink while

repelling image ink3 Writing head — transfers the image to the PIP by laser beam4 Slit injector — where the ink jets into the nip5 Scorotron — where the PIP is charged6 Cleaning Station7 PIP drum — image carrier8 ITM cover9 ITM drum — location of the blanket10 Printing nip — point of second transfer11 Ladder12 Input substrate roll13 Dancer — keeps the substrate taut14 Separator — prepares recycled imaging oil for reuse15 Waste basket16 Impression drum — applies counter-pressure on printed web17 Ink tanks — stores heated HP ElectroInk18 Ink cans — where concentrated solid inks are stored19 Web guide 20 Output substrate roll

Figure 2-5. Inside the HP Indigo press ws2000

1 2 3 4 5 6 7 8 9

14151617181920

10 11

1213


Safety


● Overview

● Safety devices

● Maintenance safety and emergency procedures

● Emergency power cut-off

● Door interlocks and their warning indicators

● Flammable liquids and fumes

ENWW 19

Overview

This section provides guidelines to ensure the safety of personnel operating and maintaining the HP Indigo press ws2000.

The recommended safety procedures described below apply to operators and other personnel working on the HP Indigo press ws2000.

In this chapterThe HP Indigo press ws2000 is equipped with advanced safety features. The HP Indigo press ws2000 is safe to use and safe to maintain as long as you conform to the safety procedures outlined in this chapter. These procedures have been tested to enable you to work safely and effectively.

Follow these guidelines:

● Only properly trained personnel thoroughly familiar with all the safety and maintenance procedures of the press may operate and maintain the HP Indigo press ws2000.

● Read and understand the safety procedures, including local environmental protection procedures before you attempt to use the unit.

● Call an authorized HP Indigo customer engineer for service and repairs of the press. Do not attempt to service or repair the press.

Warning labels on the HP Indigo press ws2000The following symbols appear on warning labels on the HP Indigo press ws2000:

Symbol Meanings

Laser HazardDANGER. Invisible laser radiation may be present when doors are open and interlocks are defeated. Avoid direct exposure to beam.

Laser Emission Warning – Caution. Invisible laser radiation. Avoid exposure to beam. Class 3B laser product.

Laser RadiationThe lasers in the HP Indigo press ws2000 emit radiation in the invisible range. The laser unit in the writing head is well-enclosed in 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 inserted in the path of the writing head window. Do not attempt to clean the writing head window or look into it while the unit is operational.

20 Chapter 3 Safety ENWW

Electrical HazardHAZARDOUS VOLTAGE. Will cause severe or fatal injury. Press the Emergency Stop button to turn off the power.

Electrical HazardsBefore you start any maintenance procedure that involves an electrically powered subsystem, make sure the subsystem is disconnected. If you are not sure that the subsystem is turned off, turn off the main circuit breaker. Always follow the lockout procedure.

Live Parts Hazard AlertLIVE PARTS. Will cause severe or fatal injury. Press the Emergency Stop button to turn off the power before disconnecting any cables.

Entanglement Hazard AlertWARNING. Open gears and mechanical parts. Can trap hands, fingers, long hair and clothing, and cause serious injury. Stay well clear.

Pinch Hazard AlertWARNING. Pinch points between rollers, wheels and other parts can trap hands, fingers, long hair, and clothing, and cause serious injury. Stay well clear.

Pinch Hazard – Warning: Keep hands away from this area when covers are not in place.

Mechanical HazardsThe HP Indigo press has a number of rotating parts and gripping devices (drums, gears, grippers, and so on). Exercise special care when you perform maintenance work around these parts. Before starting a maintenance procedure, press one of the Emergency Stop buttons to ensure that there is no unexpected start-up of the unit or other release of hazardous energy. All mechanical repairs must be performed by authorized HP Indigo customer engineers only.

Hot Surface HazardWARNING. Hot surface. Can cause burns. Do not touch.

Heat HazardsThe blanket and ITM drum become very hot during normal operation of the HP Indigo press (temperatures exceed 130° C [266° F]). Do not touch the ITM drum or its cover with bare hands. Carelessness may cause burns. Wear thermal insulated gloves. Remove old blankets with needlenose pliers.

Symbol Meanings

ENWW Overview 21

The following warnings without symbols are also posted on the press:

Warning signsPost warning signs that clearly emphasize the dangers involved in operating and maintaining the unit. The following warnings are recommended:

● This machine is to be operated by properly trained and qualified operators only.

● Do not wear ties, other loose clothing, or loose jewelry when operating and maintaining the unit.

● Never operate a press with loose or long hair unsecured. Long hair must be protected against catching on moving parts or snagging on objects by being compacted into a hat or tied out of the way.

● Flammable vapors may be present from heated imaging oil!

● No smoking, open flame or sources of ignition allowed!

● Make sure the room is properly ventilated at all times (refer to the site preparation guide).

● Danger of pinching and crushing from moving machine parts!

● Keep hands away from moving machine parts.

● Access to main circuit breaker must remain free at all times.

● Do not operate the HP Indigo press ws2000 with doors open.

● Ink and imaging oil are irritating to eyes and skin. Use rubber gloves.

● ITM drum and blanket are hot. Use insulated gloves.

Warning

Open Gears HazardWarning: Open gears. Stay clear of gears and wheels when machine is running.

Pinch HazardWarning: Keep hands away from this area when covers are not in place.

Laser Emission WarningCaution: Invisible laser radiation. Avoid exposure to beam. Class 3B laser product.

Hot Surface WarningWarning: Hot surface. Can cause burns. Do not touch.

Hazardous Voltage WarningWarning: Hazardous voltage. Will cause severe or fatal injury.

Air Conditioning PrecautionDo not step here or place heavy weight.

Ink Pump HazardHazardous voltage. Will cause severe or fatal injury. Press the Emergency Stop button to turn off the power before handling the ink pump unit.


Safety devices

Material Safety Data Sheets (MSDS)MSDS are supplied for consumables, including the different HP ElectroInks, imaging oil, imaging agent, adhesion promoters, and adhesion promoter test fluid.

Keep the MSDS readily available in your work area. Read and consult them for your personal protection.

Keep the MSDS in a protective plastic folder.

Fire extinguishing equipmentSince the HP Indigo press ws2000 generates flammable fumes and is also internally heated, a danger of fire exists. Take the following precautions to protect against the possibility of fire:

● Place fire extinguishers in visible locations within 7.6 meters (25 feet) of the HP Indigo press ws2000 and any flammable or combustible liquid storage areas.

● Require regular inspection of the fire extinguishers (at least annually) and have designated employees trained in their use. Employees should be retrained at least once a year.

Eye wash stationsThe HP Indigo press ws2000 uses inks and imaging oil that may be irritating to skin and eyes. In extreme cases of contamination these may cause blindness if they come in contact with eyes. Take the following precautions:

● Install eye wash stations within 7.6 meters (25 feet) of areas where the ink and imaging oil are handled, dispensed or stored.

● Provide eye wash liquid at the eye wash stations to comply with ANSI standard Z358.1–1990 (available from most safety supply companies).

● When handling inks and imaging oil, wear safety glasses with side-shields and rubber gloves (nitrile disposable gloves are recommended).

Heat insulating toolsThe blanket and ITM drum become very hot during normal operation of the HP Indigo press ws2000, with temperatures exceeding 130°C (266°F). Carelessness may cause burns. Take these precautions when you work near the ITM drum or when you are replacing the blanket:

● Wear insulated thermal gloves.

● Use needlenose pliers or other grasping instruments to remove and replace the blanket.

● Do not place your hand on a moving blanket. Use needlenose pliers to grip the blanket metal bar.

ENWW Safety devices 23

Electrical safetyThe HP Indigo press ws2000 must be properly grounded at all times. Before operating the unit, ensure that it is grounded in conformance with the electrical code and the standards for your country (see the HP Indigo press ws2000 Site Preparation Guide for recommendations). If in doubt, check with a licensed electrician or with your HP Indigo customer engineer.

CAUTION Do not operate the HP Indigo press ws2000 unless it is properly grounded. Perform a weekly check of grounding cables.

If, during a maintenance procedure, a cable has to be disconnected or reconnected, you must electrically turn off and lockout the press. See "Machine lockout regulations during servicing and maintenance" on page 25. Turn off the press by pressing an Emergency Stop button.

Emergency stop buttonsPress a red Emergency Stop button to disable the main engine.

A red Emergency Stop button on a yellow background is located at each end of the unit in the input and output web transport cabinets. When pressed, these buttons prevent the unit from operating and shut off the operating voltage to most system devices.

Press an Emergency Stop button in an emergency when you need to stop the unit or whenever you perform any maintenance work within the unit.

● To turn off power press the button.

● To restore power rotate the button clockwise.

Figure 3-1. Emergency Stop buttons

Exit side

Feed side

Rewinder side (next to the substrate exit)

Emergency Stop button



Inching buttonUse the Inching button during maintenance procedures that require inching of the drums. Opening any interlocked door will put the machine in the off state. Opening either the web feed or web exit door will enable the Inching button on the side of that door. Opening both the feed and exit doors will disable inching. During inching, the machine state is in the Standby state.

Standby statePut the machine in Standby state when the system is not required for printing or when the system is to remain unattended. The press automatically goes into Standby state when it remains idle for more than 20 minutes.

Maintenance safety and emergency procedures

You must perform all maintenance procedures with an Emergency Stop button pressed, unless otherwise specified. Follow maintenance procedures exactly as outlined in this and other HP Indigo press ws2000 documents. Failure to perform any procedure exactly as outlined could result in harm or fatal injury to personnel.

Inch-safe-service method

Performing maintenance on rotating parts while the press is on is dangerous and is not permitted. Health and safety regulations require that you use the inch-safe-service method described here.

1 Stop the press and put it into a safe state. Press an Emergency Stop button to put the press into a safe state with the power on.

2 Perform the necessary procedure (for example, cleaning).

3 Release the press from the safe state, then inch the press (using the Inching button described later in this chapter) and immediately put the press back into the safe state before continuing servicing.

4 Continue inching the press, putting it into the safe state, and servicing the desired press part until the job is completed.

Machine lockout regulations during servicing and maintenance

Lockout means either locking an energy-isolating device (for example, a fuse box) in the off state in order to prevent the activation of the press, or unplugging the equipment with the plug being under the exclusive control of the person performing the servicing or maintenance.

Whenever there is any risk of unexpected machinery activation, start up, or injury to personnel, you must follow a lockout procedure.

The lockout regulation has certain exceptions for minor servicing and setup activities. However, always remember that you must perform such activities using alternative protection to prevent exposure to hazards.

The inch-safe-service method (above) used in combination with other safety precautions provides alternative protection.

ENWW Maintenance safety and emergency procedures 25

Emergency power cut-off

Use one of the following methods to cut power in an emergency:

● Main circuit breaker – The HP Indigo press ws2000 main circuit breaker is located on the lower rear wall on the web feed side. Place it in the down position to turn off all power to the system. Always maintain free access to the main circuit breaker to enable immediate power cut-off in case of emergency.

● Main plug – Pull the main plug from the wall socket.

Figure 3-2. Main circuit breaker and Power Enable switch

Main circuit breaker


Door interlocks and their warning indicators

The HP Indigo press ws2000 has door interlock safety devices that stop the machine whenever certain service doors are opened. These safety devices turn off operating voltage to disable system devices.

WARNING! Access and use of bypass keys must be restricted to specially trained personnel. Do not disconnect or override any of these safety devices when operating the system.

The following doors are interlocked:

● Front door

● Upper feed door

● Lower feed door

● Feed rollers cover

● Upper exit door

● Web exit door

● Tower (VME) door

● ITM cover

Opening any one of these doors activates the interlock and prevents the operation of necessary devices such as the high voltage power supply, the main motor, or the web handling system.

All the interlocked doors have audio (three beeps) and visual indications when they are open. The door and interlock warning indicators appear in the control panel, the Schematic window, and the Interlocks window which shows all open doors.

The press is put into the Hold state when you open a door while the press is in the ready state.

When you open an interlocked door or the ITM cover, the machine status changes to hold, the door warning icon appears in the warning indicator area within the control panel, and an indication of which door is open shows in the animated schematic indicator in the control panel. Inching is possible when the machine is in the hold state, but all machine functions that have to do with printing are disabled. Removing a subassembly or inching the machine changes the status to standby. If you simply close the door without performing any activity, the status returns to Ready.

Figure 3-3. Interlocks window

ENWW Door interlocks and their warning indicators 27

Flammable liquids and fumes

Due to the fact that the imaging oil used in the HP Indigo press ws2000 is combustible (US DOT Class 3A) follow these safety procedures when you work with it:

● Operate the press only in a well-ventilated room (as described in the HP Indigo Press ws2000 Site Preparation Guide). The HP Indigo press ws2000 is equipped with ventilation fans. If they are not functioning, the unit will enter an error state and the machine will become inoperable.

● Do not smoke or introduce sources of ignition (such as pilot lights, open flames, stoves, heaters, or halogen lights) near the press. Avoid creating sparks (static, electrical or mechanical) or introducing any spark-producing equipment within 7.6 meters (25 feet) of the HP Indigo press ws2000.

● Clean up spills immediately after they occur and dispose of soaked cleaning materials promptly.

Isopropyl alcohol (IPA)IPA is a highly volatile and flammable liquid (USDOT Class 1B). Do not apply it to hot surfaces or place it near an open flame or equipment likely to generate electrical sparks.

Use IPA to clean specified parts only. Clean with IPA only when the printing engine is idle. When you use IPA, wait two to three minutes after application before proceeding. This will allow the IPA to evaporate. If you can not tell if the IPA has evaporated, use your finger to feel for wetness.

IPA contamination

The inks used in the press are highly sensitive to IPA contamination. When you clean with IPA, always take special precautions not to contaminate the ink with even small amounts of IPA. IPA can radically change the conductivity and electrical parameters of the ink.

If you suspect contamination, thoroughly flush the ink in question from the system and replace it with fresh ink.

If you cannot visually determine whether contamination has occurred use your finger to feel for any wetness. When using IPA, wait two to three minutes to allow it to completely evaporate before proceeding.

Handling and storing imaging oil, inks, and IPATake the following precautions when handling or storing imaging oil, inks and IPA:

● To avoid fire or possible explosion hazard, store imaging oil, inks and IPA in fireproof cabinets or in a special combustible liquids storage room.

● Only trained personnel should handle imaging oil, HP ElectroInk, and IPA.

● Keep containers tightly closed at all times. If a container appears damaged, transfer the contents to a dry, clean and suitable container that can be tightly sealed.

● When handling imaging oils and inks, wear safety glasses with side shields, long sleeve overalls and protective gloves, as indicated on the MSDS.

● When draining the air-conditioning drain tank, do so carefully. Use a suitable receptacle and avoid splashing.

● Avoid drinking or otherwise ingesting imaging oil, inks, IPA or any waste fluids.

● Refer to local combustible material handling regulations.


Disposing of consumables and cleaning materialsDuring the operation of the HP Indigo press ws2000, you should properly dispose of the consumables and cleaning materials that you use. Consult with your local authorities and determine the correct manner in which to dispose of the following wastes:

● Cooler drain liquid (waste and imaging oil)

● Imaging oil and ink

● Spent HP ElectroInk containers

● Blankets

● PIPs

● Waste bags with ink waste accumulated from the separator unit

● Cleaning pads or cloths soaked in imaging oil

● Rags, pads or tissue paper contaminated with ink

● Contaminated chemical-resistant gloves

● Fluorescent lamps

● Empty imaging oil containers

Additional informationIt you have any questions regarding safe operation of the HP Indigo press ws2000, do not continue operation without contacting an HP Indigo customer engineer. Additional MSDS are available upon request from your HP Indigo customer engineer.

ENWW Flammable liquids and fumes 29

HP Indigo press ws2000 basics


● Navigating the HP Indigo press ws2000 interface

● HP Indigo online help suite

ENWW 31

Navigating the HP Indigo press ws2000 interface

The press interface is easy to use, intuitive, and fully compatible with the MS Windows NT conventions.

The toolbar menus list all the options necessary for easy work flow. Icons are available for all menu options, and you can pick and choose from among them to create your own customized toolbar. You can access submenus by clicking the toolbar icon, by choosing the menu option, or by clicking the relevant subsystem in the control panel.

User levelsDifferent levels of users have different access to HP Indigo press ws2000 windows. By default you have operator access, which provides access to all functions that are intended for performance by an operator. No password is necessary.

Sequential windowsThe HP Indigo press ws2000 helps you to perform complex procedures in the correct order. When you start a complex procedure only the window that relates to the first steps of the procedure is accessible. Additional windows become available as you progress.

WizardsThe HP Indigo press ws2000 uses wizards to cut short the usual input process by giving interactive, step-by-step instructions for complex routines. For example, the Print Cleaner wizard helps you clean the printer.

Figure 4-1. Control panel interface

Menu bar Help

Click here to open another window.

32 Chapter 4 HP Indigo press ws2000 basics ENWW

HP Indigo online help suite

About the online help suiteThe HP Indigo press online help suite consists of two separate guides: the reference guide and the operation guide. Each provides a different type of information. The reference guide describes the windows used to operate the press, and the operation guide provides step-by-step instructions on how to use the options available from these windows. These guides complement each other and can be opened simultaneously.

Reference guideThe reference guide provides detailed information about the windows you will be using in your work with the HP Indigo press. 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 the relevant help for any specific window by pressing F1 or by clicking Help in the window.

Figure 4-2. Example of a reference guide help topic

ENWW HP Indigo online help suite 33

Operation guide The operation guide provides step-by-step instructions on how to use the options available from the press windows and wizards. You can open operation guide topics by clicking Help, Contents, and Operation guide and choosing the desired 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 a operation guide help topic


Help Topics windowOpen the HP Indigo press Help Topics window by clicking Help and Contents in the control panel.

The Contents tab of the Help Topics window lists all the topics in the help. You can access topic pages from this tab by locating the relevant topic, and then clicking Open.

Figure 4-4. The Help Topics window

The Help Topics window also offers keyword and word search options.

Printing help topicsTo print a help topic, click Print at the top of the topic page.

Figure 4-5. Print button

To print an entire help chapter, perform the following steps:

1 Click Help Topics at the top of the topic page. The Help Topic window opens.

2 If the Contents page is not already on top, click the Contents tab to bring it forward.

3 Select the required chapter by clicking the chapter title.

4 Click Print. The entire chapter is sent to the default printer as defined under Start, Settings, and Printers. Each topic is printed on a separate page.

ENWW HP Indigo online help suite 35

Related topics You can open a related reference topic while reading the steps of a procedure in order to locate the icons or fields that are described in the procedure. Similarly you can open a related operation procedure topic, while reading about a window, in order to view all steps in a procedure performed using the window.

All related topics can be accessed from the related topics options at the top of the topic pages (in the non scrolling area).

Figure 4-6. Related topics options


The main windows


● Using the control panel

● Managing jobs

● Using the Job Editor

● Configuring the Hotfolder

● Job imposition

ENWW 37

Using the control panel

The control panel is the main press window. It opens automatically whenever you load the press software. From this screen, you can control the entire operation of the HP Indigo press ws2000.

The control panel consists of the following items:

● A menu bar (Provides access to functions through a series of submenus.)

● A customizable toolbar (Place anywhere on the screen. Click the Options menu, and then select Customize Tool bar and Customize to customize the toolbar.)

● An error indicator (Gives a detailed list of press events, including warning and error messages, when you click the error indicator icon. You can sort the messages to help you solve problems.)

● A warning indicator (Lights up when the press detects a condition that requires your attention. The indicator identifies the system that needs attention and remains lit until the problem is solved.)

● A machine state indicator

● Print buttons

● The current print job panel

● The print mode selector (Enables you to print jobs uninterruptedly in one continuous session or in steps, one job at a time.)

● The Job Manager button (Gives you access to the frequently used Job Manager window.)

● The schematic animated indicator (Click to display the Schematic window.)

You can access options from the menu or toolbar or by clicking the appropriate area on the schematic indicator.

Menu bar

The control panel is designed for ease of use. The main menu bar is divided into submenus arranged according to subsystems.

Figure 5-1. Control panel

Error indicator

Warning indicator

Print buttons Current print job panel

Machine state indicator

Animated schematic indicator

Job Manager button

Print mode selector

Copies/spreads

38 Chapter 5 The main windows ENWW

Machine state indicator

The press goes through different stages as it passes from total stop to full function. Each of these machine stages has a precise name and specific servicing procedures. There are also distinct functions that can be performed while the press is in these various stages.

Pay attention to machine state while operating the press since most machine functions are possible only at a defined machine state. Pay particular attention to machine status while servicing the press. Each maintenance procedure details the machine status for the safe performance of that procedure.

Current print job

The panel displays a number of job properties:

● job name

● number of copies to be printed and number of copies printed (the last field can be reset)

● number of spreads in the job

● access to job properties, some of which can be changed while the job is being printed

● the next job to be printed

Figure 5-2. Machine state indicator

Figure 5-3. Current print job panel

ENWW Using the control panel 39

The Schematic windowThe Schematic window is a representation of the press as it is seen from the front. It can appear in several forms on the control panel. Each form indicates a different machine status.

Accessing the schematic

In the control panel window, click the schematic animated indicator.The Schematic window opens with the present status of the press indicated.

If the press is unable to change from Standby status to Ready status, the problem subsystems are highlighted in the figure. These subsystems could include missing subsystems, blankets that have not reached working temperature, inks that have not reached working temperature, or density and conductivity problems. A glance at the Schematic window suffices for a quick diagnostic look at the press.

Note The cursor takes two forms when it is placed on the Schematic window: an arrow and a hand.

● When the cursor is on a non-linked area, it takes the form of an arrow.

● When it is on a hot spot (linked area) it takes the form of a hand.

Accessing a subsystem

Access a subsystem using either of the following methods:

● Click on the subsystem in the Schematic. A pop-up window opens.

● Use the toolbar or the control panel menu.

Figure 5-4. Animated schematic indicators

Print statusStandby status


1 Catch tray — collects excess ink for recycling2 Developer drum — forms an electric field that attracts excess (non-image) ink while

repelling image ink3 Writing head — transfers the image to the PIP by laser beam4 Slit injector — where the ink jets into the nip5 Scorotron — where the PIP is charged6 Cleaning Station7 PIP drum — image carrier8 ITM cover9 ITM drum — location of the blanket10 Printing nip — point of second transfer11 Ladder12 Input substrate roll13 Dancer — keeps the substrate taut14 Separator — prepares recycled imaging oil for reuse15 Wastebasket16 Impression drum — applies counter-pressure on printed web17 Ink tanks — stores heated HP ElectroInk18 Ink cans — where concentrated solid inks are stored19 Web guide

20 Output substrate roll

Figure 5-5. Inside the HP Indigo press ws2000

1 2 3 4 5 6 7 8 9

14151617181920

10 11

1213

ENWW Using the control panel 41

Managing jobs

As part of your working routine, you will be importing, maintaining, arranging an order for, and printing jobs. All these activities are performed in the Job Manager.

Jobs are imported into the system from the HP Indigo RIP and, depending on their After load definition, appear in the Job Manager window either in the Loaded Job List or in the Print Queue. You can also import jobs manually, using the Import option in the Job menu. Limited editing is possible when jobs appear in the list.

The Job Manager is fully automatic. The location of jobs after they have been loaded or printed, and job status once a job has reached the top of the Loaded Jobs list, are all determined by default. To override the default values, you must assign a specific job definition.

Note A print job is defined as text and graphic elements assembled for printing in a single printing session.

The Job Manager windowAccess the Job Manager window using either of the following methods:

● Click the Job Manager button on the control panel (it is located at the lower right side of the panel)

● 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 print in the order they appear in the queue. Jobs on the Loaded Jobs list are jobs that have not been scheduled for printing. They can be moved to the Print Queue or they can remain in the Loaded Jobs list for as long as necessary.

The positioning toolbar in the Job Manager window contains options for repositioning jobs within both the Loaded Jobs list and the Print Queue. It also enables you to move jobs between the two lists.

Figure 5-6. Job Manager window

Print Queue – Displays all jobs to be printed, in the order that they will be printed.

Loaded Jobs list – Displays the jobs that are either not ready for printing or that have already been printed

Positioning toolbar

Job properties – Displays specific job parameters


The Loaded Jobs listJobs in the Loaded Jobs list are jobs that are either not ready for printing or that have already been printed. Move these jobs to the Print Queue for proofing or for printing a full run.

Moving a job to the Print Queue

Drag and drop the job to the Print Queue, or select the job and click the relevant positioning button.

Sorting jobs

Jobs in the Loaded Jobs List can be sorted according to their properties. Click on the property header to sort the jobs according to that property. Click again to reverse the order.

Customizing Job Properties field displayCustomize the display information in the Print Queue and Loaded Jobs List by adding or deleting fields.

1 With the right mouse button, click on any field. A list of additional fields opens.

2 Click on the field of choice. The field is added to the display information.

3 To delete a field, click on the field of choice and press DELETE.

Changing the order of the Print QueueThe Print Queue displays all jobs to be printed, in the order that they will be printed. Sorting of jobs in the Print Queue is not allowed, since job order reflects printing order.

Change the order of the items in the Print Queue in one of the following ways:

● Select Move Up or Move Down in Queue from the Queue menu.

● Select Move Up or Move Down from the positioning toolbar.

● Drag and drop jobs to change their order in the list.

The positioning toolbar in the Job Manager window contains options for repositioning jobs within the Loaded Jobs list and the Print Queue. It also enables you to move jobs between the two lists.

Figure 5-7. Positioning toolbar

Move job up in list.

Move job down in list.

Take job from Loaded Jobs list and print a proof.

Move job from Print Queue to Loaded Job list.

Move job from Loaded Job list to Print Queue.

ENWW Managing jobs 43

End of print status

After a job has been printed, its end of print status determines whether the job is returned to the Loaded Jobs List, is deleted, or is copied to the Retained Jobs List before it is deleted. End of print status is generally defined as part of the default job properties on the HP Indigo RIP or by redefinition of the job properties.

Retained jobsThe Retained Jobs list consists of jobs that have been marked for deletion (in job properties) after a specified time. You can access these jobs for reprinting or exporting (archiving) as long as they remain on the Retained Jobs list.

Access the Retained Jobs list in either of the following ways:

● Click Retain List... on the Job menu.

● Click the Retained Jobs button on the toolbar.

Archiving

The following functions can be performed on one or more jobs concurrently.

Exporting a job

1 Select the relevant job in the Loaded Jobs list.

2 Click Export on the toolbar.

3 Choose a destination.

Importing an archived job

1 Click Import on the toolbar.

2 Select the required job.

3 The imported job appears in the Loaded Jobs list.


Using the Job Editor

The Job Editor enables you to preview a job and make changes to the job before printing.

Job Editor functionsThe following are functions of the Job Editor.

● view a job exactly as it will be printed on the press

● change the position of items in a job

● align groups of items

● copy and paste items within a job or between jobs

● rotate elements

● create/delete spreads, elements or channels in a job

● add crop marks to a job

● create new jobs using RIP’d elements

● create a personalization job by inserting a multiple spread job as a channel

● view the hierarchy of spreads, elements and channels within a job

● use step-and-repeat elements

● impose jobs, using HP Indigo’s imposition templates

Accessing the Job Editor

Open the Job Editor in one of the following ways:

● From the Job Manager window, select Job and Job Editor.

● Click the Job Editor button on the Job Manager toolbar.

● From the Job Properties window, click Job Editor.

Figure 5-8. Job Editor window

ENWW Using the Job Editor 45

Configuring the Hotfolder

The press Hotfolder enables automation of job management for the following purposes:

● Automatic load of image files. Image files that are placed in the press Hotfolder are automatically loaded into the system as jobs. Once loaded, these jobs are displayed in the Job Manager window. The press Hotfolder currently supports JPEG, TIFF and EPS file formats. Jobs that are created in this way are used as building blocks for creating or editing jobs in the Job Editor.

● Automatic load of embedded personalization template-based jobs. See the HP Indigo Yours Truly Designer user guide for further details.

● Automatic load of previously archived jobs. Jobs that were previously exported for archiving can be loaded for reprint through the press Hotfolder.

Follow the instructions below to configure the Hotfolder:

1 From the control panel, select Options and Hot Folder.

Figure 5-9. Hotfolder Parameters window


2 Click the Hot Folder tab to define the Hotfolder path.

Job imposition

Job imposition allows you to obtain maximum use of substrate for printing and thus minimize waste. Using job imposition, printed areas are oriented on the substrate for maximum efficiency.

Job imposition is controlled from the Imposition window. Access the Imposition window by selecting Imposition on the Job Editor Tools menu.

Figure 5-10. Defining Hotfolder path

Figure 5-11. Imposition window

ENWW Job imposition 47

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.


Operating the press


● Overview

● Job maintenance

● Advancing the system

ENWW 49

Overview

The diagnostic windows of the HP Indigo press ws2000 enable you to follow blanket temperature, ink tank temperature, 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 photoelectric image plate (PIP). But most routine procedures, such as applying a cleaner page and priming injectors are fully automated (unless you set the machine to ask for operator confirmation).

Turning the press on1 Turn on the main circuit breaker at the rear of the machine and wait for the control

panel to appear on the screen (this may take several minutes).

Figure 6-1. HP Indigo press ws2000 Schematic window

If this area appears in red, the developer and catch tray are not in place.

If this area appears in red, close ITM cover.

Look for colors on the schematic. They provide important information.

If this area appears in yellow, the ink temperature is too low.

50 Chapter 6 Operating the press ENWW

2 When a prompt appears, press the Power Enable switch on the input side of the press. The press is now in Standby state.

Turning the press off1 On the control panel, click the System menu, and then select Shutdown. The

Shutdown window opens:

2 Select the desired option and click OK.

3 Turn off the main circuit breaker at the rear of the machine. The system is now shut down.

WARNING! Switch off the main circuit breaker only after selecting Shut down the press in the Shutdown window. Turning off the unit prior to this could disrupt computer functions.

Preparing the pressThe following are guidelines for preparing the press:

1 Make sure that all the subsystems are assembled on the press.

2 Make sure that the blanket was cleaned the preceding day.

3 Load the substrate type for the first job to be printed.

4 Select threading mode (straight path or double S) according to the substrate type.

Figure 6-2. Main circuit breaker and Power Enable switch

Figure 6-3. Shutdown window

Power Enable switch

Main circuit breaker

ENWW Overview 51

5 Close all doors.

6 Press Get Ready on the control panel. The press drums begin to roll and the various subsystems start. When the preset conditions are met, the press status changes to Ready.

Printing jobsThe HP Indigo press ws2000 jobs begin the printing process in the printing queue. Their position on the list depends on urgency, substrate type, substrate thickness, number of colors in the job or any other job property.

Arrange your jobs so that the list facilitates the workflow—for example, all jobs that use the same substrate type, or all jobs that use the same fifth and sixth color should be grouped and printed consecutively. It is impossible to set guidelines for the best way to organize your Print Queue since priorities change daily. However, the system is flexible enough to let you customize the Print Queue every day, in accordance with that day’s preferences and needs.

Use the following procedures to print with the HP Indigo press ws2000:

Stage 1: Preparing the press

1 Set the Print Queue.

2 Set the Loaded Job list.

3 Make sure that Job Properties—for example, repeat length, number of copies, print range, screen ruling—are defined as required. If necessary change them.

Stage 2: Proofing

1 Drag the job to the current print job panel in the control panel window.

2 On the Print Job menu, select Proof.

The press prints one copy of your job.

3 Evaluate your print. Check gap between images. Make sure gap size between images is consistent. If necessary, correct by accessing Job Properties and Repeat length.

Figure 6-4. Image placement on the spread

Web movement

Repeat lengthImage (max 308×437 mm [12.13x 17.20 inches])

Gap

Leading edgeNon-printable area, 10mm (.39 inch)

Spread (as shown in job editor)Absolute max 464 mm (18.27 inches)Recommended max 457 mm (18.00 inches)


4 Make sure that the image is not skewed. If needed, correct (see "Correcting image skew" on page 86, and "Image deskew" on page 106).

5 Check for color values. If a previous print or a proof is available, compare them. To increase and decrease color values access the Color LUT or Color Match pages of the Job Properties dialog box.

6 Check image integrity, full ink coverage, right sheet sequence and same image placement for all jobs.

7 If changes other than job properties are required (for example, wrong image, typographical errors, and so on), notify the supervisor or customer.

8 Evaluate a second proof.

9 If there is a time delay between proof approval by the customer and the actual full run, print one proof immediately before the beginning of the full run print to make sure it matches the approved proof.

Stage 3: Printing the full run

1 Click the Print button to print the full run.

2 If the print mode selector in the control panel 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.

3 If the print mode selector in the control panel is set on Step, the next job in the Print Queue is moved to the top of the Print Queue and appears in the current print job panel. The machine status changes to Ready.

4 Make sure the required substrate type for the subsequent job is loaded on the press.

5 Print a proof.

6 Repeat stages 2 and 3.

Figure 6-5. Straight pass image skew adjustments

Image

ImageImage

ImageImageImage

ImageImage

Properly aligned

Lateral adjustment roller

Machine walls

Image skew

ENWW Overview 53

Second pass reinsertion jobsYou can print a second pass print on the simplex side or the duplex side. The HP Indigo press ws2000 is equipped with an optic detection system to ensure first pass print to second pass print registration.

When planning a product made of two pass prints, special care is required for the job planning, image placement and eye-mark location. Eye-marks are special registration marks designed for first-to-second pass registration.

We have included detailed instruction for the pre-press operator. Please follow the instructions to ensure flawless production. See "How to design first and second pass jobs" on page 130.

If a double pass job has not been planned, you can add eye-marks using the Job Editor. (See "Inserting eye-mark on the HP Indigo press ws2000" on page 124.)


Job maintenance

Loaded jobs can take up a great deal of system space and managing disk resources can be a constant source of concern.

The HP Indigo press ws2000 is equipped to manage your post print jobs automatically.

Do not keep unnecessary jobs on your system. The press will discard, save, save for a limited period of time or archive jobs that have already been printed.

You define what is to be done with a job after printing in by clicking Job Properties, General, and After Print.

If you want to save a job for a limited period of time, specify the period of time within which you might need it. To do that, access Job Properties and Retain for and enter the period of time. After that period of time the job will be deleted automatically from the image disk. If you need the job within that period of time, access the Retained Jobs window from Job Manager, Job, and Retained list..., and drag the selected job into either the Loaded Jobs list or to the Print Queue.

You can archive jobs through Job and Export to any external memory device.

Retrieve an archived job by accessing Job Manager, Job, and Import. Access the required directory or drive and select the file to be imported.

Editing job properties When a job appears in your Loaded Jobs list, it has already been defined and you do not have to redefine it. But after you pull and evaluate a proof, you might decide that some of the job properties require redefinition. The HP Indigo press ws2000 gives you several options for editing job properties.

ENWW Job maintenance 55

The Job Properties windowYou edit job properties in the Job Properties window. The Job Properties window is divided into the following tabbed subwindows:

● General — defines non-machine related parameters such as number of copies, collation printing, mirroring, tumbling and rotating the job.

● Color LUT — allows you to change a job’s color look-up table.

● Color Order and Screening — allows you to choose a color order template from an HP Indigo supplied list.

● Color Match — enables you to alter color brightness.

● Image Placement — can be changed.

● Repeat length — enables you to edit the job’s repeat length for each spread individually.

Figure 6-6. Job Properties window - general tab


Look-up tables (LUTs)Look-up tables are tables that enable you to change the printed dot size in relation to the dot size as defined in the original graphics files. LUT editing enables you to control the dot gain for every dot size individually. HP Indigo supplies several tailored LUTs, ranging 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.

ScreeningJobs can be printed with different screen rulings. The higher the screen ruling the better the rendering detail. Higher screen rulings are more demanding as they demand a more finely tuned machine calibration.

HP Indigo supplies four screen rulings:

● Sequin — an average of 144 lines per inch (lpi)

● HDI_set 2 — an average of 250 lpi

● HDI_set 3 — an average of 195 lpi

● HDI-175 — an average of 175 lpi

Color matchColor matching is the tool to use when color intensity is to be changed. Unlike changing a LUT where every dot size can be manipulated individually, color matching is a fast but rougher tool. The whole gray scale is shifted either up or down. All you have to do is define the new optical density value for the 100% dot and for the 50% dot for each ink individually. You can do this while printing. The system readjusts itself to the new values on the fly and the change is immediate. The very next sheet is printed with the new values. These values are saved as part of the job properties for future reruns.

Image placementYou can adjust image placement in relation to the top-left corner of the sheet. To adjust image placement, click Pause, adjust the image placement and continue printing. These changes can be saved as part of the job properties or be used only for the current run.

Figure 6-7. Different LUTs

Prin

ted

dot s

ize

Dot size in graphic file Dot size in graphic file

Prin

ted

dot s

ize

Chromalin Linear

ENWW Job maintenance 57

Repeat lengthYou can adjust the length of each spread individually as needed.

Advancing the system

When you need to replace the PIP or blanket, or when you need easy access to certain parts of the press, you have to advance the system to a predetermined angular position. Do this by one of the following two methods:

● The inching method, in which you move the machine via one of the control pads.

● Manually turn the handwheel counter-clockwise.

WARNING! Always advance the machine forward. Rotating the drum system backwards may damage the impression film and the PIP.


Control padsThe easiest way to manually advance the press is by using one of the two control pads located just inside the input door and exit door of the press. The control pads contain the following buttons:

● Emergency Stop

● Web Feed

● Inching

● Find Mark

Emergency StopPress an Emergency Stop button to cut all power to the main engine only when necessary. Pressing Emergency Stop during printing may cause damage to the PIP and blanket and contaminate the colors.

When you press down on an Emergency Stop button, the machine comes to an immediate halt and power is cut off to the main engine and to the high voltage power supply (HVPS). When you twist it counterclockwise (in the direction of the arrows on the button) you release the mechanism that stops the machine.

After an emergency stop, twist the button counterclockwise and click on Get Ready (in the main control panel on the computer screen) to re-enable the system.

Web FeedThis is a toggle button that advances the web at slow speed.

Figure 6-8. Control pads

Feed Side

Exit Side

Rewinder Side



ENWW Advancing the system 59

InchingAn Inching button is located on each of the control pads. The Inching button advances the machine at slow speed. Press and hold the button down to move the machine forward. Release the button and the forward movement stops.

If the machine is in Ready or a higher state and an interlocked door is opened, the machine switches to Hold status. If you press the Inching button at this stage, the machine will switch to Standby. As the Inching button is released, the machine switches to Off.

To inch from the control pad at the exit door, the upper and transparent doors must be closed. To inch from the input side, the ITM cover and upper input door must be closed.

Find MarkThis button advances the web at slow speed. It stops immediately when an eye-mark is detected by the selected eye-mark sensor.

You should calibrate the eye-mark sensor prior to using the Find Mark button.

Using the handwheelThe Handwheel manually advances the machine. It is located behind the front door and is generally used when it is inconvenient to use one of the control pads. To operate the handwheel, push in and turn counterclockwise.

CAUTION Always rotate the machine forward. Rotating the drum system backwards may damage the impression film and the PIP.

Figure 6-9. Handwheel

Forward motion counterclockwise


Angle indicatorThe angle indicator indicates the angle setting of the machine. This facilitates alignment of certain components during replacement of consumables during servicing, or when resetting the machine to its home position. The angle indicator is located on the front end of the PIP drum.

Mechanical reset optionAfter advancing the machine manually, either by using one of the control pads, turning the handwheel, or pulling the drive belt, the system must be reset to its home position. If the machine is cold and you are ready to print, close all service doors and click on the Get Ready button in the control panel. The system automatically resets to its home position and proceeds to Ready status.

You can also return the machine to 248°, its home position, manually, or click on Get Ready and when the machine stops, click on Go to Standby.

Figure 6-10. Angle indicator

Web50_dial

Angle indicator

ENWW Advancing the system 61

Web transport system


● Overview

● Threading procedures

● Double S threading procedure

● Straight path threading procedure

● Web replacement procedure

● Using the web pump

● Setting substrate flow rate with the web pump

● Troubleshooting web jams

● Checking image placement accuracy

● Adjustment procedures

● End-of-roll indicator

ENWW 63

Overview

The purpose of the web transport system is to support correct feeding, transport and collection of the web substrate through the press. The system incorporates mechanical, electrical, and pneumatic devices to ensure web transport stability (including tension, collection tightness, stable lateral positioning, and so on), and to eliminate web jams.

System descriptionFigure 7-1 illustrates the mechanical structure and arrangement of the Web Transport System. The thick line describes the web substrate path, which flows from the feed area on the right side, to the Exit area on the left.

The web transport system consists of a mechanical subsystem, an electrical subsystem and a tension control subsystem.

Figure 7-1. Web transport system substrate path—double S threading

Call-out numbers for Figure 7-1

1 - Rewinder 9 - Idler #1. 17 - Indexer pressure roller2 - Indexing 10 - Impression drum 18 - Indexer drive roller3 - Printing engine 11- Idler #2 19 - Rewinder dancer4 - Unwinder 12- Unwinder dancer 20 - Rewinder roller 3 inch

or 6 inch core5 - ITM 13 - Unwinder roller 3 inch

core21- Layon roller

6 - Unwinder pressure roller

14 - Idler #3 22 - Idler #5

7 - Ladder 15 - Idler #4 23 - Friction cylinder8 - Unwinder drive NIP 16 - Lateral adjustment

roller (double S)24 - Spiral tension roller

1 2 3 4

20

19

22

23

24

21

17

16

15

18

14

11

9

6

8

7

12

13

10

5

Straight path (for labels)

Double S path (for thin films)

64 Chapter 7 Web transport system ENWW

Threading procedures

To ensure free and flawless substrate feed to the press, to avoid web jams, and to assure consistent image placement upon the substrate, perform the following:

● Make sure all rollers are free of adhesive and ink residue. If not, clean using a lint-free wipe soaked with IPA.

● Check impression film for placement and cleanness. If you notice a track of adhesive residue at the leading edge – replace impression film (see "Mounting the impression film" on page 238) when dirty, torn or crumpled. Impression film should be replaced approximately every100,000 impressions.

Figure 7-2. Checking the impression film

Impression drum

Impression film

A shiny strip (adhesive residue)

ENWW Threading procedures 65

Defining substrate typePerform this procedure whenever you introduce a new substrate.

1 On the Options menu, select the Substrate List option.

2 If the required substrate appears in the Substrate List, select it and click Close.

3 To define a new substrate click the New button.The Edit substrate definition window opens.

4 Fill in substrate name.

5 Fill in substrate width.

6 Fill in substrate thickness.

7 Measure substrate Optical Density (OD) for each channel (CMYK) and fill in the relevant fields.

8 Check the Metallized check box if the substrate is metallized.

9 Leave the Exit Fan disable and the BKT Fan disable check boxes clear.

10 Click the OK button.

Editing an existing substrate properties1 From the Options menu, select the Substrate List option.

2 Select the desired substrate.

Figure 7-3. Substrate List window

Figure 7-4. Edit substrate definition window


3 Click the Edit button.The Edit substrate definition window opens.

4 You can edit any of the substrate definition fields.

5 When completed, press the OK button.

Selecting a threading modeSelecting a web threading mode is mainly based on substrate thickness.

For substrates equal to or thicker than 100 microns, use Straight Pass threading (see "Straight path threading procedure" on page 89).

For substrates thinner than 100 microns, use Double S threading (see "Double S threading procedure" on page 68).

Figure 7-5. Edit substrate definition window

Figure 7-6. Web transport system structure and substrate path

Select Substrate

Substrate Thickness

≥ 100 µ

Apply Dancer Weights

Straight Threading

Remove Dancer Weights

Double S Threading

No Yes

ENWW Threading procedures 67

Double S threading procedure

To thread a substrate into the press, carry out the following procedure (see Figure 7-1 for the Double S threading layout).

WARNING! Pinch hazard: Failure to activate an Emergency Stop button before performing this procedure may cause injury.

Pre-threading procedure1 Open the feed rollers cover.

Note It is impossible to close the cover all the way when the feed rollers are not engaged. The interlock circuit is interrupted until the rollers are engaged. Printing is not possible. A red light turns on in the control panel.

Figure 7-7. Interlock chain interruption warning

Interlock warning


2 Release the lock screws in the ladder’s side guides and increase the gap between the two guides.

3 Disengage the unwinder pressure roller. Release the roller’s two eccenter screws.

Figure 7-8. Ladder

Figure 7-9. Release the unwinder pressure roller eccenter

Unwinder

Side guide(front)

Side guide(rear)

Lock screwLock screw

Push guides this way

Eccenter

ENWW Double S threading procedure 69

4 Disengage the indexer pressure roller by turning its eccenter.

WARNING! When releasing the eccenters, take care not to catch your fingers between the rollers.

Figure 7-10. Release indexer pressure roller

Eccenter

Lateral adjust roller

Backfeed drive roller

Indexer pressure roller


5 Adjust the lateral adjustment knob to a 3 mm (0.12 inch) gap. Use the following procedure to adjust the lateral adjustment knob:

a Loosen the locking screw (knob).

b Measure the gap using a gauge jig.

c Turn the lateral adjustment knob clockwise to diminish the gap.

d Turn the lateral adjustment knob counterclockwise to enlarge the gap.

e Lock the locking screw (knob).

.

6 Select the required substrate for the job. The selected web should have a cardboard core with an inner diameter of 76.2 mm (3 inches); external core diameter approximately 100 mm (4 inches).

Figure 7-11. Lateral adjustment roll

Lateral adjustment knob

3 mm (0.23 inch) gap

Locking screw

Rear wall


7 Access Maintenance and Web Threading to open the Web Threading Routine window.

8 Click Define substrate to open the Substrate List window.

9 Select the required substrate (see "Defining substrate type" on page 66).

10 In the Web Threading Routine window, click Select Threading mode.

11 In the Select Threading Mode window, click the required threading mode.

12 Make sure that all steps in the Web Threading Routine window are checked.

Figure 7-12. Web Threading Routine window

Figure 7-13. Select Threading Mode window


13 For a schematic description of the selected threading mode, click Thread Web....

Threading

WARNING! Activate an Emergency Stop button before performing this procedure.

1 Place the roll on the floor (with the web rolling away from you) and insert the deflated unwinder core shaft into the core.

2 Center the shaft in the core and inflate it using the compressed air hose (6 BAR air pressure). Make sure that the core shaft is inflated completely and does not move within the core.

Figure 7-14. Double S schematic drawing

Figure 7-15. Unwinder core shaft (deflated)

Air Valve


3 Place the web on the floor, insert the web loading device under the core shaft on both sides as shown in the figure below, and lift it from the floor.

Note There are different kinds of loading devices. The one shown in Figure 7-16 is optional. Such a device can be purchased from HP Indigo (see Chapter 13).

4 Position the web in the unwinder unit of the press (see Figure 7-17), lower it using the web loading device and place the core shaft on the two flat surfaces at the bottom.

WARNING! Exercise caution to avoid getting your fingers caught under the core shaft.

5 Hold the roll to prevent it from slipping off the machine, remove the web loading device and roll the web forward until it goes into the two recesses.

6 Make sure that the web roll is centered between the unwinder walls. If it is not centered, deflate the core shaft, center the roll, and then inflate the core shaft.

WARNING! The unwinder dancer roller moves freely under its own weight. When threading the substrate into the press, exercise caution to avoid placing your hands in the path of the dancer roller’s arms.

Figure 7-16. Web loading device

Lift direction

Figure 7-17. Loading substrate into the unwinder unit


7 Insert the deflated rewinder core shaft into an empty rewinder roll.


9 Pull the substrate upwards (see Figure 7-19), until it reaches the unwinder roller.

Figure 7-18. Rewinder core shaft (deflated)

Figure 7-19. Pulling the substrate from the unwinder roll

Air valve


10 Thread the substrate over the first step of the ladder, below the second, above the third and below the fourth.

11 Insert the substrate between the unwinder pressure roller and unwinder drive roller, then above idler roller #1.

12 Using both hands, push the substrate forward until its end reaches the bottom of the machine.

Figure 7-20. Input ladder

Figure 7-21. Threading the substrate into the unwinder unit

Process direction

Centering ruler

Idler roller #1

Centering ruler

Thread web in here


13 Push the center bar of the unwinder dancer roller forward, pull the substrate towards you (behind the bar) and in front of the unwinder dancer roller.

14 Pass the substrate under the unwinder dancer roller and pull it upwards until the dancer roller is lifted to mid position.

15 Pull the substrate approximately 1 to 1.5 m (3.28 to 4.92 ft).

16 Insert the substrate between the third anti-static brush and idler roller #2.

17 Lift the ITM cover.

WARNING! Use the "Inch-safe-service method" on page 25.

18 Press the Inching button (a few short strikes) to turn the drums until the leading edge of the blanket is positioned right above the impression drum.

19 Using scissors, cut off the wrinkled end of the substrate.

Figure 7-22. Threading over the unwinder dancer roller

Figure 7-23. Threading the substrate over idler roller #2

Dancer bar


Note It is difficult to perform step 20 when threading a thin and flexible substrate. To facilitate the procedure, attach the end of the required substrate to 0.5 meter (1.64 ft) of a different substrate which is at least 100µ thick and has the similar width (or to a heavy sheet of A3 paper) and then thread the substrate between the drums.

WARNING! Pinch hazard.

20 Thread the substrate between the blanket and impression drum, while moving it slightly sideways to prevent the substrate from sticking to the blanket. Push it forward approximately 0.5 meter (1.64 ft) beyond the drums.

21 Go over to the rewinder unit. Pass the substrate under idler roller #3.

22 Thread the substrate in an S shape around the adjustable roller (above, towards you and under) and idler roller #4.

Figure 7-24. Threading the substrate between the drums

Figure 7-25. Passing the substrate under idler roller #3

ITM drum

Idler #3


Idler #4


WARNING! Hold the substrate with the other hand, to prevent it from being pulled back by the unwinder dancer roller.

23 Continue to support the substrate with one hand and thread it in an S shape around the indexer pressure roller and the indexer drive roller.

Figure 7-26. Threading the substrate around the lateral adjustment roller and idler roller #4


Idler #4

Figure 7-27. Threading the substrate around the indexer roller


Indexer pressure roller

Indexer drive roller


24 Insert the web between the lower set of the anti-static brushes.

25 Lift the layon roller

Figure 7-29. Lifting the layon roller

Figure 7-28. Threading the substrate between the anti-static brushes

Insert web here

Layon roller in service position


26 Pass the substrate under the two anti-static brushes and over idler roller #5.

WARNING! The rewinder dancer roller moves freely under its own weight. Exercise caution to avoid placing your hands in the path of the dancer roller’s arms.

27 Pull approximately 1 meter (3.28 ft) of substrate. Pass the substrate under the rewinder dancer roller and pull it to the top of the machine (see Figure 7-30).

28 Thread the substrate between the friction cylinder and the anti static brush.

Figure 7-30. Threading substrate over idler roller #5 and rewinder dancer roller

Anti-static brush

Figure 7-31. Threading the substrate over the friction cylinder

Friction cylinder

Spiral tension roller


29 Route the substrate behind the spiral tension roller. Cut the substrate allowing its end to reach the rewinder roll, then use adhesive strips to attach it to the core. Make sure that the substrate is evenly tight across the core.

30 Check the web path and make sure the web is centered all along the path. Use guide collars to center the web.

31 Turn eccenters to engage indexer pressure roller.

WARNING! Ensure that all equipment, tools and materials are removed from the unit and that all doors are closed before operating the machine.

32 Close the rewinder top door, upper exit door and ITM cover.Press the Power Enable switch.

Figure 7-32. Attaching the substrate to the rewinder roll

Figure 7-33. Turn the unwinder pressure roller eccenter to engage


Adhesive stripsWeb core

Eccenter


33 Press the Paper Feed button for a few seconds, and then check that the substrate has not drifted (that is, is still centered) over the output roll. If it has drifted, press the Emergency Stop button, cut the substrate, let the air out of the inflatable shaft, center the output roll on the shaft, inflate the shaft and reattach the substrate using adhesive tape.

.


34 Lower the layon roller to the working position.

Figure 7-34. Rewinder roll centering

Layon roller

Rewinder roll



35 Release the Emergency Stop button.

Figure 7-35. Layon roller in working position

Layon roller

Spiral tension cylinder


36 Press the Paper Feed button again for a few seconds to let the web transport stabilize throughout the press, and then check that the substrate is correctly transported through all stations from the unwinder unit to the rewinder unit.

Figure 7-36. Fully threaded substrate

Layon roller

Friction cylinder

Rewinder dancer


Setting repeat lengthImage length is size of the printed image. A gap can be set between images. The size of the gap and the image together are called repeat length. This size differs from one job to another and should be set by the press operator.

In multi-spread jobs, each spread’s repeat length can be defined individually.

1 Select the job, open its Job Properties window, and then click the Repeat Length tab.

2 The repeat length value is determined by image size in the PostScript file. Check this value to make sure the gap between images is included. If not, modify the repeat length value.

3 Print seven copies.

4 Measure the job’s repeat length (leading edge to leading edge).

Correcting image skew1 Click the OK button in the Job Properties window.

2 Load the job.

3 Print six copies.

4 Measure image skew (Figure 7-38).

Figure 7-37. Repeat Length tab

Figure 7-38. Double S image skew adjustment - top view (skewed)

Turn counterclockwise to deskew images

Image skew


Image ImageImage Image


5 If the image is skewed, open rewinder top door and release the Lateral adjustment set screw.

6 Close the rewinder top door.

7 Renew printing.

Figure 7-39. Double S image skew adjustment - side view

Figure 7-40. Properly printed image - top view (corrected)

Figure 7-41. Lateral adjustment set screws

Idler #4Printing direction

Turn counterclockwise to deskew images



Rear wall


Set screw


8 Turn the image lateral adjustment screw to adjust skew.

9 Check image deskew. Repeat step 8.

10 Stop the press.

11 Open rewinder top cover.

12 Tighten the lateral adjustment set screw (Figure 7-41).

13 Resume printing.


Figure 7-42. Image skew adjustments

Image lateral adjustment knob


Straight path threading procedure

WARNING! You must activate an Emergency Stop button before performing this procedure.

Figure 7-43. Substrate threading workflow

Substrate Thickness

≥ 100 µ

Apply Dancer Weights

Straight Threading

Remove Dancer Weights

Select Substrate

Double S Threading

YesNo

ENWW Straight path threading procedure 89

Call-outs for Figure 7-44

Pre-threading procedureTo thread a substrate into the press, carry out the following procedure.

1 Disengage the unwinder pressure roller. Release the roller’s two eccenter screws.

Figure 7-44. Straight pass threading

1 - Spiral tension roller 8 - Underwinder pressure roller

15 - Idler #4

2 - Friction cylinder 9 - Ladder 16 - Index drive roller3 - Idler #5 10 - Underwinder drive 17 - Winder dancer4 - Indexer pressure roller 11 - Underwinder roller

76.2 mm (3 inches) core

18 - Layon roller

5 - Idler #3 12 - Underwinder dancer 19 - Rewinder roller6 - Impression drum 13 - Idler #27 - Idler #1 14 - Impression drum

Figure 7-45. Release the underwinder pressure roller eccenter

16

15

5

13

87 9

10

12

11

6

143

17

19

18

1

24

Eccenter

Feed roller cover


2 Release the set screws in the ladders’ side guides and increase the gap between the two guides.

3 Disengage the indexer pressure roller by turning its eccenter.

Figure 7-46. Ladder

Figure 7-47. Release pressure indexer drive roller

Unwinder

Side guide(front)

Side guide(rear)

Set screw Set screw

Push guides this way


Eccenter Indexer pressure roller

Backfeed drive roller



4 Release the lateral adjustment roller set screw.

5 Adjust the lateral adjustment roller to a 9 to 9.5 mm (0.35 to 0.39 inch) gap between the roller’s edge and the inside rear wall. Use the following procedure to adjust the lateral adjustment roller:

a Turn the adjustment knob clockwise to diminish gap.

b Turn the screw counterclockwise to increase gap.

c Set the gap from 9 to 10 mm (0.35 to 0.39 inch).

d Lock the set screw.

Figure 7-48. Lateral adjustment knob

Figure 7-49. Lateral adjustment

Set screw


Front wall

Set gap to 9.5 mm (.37 inch)

Rear wall



6 Access Maintenance and Web Threading to open the Web Threading Routine window.

7 Click Define substrate to open the Substrate List window.

8 Select the required substrate.

9 On the Web Threading Routine window, click Select Threading Mode....

10 On the Select Threading Mode window, click the required threading mode, and click OK.

Figure 7-50. Web Threading Routine window

Figure 7-51. Select Threading Mode window


11 For a schematic description of the selected threading mode, click Thread Web....

12 Select the required substrate for the job from Consumables and Substrate. The selected web should have a cardboard core with an inner diameter of 76.2mm (3 inches); external core diameter 100 mm (4 inches); or a core with an inner diameter of 152.4 mm (6 inches); external core diameter at least 180 mm (7.09 inches).

13 Select all check boxes in the Web Threading Routine window.

Threading procedure1 Place the roll on a table (with the web rolling away from you) and insert the deflated

core shaft into the core see (Figure 7-53).


Figure 7-52. Straight mode threading - schematic drawing

Figure 7-53. Unwinder core shaft (deflated)

Air valve


3 Place the web on the floor, insert the web loading device under the core shaft on both sides as shown in the figure below, and lift it from the floor.

Note There are different kinds of loading devices. The one described in Figure 7-54 is optional, and maybe purchased from HP Indigo (see Chapter 13).

4 Position the web in the unwinder unit of the press (see Figure 7-55), lower it using the web loading device and place the core shaft on the two flat surfaces at the bottom.

WARNING! Exercise caution to avoid getting your fingers caught under the core shaft.

5 Holding the roll to prevent it from slipping off the machine, remove the web loading device and roll the web forward until it goes into the two recesses.

6 Make sure that the web roll is centered between the unwinder walls. If it is not centered, deflate the core shaft, center the roll, and then inflate the core shaft.

WARNING! The unwinder dancer roller moves freely under its own weight. When threading the substrate into the press, exercise caution to avoid placing your hands in the path of the dancer roller’s arms.

Figure 7-54. Web loading device

Lift direction

Figure 7-55. Loading substrate into the unwinder unit


7 Insert the deflated rewinder core shaft into an empty rewinder roll.


9 Pull the substrate upwards as shown below, until it reaches the unwinder roller.

Figure 7-56. Rewinder core shaft (deflated)

Figure 7-57. Pulling the substrate from the unwinder roll

Air valve


10 Thread the substrate over the first step of the ladder, below the second, above the third and below the fourth.

11 Insert the substrate between the unwinder pressure roller and unwinder drive roller, then above idler roller #1.

Figure 7-58. Input ladder


Process directionCentering ruler

Idler roller #1

Centering ruler


12 Using the other hand, lock the two eccenters of the unwinder pressure roller.


13 Insert the substrate between the unwinder pressure roller and unwinder drive roller, then between the second anti-static brush and idler roller #1 (see Figure 7-60).

14 Using both hands, push the substrate forward until its end reaches the bottom of the machine.

15 Push the center bar of the unwinder dancer roller forward, pull the substrate towards you (behind the bar) and in front of the unwinder dancer roller.

16 Pass the substrate under the unwinder dancer roller and pull it upwards until the dancer roller is lifted to mid position (see Figure 7-19).


Feed roller cover

Eccenter

Figure 7-61. Threading substrate over the dancer roller

Dancer bar


17 Pull the substrate approximately 1 to 1.5 m (3.28 to 4.92 ft).

18 Insert the substrate between the third anti-static brush and idler roller #2 (see Figure 7-61).

19 Lift the ITM cover.

WARNING! Use the "Inch-safe-service method" on page 25.

20 Bring the machine to Standby state.

21 Using scissors, cut off the wrinkled end of the substrate.

22 Thread the substrate between the blanket and impression drum, while moving it slightly sideways to prevent the substrate from sticking to the blanket. Push it forward approximately 0.5 meter (1.64 ft) beyond the drums.

Figure 7-62. Pulling the substrate from under the dancer roller

Figure 7-63. Threading the substrate between the drums

ITM drum


23 Go over to the rewinder unit. Pass the substrate under idler roller #3.

24 Thread under idler roller #4 (see Figure 7-64).

Note Hold the substrate with the other hand, to prevent it from being pulled back by the unwinder dancer roller.

25 Continue to support the substrate with one hand and thread it between indexer pressure roller and indexer drive roller.

26 Thread the substrate between the upper set of the anti-static brushes.

Figure 7-64. Passing the substrate under the idler roller #3

Idler #3


Idler #4

Figure 7-65. Threading the substrate between the anti-static brushes

Insert web here


27 Pass the substrate over idler roller #5.

WARNING! The rewinder dancer roller moves freely on its own weight. Exercise caution to avoid placing your hands in the path of the dancer roller’s arms.

28 Pull approximately 1 meter of substrate. Pass the substrate under the rewinder dancer roller and pull it to the top of the machine (see Figure 7-67).

Figure 7-66. Threading substrate over idler roller #5 and rewinder dancer roller

Anti-static brushes

Idler #5

Rewinder dancer


29 Thread the substrate between the friction cylinder and the anti static brush.

30 Route the substrate behind the spiral tension roller.

31 Cut the substrate, allowing its end to reach the rewinder roll, and then use adhesive strips to attach it to the core. Make sure that the substrate is evenly tight across the core.

32 Check the web path and make sure the web is centered all along the path. Use guide collars to center the web.

Figure 7-67. Threading the substrate over the friction cylinder

Figure 7-68. Attaching the substrate to the rewinder roll

Friction cylinder



Adhesive stripsWeb

core


33 Engage the unwinder pressure roller by turning the roller’s eccenter.

34 Turn the eccenters to engage indexer pressure rollers.

35 Close the rewinder top door, upper exit door and ITM cover. Press the Power enable switch.


Figure 7-69. Turn the underwinder pressure roller eccenter to engage

Eccenter


36 Press the Paper Feed button for a few seconds, and then check that the substrate has not drifted, that is, it is still centered, over the output roll. If it has drifted, press the Emergency Stop button. Cut the substrate, release the two core holders by opening the two Allen screws, center the output roll on the shaft, tighten the Allen screws and reattach the substrate using adhesive tape (see Figure 7-70). Release the Emergency Stop button.

37 Lower the layon roller to its working position.

38 Press the Paper Feed button again for a few seconds to let the web transport stabilize throughout the press, and then check that the substrate is correctly transported through all stations from the unwinder unit to the rewinder unit.

Figure 7-70. Rewinder roll centering

Figure 7-71. Fully threaded substrate

Layon roller

Rewinder roll


Rewinder dancer

Friction cylinder

Layon roller


Centering the webAll along the web path the substrate should be centered on the different rollers. To facilitate this, several rollers are equipped with two collars, one at each end of the roller. Those collars are fixed to the shaft using a 5mm Allen key.

To center the substrate, release the collars and push them until they touch the web on both sides. The distance from each machine wall to the collars, left and right should be equal.

The following rollers are equipped with centering collars:

● Input ladder (Figure 7-46)

● Idler #3 (Figure 7-64)

● Friction cylinder (Figure 7-72)

● Spiral tension roller (Figure 7-72)

Figure 7-72. Friction cylinder and spiral tension roller centering

Friction cylinder

CollarsSpiral tension roller

Layon roller in working position

Layon roller in non-working position


Setting repeat lengthImage length is size of the printed image. A gap can be set between images. The size of the gap and the image together is called the repeat length. This size differs from one job to another and should be set by the press operator.

In multi-spread jobs, each spread’s repeat length can be defined individually.

1 Select the job, open its Job Properties window, and click the Repeat Length tab.

2 Repeat length value is determined by image size in the PostScript file. Check this value to make sure the gap between images is included. If not, modify the repeat length value.

3 Print seven copies.

4 Measure the job’s repeat length (leading edge to leading edge).

Image deskewWhen the substrate does not flow precisely centered between press walls, the printed image might be skewed. The following procedure is aimed at checking image skew and correcting it.

1 Load the job.

2 Print six copies.

Figure 7-73. Repeat Length tab


3 Measure image skew.

4 Loosen the lateral adjustment set screw.

Figure 7-74. Straight pass image skew adjustments

Figure 7-75. Lateral adjustment roller

Image skew

Machine walls


Properly aligned images





5 Turn image lateral adjustment hand knob to adjust skew.Keep adjusting until you reach the desired value.

6 Tighten the set screw.

Web replacement procedure

To replace the web, perform the following procedure:


1 Cut the web substrate at the unwinder unit.

2 Gently release the substrate.

CAUTION The dancer might be damaged if not held.

3 Remove the unwinder roll.

4 Remove the core shaft and insert it into the new web.

5 Install the new unwinder roll.

6 Use adhesive tape to attach the new substrate to the end of the old one.


WARNING! Press the Paper Feed to thread the substrate through to the rewinder roll. Make sure that all equipment, tools and materials are removed from the unit and that all doors are closed before operating the machine.

Figure 7-76. Output control panel

Set screw


Front wall


Using the web pump

The friction roll is located at the exit side of the press roll to roll (RTR). It is a static roll with small holes, through which air can either flow in – to create low pressure (vacuum); or flow out – to create high pressure (pressure). This device enables handling webs with different coefficients of friction (COF). The press’ web pump controls the air pressure.

Note Currently the web pump supports only 320mm (13 inch) wide webs.

1 For best results, activate the web pump using the Web Pump wizard. To do so, access Consumables , Substrate, Machine Parameters, and Web Pump.

The direction buttons are Pressure to handle substrate with high COF, and Vacuum to handle substrate with low COF.

2 The need for the web pump can be evaluated only during printing.Access Consumables, Substrate , Machine Parameters, and Transport to activate the substrate transport system.

Figure 7-77. Web Pump Wizard

Figure 7-78. Substrate transport window

ENWW Using the web pump 109

3 Monitor transport at the friction roller.

a On — the pump is on in all machine states.

b Off — the pump will be always off. This is needed in cases in which web with standard coefficients of friction is handled.

WARNING! Exercise extra care when operating the web pump in the vacuum mode to prevent damage to the substrate, to the web core, or to the press.

Setting substrate flow rate with the web pump

To adjust the flow rate of the substrate, adjust knobs on the inner rear wall of the rewinder.

To test friction between the substrate and the friction cylinder, gently pull the substrate towards the output.

To increase the substrate flow rate, turn the pressure adjust knob counterclockwise, with the vacuum adjust knob turned fully clockwise.

To decrease the substrate flow rate, turn the vacuum adjust knob clockwise, with the pressure adjust knob turned fully counterclockwise.

Troubleshooting web jams

Refer to the following list to rectify possible web jams in the press.

WARNING! You must activate an Emergency Stop button before performing this procedure.Use the Inch-Safe-Service method shown in "Inch-safe-service method" on page 25.

1 Remove the cleaning station and scorotron (to prevent damage to the PIP if it is rotated backwards against the cleaning station).

2 Carefully pull the substrate backwards (the two dancer rollers will move down).

3 Check for possible damage to substrate, drums, blanket or PIP.

4 If possible, remove ink from the blanket.

Figure 7-79. Vacuum/pressure control

Vacuum adjust knob

Pressure adjust knob

PRESSUREADJUST

VACUUMADJUST

- - ++

(open for vacuum) (close for pressure)


5 If the web is torn, re-thread the web.


7 If there is no damage, press the Paper Feed button until the substrate is straight and tight.

8 Reinstall the cleaning station and scorotron.

WARNING! Ensure that all equipment, tools, and materials are removed from the unit and that all doors are closed before operating the machine.

9 Print a few images and check for general quality. If necessary replace the PIP blanket.

Checking image placement accuracy

PurposeIf unable to keep a constant gap between images, or to deskew images, check the indexing mechanical accuracy. If unable to register a second pass image with a first pass image, either in the process or lateral direction, you should also test the Reinsertion registration accuracy.

Test jobsThere are two test jobs supplied by HP Indigo, necessary for the performance of the procedure: the GP-SQ-Man job intended for indexing accuracy checking, and the RI-Man job for the checking of a reinsertion registration.

The job structure is as follows:

● Two arrays of vertical squares labeled Skew Test and Gap Test at the leading edge as shown in Figure 7-80. Each array is labeled from +0.5 mm to -0.5 mm with a labeled central target.

● Below this is the instructions section for necessary lateral and longitudinal adjustments to both the straight web and double S web paths. Should the desired target not be aligned with the solid rectangles, then the appropriate adjustment, written above the test should be performed.

● Four arrays of horizontal and vertical solid rectangles are at the trailing edge as shown in Figure 7-81. The external horizontal and vertical arrays are used to measure the mechanical indexing accuracy. The internal horizontal and vertical arrays are used to test the reinsertion option.

The main object of the job test is to overlap and align all of the squares of the previous image with all of the external solid rectangular arrays to give the best registration. When the solid rectangle is aligned with the target square, perfect registration is achieved. When printing the image, the frame length should align each member of the external solid rectangles inside the two arrays of vertical squares from the previous image.

The RI-Man job is a reinsertion test job intended for printing over the same roll, and the same side (simplex), as the GP-SQ-Man job.

ENWW Checking image placement accuracy 111

The image consists of two columns of empty squares similar to those for the GP-SQ-Man job, but positioned to be printed over the two internal columns of solid rectangles.

To use the test jobs, follow the instructions below.

1 Perform the necessary machine and web adjustments.

Note Web width should be 320 mm (12.6 inches).

2 Load the GP-SQ-Man job.

3 Print several copies of the job.

4 Perform the adjustments shown in Figure 7-81 so that the solid rectangles completely fill the inside of the empty squares from the previous image.

Figure 7-80. Printed test sheet without overlap (GP-SQ_Man)

Figure 7-81. Printed test sheet without overlap (GP-SQ_Man)

Skew test fields. For corrections, see instructions below

Longitudinal placement test fields, For corrections, see instructions below


5 Perform final lateral adjustments according to the printed instructions within the job (for details see "Image deskew" on page 106 for Straight Pass threading).

6 Print the GP-SQ-Man job again.

• When testing the mechanical indexing, print 30 copies only.

• When testing reinsertion indexing, print 100 copies in mechanical indexing mode.

7 Check which square or squares have the following:

• Perfect vertical registration for the gap test array

• Perfect horizontal registration for the skew test array

8 Record the values for the perfect registration of the gap and skew tests.

9 If the printed squares images show two consecutive solid rectangles in perfect registration for either of the Gap or Skew Tests, then record the average of the two values. The machine meets the RI-125 specifications if:

a The gap span (maximum–minimum values) of the 30 images is less than or equal to 0.5 mm

b The maximum skew is +0.25 mm and the minimum skew is –0.25 mm

Should one or more of the data points be outside the specification, call HP Indigo Service.

10 Reinsert the roll used for the GP-SQ-Man job for second pass simplex printing without rewinding.

Figure 7-82. RI-Man (not overlapping)

ENWW Checking image placement accuracy 113

11 Load and print the RI-Man job (see Figure 7-82) using the same parameters adjusted in procedure above.

12 Print several images and, if necessary, perform readjustments as in step 4 above.

13 Print about 30 images of the job.

14 Make sure that all the images from the first pass (printing of previous job) have the correct frame length but do not reach the earliest test calibrations.

15 Repeat steps 9 to 11.

Note First to second pass lateral registration can be affected by input roll straightness. Make sure that the input roll is properly rewound.

16 If you are unable to reach registration, call a customer engineer.

Adjustment procedures

Pressure rollers tension adjustmentFigure 7-84 shows the tension device for the unwinder and indexer pressure rollers. If you encounter uneven tension between the pressure rollers (waves in the substrate or uneven rolling on the rewinder roll), check to see if the following tension devices are properly adjusted to a distance of 16 mm (0.63 inch):

● The unwinder pressure roller on both sides

● The indexer pressure roller on both sides

Figure 7-83. RI-Man second pass image in perfect registration


If necessary, use the adjustment knobs to adjust the tension devices.

End-of-roll indicator

An end-of-roll indicator indicates when the feed roll is approaching its end. This helps prevent an abrupt press stop.

An error message is issued when the sensor detects that the amount of substrate on the roll has reached a certain minimum. The indication will be issued during all machine states. The error message reads: The end of Feed Roll has been reached.

To set end-of-roll working mode, perform the following procedure:

1 Access Consumables and Substrate.

Figure 7-84. Tension device

16mm (.63 inch)

Adjustment knob

Tension spring

16m

m (.63 inch)

Figure 7-85. Substrate window

ENWW End-of-roll indicator 115

Note The Substrate window might look slightly different on different press configurations. However, the end-of-roll sensor is always located in the bottom left corner of the window.

2 The Stop Printing state is checked after power-up. When this option is selected, the press switches from Print to Ready when end-of-roll is detected, and a message is issued warning the operator that the web is about to end.

When Warning Only is selected, a warning is issued when the end-of-roll is detected, but the system continues printing.

End-of-roll sensor adjustmentThis procedure should be performed when the web core external diameter is changed.

Note It is recommended to keep several old web cores of different diameters. The web core should contain 2 to 3mm (0.08 to 0.12 inch) thick substrate for adjustment and testing of the sensors.

1 Mount a used web core onto the input shaft.


2 Mount the shaft with the web core on the unwinder shaft supports.

3 Loosen the 4 mm fixing screws (Figure 7-86) on both sensor slides.

4 Adjust the transmitter on the front wall.

a Place a ruler on the web core (Figure 7-86), and attach it to the transmitter surface.

b Using the adjusting screw, slide the sensor until the sensor’s red light is directed against the lower corner of the ruler.

c Tighten the 4 mm fixing screw on the slide.

Figure 7-86. End-of-roll sensor adjustment

Fixing screw

Adjustment screw

Ruler

Transmitter light position

Web core

Input Shaft


5 Adjust the receiver on the rear wall.

a Using the adjusting screw, slide the receiver towards the core until the red light switches off.

b Using the adjusting screw, slide the receiver away from the core until both the red and green indicators are clearly lit.

c Tighten the 4 mm screw on the slide.



ENWW End-of-roll indicator 117

Second pass printing


● Second pass printing introduction

● Glossary

● Planning

● Eye-mark placement

● Eye-mark placement and size

● How to design first and second pass jobs

● Designing a simplex job with rewind

● Designing a simplex job without rewind

● Designing a duplex job with rewind

● Designing a duplex job without rewind

● HP Indigo press ws2000 operator instructions

● QuarkXpress operator instructions

● Operator – setting the press

ENWW 119

Second pass printing introduction

The eye-mark indexing system is an optical register detection system that ensures accurate registrations on substrates that pass through the HP Indigo press ws2000 more than once. This second pass printing may consist of a second printing on the printed face of the substrate (simplex) or a printing on the flip side of the substrate (duplex).

The eye-mark registration system is relevant in all cases where two-sided printing is necessary, or when short run fast additions are required on the simplex side. It can be also used for one pass simplex prints.

In order to assure first to second pass registration, a register mark (eye-mark) is printed along with the first pass image. Placement of the eye-mark determines placement of the second pass image.

The following pages describe work procedures for using the eye-mark system. The procedures are organized according to the different functions of the different participants in the workflow.

System descriptionFirst pass prints must include register marks for second pass image placement. The HP Indigo press ws2000 registration mark is called the eye-mark. The HP Indigo press ws2000 system contains two optical sensors to detect the eye-mark – one above the web (for second pass simplex printing) and the other below the web (for duplex printing). During printing, only one of the sensors is active.

Figure 8-1. Sensors location

During second pass printing, the press detects the eye-marks of the first pass images in order to place each of the second pass images in register with the previously printed first pass images. The distance between the simplex sensor and the “about to be printed

ITM

Impression drum

“Just printed” image

About to be printed Image

Trailing edge

“Next image” leading edge

Idler

Simplex eye-mark

Duplex eye-mark

First pass printSecond pass print

Simplex optical sensor

Duplex optical sensor

About to be printed second pass print

120 Chapter 8 Second pass printing ENWW

image” leading edge of the spread is approximately 66 mm (2.60 inches) in a simplex second pass printing. The distance between the duplex sensor and the "about to be printed" image leading edge is approximately 20 mm (0.79 inch) in duplex second pass printing. Placement correction (through job definition) of between 0 and +5 mm (0.20 inch) might be required when printing the second pass images.

Web motionThe figure below illustrates the web speed at the different stages of one print cycle. It also illustrates what happens if no eye-mark is detected, see the detailed description below.

Figure 8-2. Web motion

1 Forward motion as in normal print sequence. During this motion, the impression and ITM drums are engaged and the image is transferred to the substrate.

2 Backward motion as in normal printing sequence. This motion is automatically extended by half the distance defined for the search window.

3 Second forward motion, in search of the eye-mark.

4 The eye-mark is detected and the indexing motor stops immediately.

5 If the eye-mark is not detected, the motor continues.

The motor stops after approximately 5 mm (0.20 inch), defined as the search window.

6 The indexing motor returns the web half the distance defined in the search window. The indexing motor stops at the place where the eye-mark should have been placed so that on the next cycle the eye-mark will not be missed.

1

2

3 4 5

6

Impression/ITM engage Impression/ITM disengage

Inde

xing

mot

or s

peed

time

ENWW Second pass printing introduction 121

Glossary

The following terms are used in this section. We have tried to adhere to conventional Graphic Arts terminology as much as possible.

Figure 8-3. Frame, spread, image, and gap

● Eye-mark - A short black strip printed as part of the first pass image. It is used for registering second pass image to the first pass image previously printed. Size and position are detailed below.

● Simplex - The top (outside) face of the web.

● Duplex - The other face of the web.

● Leading edge - Since a web does not have a real leading edge, it is a virtual leading edge, which is treated as the beginning of a spread. The first 10 mm (0.39 inch) after the leading edge are unprintable.

● Trailing edge - The opposite edge of the “sheet”.

● Maximum image area - 308 x 437mm (12.13 x 17.20 inches) is the largest image printable in one machine pass.

● Gap- The distance between two adjacent images.

● Frame - The distance from one leading edge to the next leading edge, repeat length that equals image length plus the gap.

● First pass image - The image printed on the substrate in the first pass print (not necessarily on the HP Indigo press ws2000).

● Second pass image - The image printed on the HP Indigo press ws2000 in the second pass. For the purposes of this section, the second pass image is always printed on the HP Indigo press ws2000 and does not contain an eye-mark.

Image (max 308 × 437mm) (12.13 x 17.2 inches)

Frame

Gap

Spreadmax 464 mm (18.3 inches)

Non-printable area, 10 mm (0.4 inches)

Web movement

Leading edge


Planning

Since the eye-mark has to be printed in the first pass print, often on another press, and since there are several methods of web reinsertion, planning before the first pass print is of utmost importance.

The parameters that should be taken into consideration before printing the first pass image are listed below.

Figure 8-4. Decisions that effect eye-mark placements

Each possibility requires different placement for the eye-mark.

Note HP Indigo recommends that you enclose a dummy of the finished job. The decision whether to unwind the web before the second pass printing or not, is not part of the job definition. Make sure that all participants in the workflow are aware of the decisions made.

No rewinding

Second Pass Print side

Insertion method

Insertion method

Rewinding

Simplex Duplex

Rewinding No rewinding

ENWW Planning 123

Eye-mark placement

The illustration below describes eye-mark placement on the first pass print in relation to placement on the second pass image. The first pass image is marked in black lines; the second pass image is marked in gray lines.

Inserting eye-mark on the HP Indigo press ws2000When a first pass job does not contain an eye-mark, you can add one using the Job Editor.

1 Make sure the job is located in the Loaded Jobs list (and not in the Print Queue).

2 Select the required job.

3 Click the Job Editor button.

4 On the Job Editor Edit menu, select Second Path.The Add Second Pass Eye Mark window opens. The graphic representation of the job shows a preview of the location of the eye-marks for each possible selection.

Figure 8-5. Adding an eye-mark to a job on the HP Indigo press ws2000

5 Define the side of substrate that you want to print during the second pass printing. The options are:

• Simplex — prints the second pass on the same side as the first pass.

• Duplex — prints the second pass on the opposite side (back) of the first pass.

6 Define the web insertion method. The options are:

• No Rewinding — the web was not rewound after the first pass.

• Rewinding — the web was rewound after the first pass.

7 Click OK.

The eye-marks are automatically placed in the appropriate positions, according to your selection. Placing an eye-mark as part of an image is performed by the pre-press operator.


Simplex reinsertion with rewinding1 Place the eye-mark on right side (between the image center and its right margin) of

the image.

2 Place the eye-mark 66 mm (2.60 inches) below the second pass leading edge.

Figure 8-6. Simplex reinsertion with rewinding

Leading edge first passLeading edge second pass

Eye-mark

66 mm (2.60 inches)

First pass spread

movem

ent

Second pass spread m

ovement

ENWW Eye-mark placement 125

Simplex reinsertion without rewinding1 Place the eye-mark on the bottom left side of the image.

2 Place the eye-mark 66 mm (2.60 inches) above second pass leading edge.

Figure 8-7. Simplex reinsertion without rewinding

Leading edge first pass

Leading edge second pass

eye-mark

66 mm (2.60 inches)


ovement

First pass spread

movem

ent


Duplex reinsertion with rewinding1 Place the eye-mark on left side of the image.

2 Place the eye-mark 20 mm (0.79 inch) below the second pass leading edge.

Figure 8-8. Duplex reinsertion with rewinding

Leading edge first passLeading edge second pass

eye-mark

20 mm (0.79 inch)

first pass spread movem

ent

second pass spread movem

ent

ENWW Eye-mark placement 127

Duplex Reinsertion without rewinding1 Place the eye-mark on right side of the image.

2 Place the eye-mark 20 mm above second pass leading edge.

Figure 8-9. Duplex reinsertion without rewinding

The method of second pass web reinsertion and information about whether the job is a second pass duplex or simplex must be determined at the job design stage and must be communicated to all participants in the workflow.

Eye-mark placement and size

Although first and second pass images are printed as part of the same project, they are not part of the same job. They are printed individually, usually with long intervals between passes, and at times do not even use the same printing technology. The eye-mark is printed only as part of the first image of the two passes.

Following are the size details of the eye-mark. Placement of eye-mark depending on the job planning is detailed in "Planning" on page 123.

Leading edge first pass

Leading edge second pass

Eye-mark

20 mm (0.79 inch)


ovement

First pass spread m

ovement


Eye-mark sizeHeight: 2 mm (0.08 inch)

Width: 5 mm (0.20 inch) (minimum)

Background (for simplex printing): 4 mm (0.16 inch) long (minimum) clear (not printed) strip before the eye-mark (from second pass print orientation) as illustrated in Figure 8-10

When designing the first pass for duplex printing, leave an finitely-long clear strip in which only the eye-marks will appear. This will allow automatic eye-mark sensor calibration. It is recommended that the eye-mark be made as wide as possible (>5 mm [0.20 inch]).

In line position:

Figure 8-10. Eye-mark size

Simplex - 66 mm (2.60 inches) away from the second pass leading edge.

Duplex - 20 mm (0.79 inches) away from the leading edge of second pass.

Eye-mark positionThe following are four possible eye-mark positions on the first pass image, according to the reinsertion mode.

● Simplex with rewind

● Simplex without rewind

● Duplex with rewind

● Duplex without rewind

Note To summarize, the illustration above shows the position of the eye-mark printed as part of the first pass, and specifies the distance between the eye-mark printed in the first pass print and the leading edge of the image printed in the second pass printing.

Second pass leading edge

20 to 66 mm(0.79 to 2.60 inches)

2 mm

(0.078 inch)

4mm (0.157 inch)clear strip(simplex)

5 mm(0.197 inch)

Only eye-marks appear in this strip(duplex)

ENWW Eye-mark placement and size 129

Designing a duplex jobWhen designing a duplex job, make sure you place the image at the center of the spread. That way you will assure registration of second pass image to first pass image.

How to design first and second pass jobs

Designing a first pass spread requires the following few basic rules. The output of this procedure is two files, one containing the first pass design and the other, the second pass design.

Figure 8-11. Eye-mark position summary

As the first pass pattern (repeated image) can be printed on any printing device, it must be planned together with the second pass pattern.

The design is executed on a pre-press station, producing two files; one for the first pass and the other for the second pass.

The following example illustrates the methods for producing two different files, whether the first pass is to be printed on the HP Indigo press ws2000 or not.

Leading edge first passLeading edge of second pass for cases 1 and 3

Leading edge second pass(cases 2 and 4)

66 mm (2.6 inches) (case number 1)


20 mm (0.787 inches)(case number 3)



The following is the terminology for the job originator:

● Repeat length is the distance between two consecutive eye-marks.Repeat length = (vertical element size + gap) × (number of elements on vertical axis)Repeat length ≤ 437mm (12.20 inches)Page length ≤ 464 mm (18.27 inches) (limited by HP Indigo PPD)Page width ≤ 320 mm (12.60 inches)

● Page length = (vertical element size) × (number of elements on vertical axis) + gap × (number of elements on vertical axis –1) + 20 mm (0.79 inch)

● Eye-mark location – Eye-mark placement is relative to the first pass image. When placing a second pass spread on the first pass spread the final job is received. The eye-mark is printed as part of the first pass image. Its location varies depending whether it is printed as simplex or duplex, and whether the output roll is rewound or not.

● Element – Element is used in this document as the smallest repeatable unit in the page design. An example of a label has been used in the following examples. Naturally any other element that appears on the page at a constant frequency can replace the label in the example.

Designing a simplex job with rewind

The following describes how to create a file for a first pass image and a file for a second pass image for simplex second pass printing with rewinding. Printed web including first and second passes (Figure 8-12) illustrates the finished product including all elements and sizes.

Figure 8-12. Printed web including first and second passes

Repeat length

56 mm (2.2 inches)

Eye-mark

Image length≤ 437 mm(17.2 inches)

Gap

Substrate width

Image width

ENWW Designing a simplex job with rewind 131

Create first pass file

1 Set the page size as follows:Page width = substrate width ≤ 320 mm (12.6 inches).Page length = (element length) × (number of elements on vertical axis) + gap × (number of elements on vertical axis–1)+ 20 mm (0.787 inches).

2 Place elements on page.

3 Center elements on page.

4 Place eye-mark 66 mm (2.60 inches) below leading edge (see Figure 8-13).

Create second pass file

1 Save first pass file under another name.

2 Create a visible but not printable layer for first pass elements (layer #1).

Figure 8-13. First pass page design

Figure 8-14. Printed web with first pass only

3 Create a new visible and printable layer (layer#2).

66 mm (2.6 inches)

Eye- mark

10mm(0.39 inch)

Gap

Element length

10mm(0.39 inch)

Repeat length Web direction


4 Place second pass elements on the new layer (layer #2).

Figure 8-15. Second pass page: unprintable layer, printable layer, printed products

Designing a simplex job without rewind

The following describes how to create a file for a first pass image and a file for a second pass image for simplex second pass printing without rewinding. The figure below illustrates the finished product including all elements and sizes.


Unprintable layer (layer #1)

Printable layer (layer #2)

Printed product

56 mm (2.20 inches)

Repeat length

Eye-mark

Gap

Image length≤ 437mm(17.2 inches)

Substrate width

Image width

ENWW Designing a simplex job without rewind 133


1 Set the page size as follows:Page width = substrate width ≤ 320 mm (12.60 inches).Page length = (Element length) × (number of elements on vertical axis) + gap × (number of elements on vertical axis – 1) + 20 mm (0.79 inch).



4 Place the eye-mark 56 mm (2.20 inches) above the bottom of lowest element.

Figure 8-17. First pass image


66 mm (2.60 inches)

Eye-mark

10 mm (0.39 inch)

Gap

Element length

10 mm (0.39 inch)

Repeat length

Web direction


Create a second pass file:

1 Save the first pass file under another name.


3 Rotate first pass image 180o (layer #1).

4 Create a new visible and printable layer (layer #2).

5 Place second pass elements on the new layer (layer #2).

Figure 8-19. Second pass page: unprintable layer, printable layer, printed products

Designing a duplex job with rewind

The following describes how to create a file for a first pass image and a file for a second pass image for duplex second pass printing with rewinding. Printed web including first and second passes (Figure 8-20) illustrates the finished product including all elements and sizes.



Printed product

ENWW Designing a duplex job with rewind 135



1 Set the page size as follows:Page width = substrate width ≤ 320 mm (12.60 inches).Page length = (Element length) × (vertical number of elements) + Gap × (vertical number of elements) + 20 mm (0.79 inch).



4 Place eye-mark 10 mm (0.39 inch) below the topmost element.


10 mm (0.39 inches)

Repeat length

Eye-mark

Gap

Image length≤ 437mm(17.20 inches)

Substrate width

Image width

Eye-mark

10 mm (0.39 inch)

Gap

Element length

10 mm (0.39 inch)

10 mm (0.39 inch)






3 Mirror the first pass image about its vertical axis (layer #1).


5 Place the second pass elements on the new layer (layer #2).

Figure 8-23. Second pass page- unprintable layer, printable layer, printed products




Printed product

ENWW Designing a duplex job with rewind 137

Designing a duplex job without rewind

The following describes how to create a file for the first pass image and a file for a second pass image for duplex second pass printing without rewinding. Figure 8-24 illustrates the finished product including all elements and sizes.



1 Set the page size: as follows:Page width = substrate width ≤ 320 mm (12.60 inches).Page length = (Element length) × (vertical number of elements) + gap × (vertical number of elements) + 20 mm (0.79 inch).



4 Place eye-mark 10 mm (0.39 inch) above the bottom of the lowest element.

10 mm (0.39 inch)

Repeat length

Eye-mark

GapOne-half gap

Image length≤ 437mm (17.20 inches)

Substrate width

Image width






2 Create a visible but non-printable layer for the first pass elements (layer #1).

3 Mirror the first pass image about the horizontal axis (layer #1).


5 Place the second pass elements on the new layer (layer #2).

Gap

Element length

Eye-mark

10 mm (0.39 inch)

10 mm (0.39 inch)10 mm (0.39 inch)


ENWW Designing a duplex job without rewind 139

Figure 8-27. Second pass page - unprintable layer, printable layer, printed products

HP Indigo press ws2000 operator instructions

Upon receiving a job, first pass or second pass, that was prepared according to these instructions:

1 Make sure the job appears in the Loaded Jobs list or Print Queue.

2 Double-click the job. The Job Properties window opens.

3 Click the Image Placement tab.

4 Click Center. The image is aligned to the center of the spread.

5 Click in the Top text box and enter 0. The image is aligned to the center across the vertical axis and to the leading edge across the horizontal axis.

Figure 8-28. Job Properties window



Printed product

Image is aligned to the leading edge, and centered on the vertical axis


QuarkXpress operator instructions

If you have QuarkXpress version 4.x or later and it is equipped with the HP Indigo Yours Truly Designer Xtension, you can output J-Layout (JLT) files directly from QuarkXpress.

1 Set spread size as Max.

2 Align image to the leading edge and center it about the vertical axis.

Figure 8-29. JLT spread definition

Operator – setting the press

First pass printing


1 Thread the web.

2 Make sure the web is centered on the press.



4 Print five copies.

5 Measure the printed repeat length (measure from one eye-mark to the next).

6 If it is necessary to make small adjustments, open the Job Properties window.

Spread is aligned to leading edge, and centered about the vertical axis

ENWW QuarkXpress operator instructions 141

7 In the Job Properties window click the Repeat Length tab.

Figure 8-30. Setting repeat length value

8 Enter the desired value in the repeat length text box and click OK.

9 Print five copies.

10 Measure the job’s repeat length, if unsatisfactory repeat steps 6 to 8.

11 Print the job.

Second pass printing1 Check if the web has been rewound or not according to job planning.


2 Thread the web according to the type of reinsertion necessary: simplex or duplex, rewound or not. For threading procedure see "Threading" on page 73.

Threading options for second pass printing

There are two ways to place the substrate on the unwinder for second pass printing:

● Simplex, with or without rewinding - The input roll rotates counterclockwise, as in simple one pass printing. The roll’s position is as shown in Figure 8-31.

● Duplex with or without rewinding - The input roll rotates clockwise (see Figure 8-32).

Repeat length


Figure 8-31. Standard feel roll position (simplex)

Figure 8-32. Input roll reverse position (duplex)

3 Select the Second Pass Printing option on the Adjustment menu. The Second Pass Printing wizard Manager opens.Or,Select the Web Threading Routine from the Maintenance menu. The Web Threading Routine checklist opens.Click on the icon beside the Electronic Registration step in the Web Threading Routine Checklist. The Second Pass Printing Wizard Manager opens.

Figure 8-33. Second Pass Printing Wizard Manager

Input roll

Feed nip

Feed dancer

Input roll

Feed nip

Feed dancer

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Eye-mark sensor calibrationThe purpose of this procedure is to verify that the eye-mark sensor clearly identifies eye-marks. This guarantees a flawless second pass printing. The procedures for simplex and duplex second pass printing are different. Eye-mark sensor calibration for simplex printing is described first and then the procedure for duplex printing.

1 On the control panel, click Adjustments and Second Pass Printing to view Second Pass Printing wizard, and then click Calibrate Eye Mark Sensor. The first page of the Calibrate Eye Mark Sensor wizard opens.

Figure 8-34. Calibrate Eye Mark Sensor - Prepare

2 Change press status to Standby or Off. Click Next. The second page of the Calibrate Eye Mark sensor wizard opens.

3 Select the Thread substrate for second-pass printing check box.

4 Indicate the current reinsertion method. The options are:

• simplex (face up)

• duplex (face down)

Click the check box beside this step once selection is made.


5 Set the Simplex/duplex selector switch to the appropriate position. Click the check box beside this step once the position is set. (See Figure 8-35).

6 Adjust lateral position of the selected eye-mark sensor head until it is positioned in the middle of the printed eye-mark.

Figure 8-35. Eye-mark control panel.

7 Click Next once all of the steps are completed and checked off in the wizard window.The wizard progresses to the next step, according to the reinsertion method indicated in this wizard window. If the reinsertion method is simplex, the wizard continues to the Mark step in the wizard. If the reinsertion method is duplex, the wizard continues to the Verify step in the wizard. See "Duplex eye-mark sensor calibration" on page 149.

Simplex/duplex selector

Place above eye-mark

Front wall


Simplex eye-mark calibration1 Check that the small yellow LED on the simplex eye-mark detector amplifier is off. If it

is on, press the Reset Lamp button in the wizard window. This automatically resets the sensing assembly. When the lamp is off, the sensing assembly is working properly.

Figure 8-36. Calibrate Eye Mark Sensor - Mark (simplex)

2 Select the check box beside this step once the LED is off.

3 Once you have verified that the yellow LED is off, press (with short presses) on the Find Mark button on the input control panel until the printed eye-mark is directly under the red sensor light spot. The spot should be entirely within the mark. Click on the check box beside this step once the sensor light is entirely within the eye-mark.


4 Click Next once all of the steps are completed and checked off in the wizard window. The wizard progresses to the next step, Space.

Figure 8-37. Calibrate Eye Mark Sensor - Space (simplex)

5 Check that the small yellow LED on the simplex eye-mark detector amplifier is on. If it is off, start the Calibration procedure again from the previous step.

6 Click on the check box beside this step once the LED is on.


7 Once you have verified that the yellow LED is on, press (with short presses) on the Find Mark button on the Input control panel until the non-printed (white space) part of the web is directly under the red sensor light spot. This enables the sensor to identify white space. Click on the check box beside this step once the sensor light is entirely within the eye-mark. Click on the Next button once all of the steps are completed and checked off in the wizard window. The wizard progresses to the next step, Finish.

Figure 8-38. Calibrate Eye Mark Sensor - Finish (simplex)

8 Check that the small yellow LED on the simplex eye-mark detector amplifier is off. This indicates that the sensor has successfully identified the white space. If the LED is on, start the calibration procedure again.

9 Click on the check box beside this step once the LED is off.

10 Check that the green LED on the simplex eye-mark detector amplifier is on and is not flashing. If the LED is off or flashing, start the calibration procedure again.

11 Click on the check box beside this step once the green LED is on. Click the Finish button once all of the steps are completed and checked off in the wizard window.

12 You have calibrated the eye-mark sensor for simplex second pass printing.Proceed to the "Repeat Length Matching Verification wizard" on page 150. You must verify the repeat length after calibrating the eye-mark sensor.


Duplex eye-mark sensor calibration1 Check that the small yellow LED on the duplex eye-mark detector amplifier is off. If it

is on, press the reset lamp button in the wizard window. This automatically resets the sensing assembly. When the lamp is off, the sensing assembly is working properly.

Figure 8-39. Calibrate eye-mark Sensor - Verify (duplex)

2 Select the check box beside this step once the LED is off. Click Next once the step is completed and checked off in the wizard window. The wizard progresses to the next step, Run.

3 Press and hold down the Feed button on the exit control panel until the yellow LED on the duplex eye-mark detector amplifier turns on. As soon as the LED starts flashing, stop pressing the Feed button. Select the check box beside this step once the LED is flashing.

Figure 8-40. Calibrate eye-mark Sensor - Run (duplex)


4 Once you stop pressing the Feed button, the yellow LED should go off and the green LED should remain on. If this does not happen, start the calibration procedure again.

5 Select the check box beside this step once the LEDs have reacted as indicated.

6 Click Finish once all of the steps are completed and checked off in the wizard window. Continue with the Repeat Length Matching Verification wizard. You must verify the repeat length after calibrating the eye-mark sensor.

Repeat Length Matching Verification wizardPerform this procedure to make sure that the repeat length of the job is as desired. Once the repeat length is verified, second pass image registration to the first pass print is guaranteed.

1 From the Adjustment menu, select the Second Pass Printing option. The Second Pass Printing Wizard Manager opens.Or,From the Maintenance menu, select the Web Threading Routine. The Web Threading Routine Checklist opens. Click on the icon beside the Electronic Registration step in the Web Threading Routine Checklist. The Second Pass Printing Wizard Manager opens.

Figure 8-41. Second Pass Printing Wizard Manager window

2 Load the job. The job’s name should appear in the control panel’s Current Job text-box.

3 Click Repeat Length Matching Verification. The first step window of the Repeat Length Matching Verification wizard opens.

Figure 8-42. Repeat Length Matching Verification - step one


4 Change press status to Ready. Once the press is at Ready state, click Next. The second Repeat Length Matching Verification wizard window opens.

Figure 8-43. Repeat Length Matching Verification - step two

5 Press and hold down the Find Mark button on the input control panel until the web stops on the leading edge of an eye-mark.

Input control pads

6 You can enter the repeat length in the available field if you know the exact length for the current job. If you do not know the exact length, measure the length between the leading edge to leading edge of two consecutive eye-marks and enter the measured value in the field. You can use the Undo button to return to the previous value.

7 Click Print to print the current print job. One copy of the current job prints.

8 After printing one copy of the job, the red spot of the eye-mark sensor should fall exactly on the leading edge of the next eye-mark. If the sensor spot falls in front of the eye-mark (between the eye-mark and the press) measure the distance from the leading edge of the eye-mark to the sensor spot and add this value to the repeat length value. Correct the repeat length value that displays in the Adjust Repeat Length field.

Inching

Find mark


Paper feed


9 If the sensor mark falls after the eye-mark (between the eye-mark and you) measure the distance from the leading edge of the eye-mark to the sensor spot, and subtract this value from the repeat length value. Correct the repeat length value that displays in the Adjust Repeat Length field.

10 If the sensor spot falls behind the eye-mark, click Reverse Paper Feed to set the press for reverse web movement.

11 Once you have set the web transport system to move in reverse, press the Paper Feed button on the exit control panel. The web moves in reverse. Continue until the sensor spot is in front of the leading edge of the eye-mark. (The web transport system moves in reverse the first time you press the Paper Feed button. After releasing this button, the web moves forward again.)

12 Once the sensor spot is in front of the eye-mark, continue by performing Step 1 of this wizard window again — press the Find Mark button until the spot is exactly on the leading edge of the eye-mark. Once the sensor spot is exactly on the leading edge of the eye-mark, print the job again. If the sensor spot does not fall exactly on the leading edge of the next eye-mark, measure the difference and correct the value in the Adjust Repeat Length field. Continue this procedure until the sensor spot falls exactly on the leading edge of an eye-mark after printing.

13 Once the web stops exactly on the leading edge of the next eye-mark, click Finish and verify that the repeat length value in the Repeat Length page of the Job Properties dialog box contains the same repeat length value.


Job handling


● Working with the HP Indigo RIP

● Preparing to print

● Printing the job

● Pausing or stopping a print job

● Handling image wetness

ENWW 153

Working with the HP Indigo RIP

The HP Indigo press ws2000 jobs begin at desktop publishing stations unrelated to and often at a distance from the press. There, text and graphics are designed and integrated, pages are impositioned, and PostScript, PDF or JLT files created. The PostScript files are then transferred to the press.

The system begins at the HP Indigo RIP, where PostScript or PDF files are transformed into HP format RIP’d jobs. Once they are RIP’d, these jobs are ready to be read and printed by the press.

For operating instructions, see the HP Indigo RIP user guide.

Preparing to print

Preparing the press Prepare the press for printing:

● Make sure that all doors are closed.

● Change the machine state to Ready.

● Adjust the substrate transport system.

● Adjust the color.

● Make sure that the loaded substrate is the same as the one defined in the Substrate window.

● Select the appropriate print mode (Step or Continuous).

Preparing the jobUse the following procedure to prepare a job for printing:

1 Check that the current print job is correct and that the jobs in the Print Queue are in the correct order.

154 Chapter 9 Job handling ENWW

2 Check that the properties of the current print job are defined correctly. Properties to check are the job’s general information, color LUT, screening matrix, color match and image placement (job properties are defined in the Job Properties window).

3 Make sure that you are satisfied with the job setup (defined in the General tab of the Job Properties window). The After Print Retain For value determines whether the job is removed after printing is complete or, if retained in the Retain queue, the amount of time the job is kept before deletion.

4 Click on Print to initiate printing of all copies that are required or click on Proof to print a proof of the current print job.

Selecting a print modeBefore you initiate printing you can select either the Step or Continuous print mode.

● Step mode prints all copies of the current job and then stops the press.The machine state returns automatically to Ready. If the press is in Continuous mode, switch to Step mode by clicking the mode switch on the control panel. The switch changes to the lower position beside the Step mode.

● Continuous mode prints all copies of all jobs in the Print Queue without stopping between jobs. If the press is in Step mode, click the mode switch to change to Continuous mode. The switch changes to the higher position beside the Continuous mode.

Changing the machine state

Changing the machine state from Off to Standby

Change the machine state from Off to Standby in order to activate the control panel on your workstation monitor and begin the process of preparing the press.

1 Close all the doors.

2 Turn on the Power Enable switch on the right side of the machine. The control panel options become active and the machine state indicator points to Standby. The button under the indicator is labeled Get Ready.

Figure 9-1. The Job Properties window

ENWW Preparing to print 155

Changing the machine state from Standby to Ready

Change the machine state from Standby to Ready in order to prepare the system for printing.

Click Get Ready. The machine state indicator above the button shows the progress of the machine as it moves to the Ready State. When it has reached Ready, the arrow points to Ready and the text turns red. The button label then changes to Go to Standby.

Changing the machine state from Ready to Print

Change the machine state from Ready to Print in order to initiate printing.

1 Transfer one or more jobs to the Print Queue.

2 Click Print or Proof. The machine state indicator shows the progress of the machine as it moves to the Print state. When it is at the Print state, the arrow points to Print, the state button changes to Stop, and the animated schematic indicator becomes active and shows the movement of the drums and the transport system. The Print button label changes to Pause.

Changing the machine state from Print to Pause

Change the machine state from Print to Pause when you want to pause printing without stopping the machine completely. You can pause the press in order to make adjustments to the print job (such as changing image placement or the number of copies and spreads). The press pauses for only 60 seconds. During this period, the press remains in the Print state. After 60 seconds, the press automatically stops and changes to Ready state.

To pause the press, click Pause in the control panel. Click Print to resume printing.

Changing the machine state from Ready to Standby

Change the machine state from Ready to Standby whenever you want to be in Standby state (for example, when replacing the blanket).

Click Standby. The machine state indicator moves to Standby. The state button label changes to Get Ready.

Changing the machine state from Hold to Ready or Standby

The press automatically changes to Hold whenever a door is open in Ready state. The schematic animated indicator on the main panel shows that the drums and substrate transport system have stopped, and the open door appears in the diagram.

To change back to the Ready state, close all doors. The system remains in a Hold state until you close all open doors. If the machine was moved or adjustments were made to any inner parts of the press while the door was open, the press will return to the Standby state; otherwise it returns to Ready state.

Figure 9-2. HP Indigo press ws2000 control panel


Printing the job

Start the printing process by clicking the Print button. The Print button label changes to Pause. When Step mode is selected, all copies of the current print job are printed, and then the press stops. When Continuous mode is selected, all copies of all jobs in the Print Queue are printed before the system stops.

Printing a proofYou can check the quality of the print prior to printing the entire job by printing a proof. You can proof your work while in Step or Continuous modes.

Printing a proof while in Step mode

Use one of the methods below to print a proof in Step mode.

Method 1

1 In the control panel, click Proof. One copy of each spread of the current job is printed. The job remains at the top of the Print Queue, and the machine status automatically changes to Ready.

2 Pull proofs until you are satisfied with the quality of the printing.

3 Click the Print button to print the full run of the job.

Method 2

1 In the Job Manager window, select a job in the list of Loaded Jobs or in the Print Queue.

2 Click the Send to Queue as Proof icon at the top of the Job Manager window or select the Send to Queue as Proof option from the Job Manager Queue menu. The job is moved to the top of the Print Queue and a small red indicator appears beside the job status icon on the far left side of the job row. One full copy of the selected job is automatically printed.

3 After the proof is printed, the job returns to the Loaded Jobs list.

Printing a proof while in Continuous mode

1 Select a job in the Loaded Jobs list.

2 Click the Send to Queue as Proof icon at the top of the Job Manager window or select the Send to Queue as Proof option from the Job Manager Queue menu.The selected job moves to the top of the Print Queue.

3 When the current job finishes printing, the proof is printed. Once the copy for proofing is complete, the job returns to the Loaded Jobs list and the press continues to print the next job.

ENWW Printing the job 157

Pausing or stopping a print job

Pausing a print jobThe pause option enables you to stop printing temporarily. Use it if you want to perform last-minute updates for a job, for example, to define a specific copy or spread number that you want to start printing from, in order to reprint spreads.

Click Pause in the control panel to pause printing. The system stops printing after the current spread is printed.

After you click Pause, the schematic animated diagram shows the transport system stopped. The number of copies and spreads, which appears in the current print job window in the control panel, stops at the last copy and spread printed.

The press pauses for only 60 seconds. During this period, the press remains in the Print state. After 60 seconds, the press automatically stops and changes to the Ready state.

Click Print to resume printing. The animation shows that the machine is printing. The counter continues from where it left off.

Switching between jobs during printingUse one of the methods below if you want to interrupt the printing of the current job and initiate the printing of the next job in the Print Queue.

Method 1

On the control panel toolbar, click Switch. The current job becomes the second job in the queue, and the next job becomes the current job.

Method 2

Click and drag the job that you want to print to the top of the Print Queue list. The dragged job becomes the current job, replacing the previous current job.

Method 3

Click and drag the job that you want to print to the current print job panel in the control panel. The dragged job becomes the current job, replacing the previous current job.

If you are printing in Continuous mode, the new current job is automatically printed according to properties specified for that job. If you are printing in Step mode, you must click on Print or Proof to initiate the printing of this new job. When the new current job is complete, the next job (which was previously the current job) moves up in the list.

Figure 9-3. Current print job panel


Ending the current jobUse one of the methods below to remove the current job from the Print Queue without completing the specified print requirements. The job is removed only after the current copy has been printed.

Method 1

Click End Job in the control panel. The current print job is terminated once the current copy is printed. The job is moved to the Print Queue list.

Method 2

Click and drag the current job from the Print Queue window to the Loaded Jobs list.The current print job is terminated once the current spread is printed.

In Continuous mode, the next job in the Print Queue is automatically printed. In Step mode you must click Print or Proof to initiate the printing of the next job in the queue.

Information regarding the number of completed spreads and copies of the terminated job, is stored in the Printing Log.

Printing from a specified copy or spread numberTo initiate printing from a specified copy and/or spread number you must first access the Current Copies & Sheets window.

1 In the current print job panel in the control panel, click on Copies or Sheets.The Current Copies & Sheets window opens.

The copy and spread numbers that were most recently printed appear in the fields at the top of the window. A note above the current copy and spread information tells you whether the current job is defined as collated or non-collated.

2 Use the spin buttons to select the appropriate copy and spread number. Clicking on the spin buttons when a job is collated increases or decreases the spread number until it reaches the last spread number. At this point, it increases or decreases the copy number by one and then begins to change the spread numbers again. This way, you can re-print a selected number of spreads with collation automatically taken into account.

Clicking on the spin buttons when a job is non-collated automatically increases or decreases the copy number until it reaches the last copy. At this point it increases or decreases the spread number. This way, you can re-print a selected number of spreads with non-collation automatically taken into account.

3 Click OK to initiate printing from the selected copy and spread number.

Figure 9-4. Current Copies & Sheets window

ENWW Pausing or stopping a print job 159

Stopping a job before the full run is printedUse this option when you want to stop printing a job before all defined copies have been printed and leave the job in the Print Queue. This option is necessary when you perform a routine maintenance procedure that must be executed before the printing is complete (for example adding substrate).

Click Stop under the machine state indicator in the control panel. Wait for the press to reach the Ready state; this may take a few seconds. When the press changes to the Ready state, the drums stop rotating and the transport system stops feeding substrate. The job remains in its current position in the Print Queue.

Click Print in the control panel when you are ready to resume printing. The job continues printing from where it stopped.

Stopping the system in case of emergencyUse this option to stop the press in case of emergency only.

Press the Emergency Stop button on the input door control pad or on the exit door control pad. The drums stop turning and the transport system comes to an immediate halt. Stopping the press in this manner affects the quality of printing since it may cause damage to the PIP and blanket and may cause ink contamination.

Handling image wetness

The degree of image wetness on the blanket is substrate dependent. Absorbent substrate types result in a dry image. The function of the feed blanket fan is to get rid of the excess wetness. You can regulate feed blanket fan flow rate to avoid over-drying of the image.

You can identify an over-dry image by analyzing the print. Missing parts of the image that are found either on the blanket or as part of the next spread, are an indication that the image is too dry.

Under standard operating conditions, you should work with the feed blanket fan on. The feed blanket fan is enabled/disabled under the Substrate Definition window. You can also view the feed blanket fan status in the Substrate List window.


Changing feed blanket fan mode onpresses not equipped with dripping prevention kitPerform the following procedure only when you have detected an image quality problem stemming from an image that is too dry.

1 To view the feed blanket fan current operation level, click Consumables and select Substrate. The Substrate window opens.

2 To disable the feed blanket fan, click Options in the control panel menu and select Substrate List. The Substrate List window opens.

3 In the Substrate List window, select the desired substrate and double-click it. The Edit existing substrate definition window opens.

4 In the Edit existing substrate definition window, select Off from the BKT Fan Level drop-down list, and then click OK. You have disabled the feed blanket fan for the selected substrate type.

This procedure can be performed in all machine states and is applied immediately.

Figure 9-5. Substrate window - Feed Blanket fan enabled

Figure 9-6. Edit existing substrate definition window

ENWW Handling image wetness 161

Changing feed blanket fan mode onpresses equipped with dripping prevention kitPerform this procedure only when you have detected an image quality problem stemming from an image that is too dry.

1 To view the feed blanket fan current operation mode click Consumables and select Substrate. The Substrate window opens. If the image is too dry and does not transfer well to the substrate, change feed blanket fan operation level by following the instructions below.

2 To change the feed blanket fan operation level, click Options in the control panel menu and select Substrate List. The Substrate List window opens.

3 In the Substrate List window, select the desired substrate and double-click it. The Edit existing substrate definition window opens.

4 In the Edit existing substrate definition window, click the BKT Fan Level arrow. A drop-down list containing four feed blanket fan operation levels opens. These are the four operation levels: Off, Low, Medium and High. High is the default operation level of the feed blanket fan.

Figure 9-7. Substrate window



5 Select Medium.

6 Print five copies and examine them. If problem persists, switch to Low operation level.

7 Print five copies and examine the prints. If the image is still incomplete, select Off to turn the feed blanket fan off. This option disables the feed blanket fan for the selected substrate type whenever it is loaded.

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Handling consumables


● Working with ink

● Maintaining the blanket

● Working with ink

● Maintaining the blanket

● Maintaining the PIP

● Defining substrate type

● Maintaining the separator

● Maintaining the scorotron

ENWW 165

Working with ink

HP ElectroInkHP ElectroInk is an HP Indigo patented liquid ink composed of a suspension of imaging oil and solid pigment particles. The concentration of the ink, that is, its 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 goes below the desired level. The concentrated ink is pumped from the ink can. Once an ink can is empty, it must be manually replaced.

Imaging oilImaging oil serves as a carrier for the pigment. It does not adhere to the printed substrate but rather evaporates and must be replenished manually. When prompted, pour imaging oil directly into the separator, which distributes it between the different ink tanks.

Draining the ink tankFollow this procedure to drain all the ink from the ink tank. Before performing the procedure, make sure that you have the following items:

● 10-liter container for drained ink

● ink-resistant gloves

You should drain the ink tank whenever the following conditions exist:

● Working ink is contaminated.

● There is ink overflow.

● A fifth or a sixth color needs to be changed.

● There is a long-term shutdown.

Follow the instructions below to drain the ink tank.

1 Click Go to Standby in the control panel. The system changes to Standby state.

2 Press an Emergency Stop button on the press.

3 Open the ink can door and remove the lower ink tank door.

4 Place the container that will hold the drained ink close to the ink tank.

5 Locate the drain hose on the right side of the ink tank.

Figure 10-1. Adding imaging oil

166 Chapter 10 Handling consumables ENWW

6 Crimp the flexible hose to stop ink flow.

7 While holding the hose, unscrew the cap and place the end of the hose in the empty container.

8 Straighten the hose. The ink flows into the waste container.

9 If necessary, tilt the waste container to enable the ink to drain.

10 When finished, place the hose back in the ink container and screw the cap onto the waste container.

11 Dispose of the contaminated ink in accordance with waste disposal recommendations. Drained ink that is not contaminated can be stored in sealed containers and retained for re-use later.

12 Release the Emergency Stop button by turning the knob until it is released.

CAUTION Ensure that all equipment, tools, and materials are removed from the unit and that all doors are closed before operating the machine.

Refilling the ink tankThis procedure refills the ink tank with imaging oil. Before carrying out the procedure, make sure that you have the following items:

● about 4 liters of clean imaging oil in a container and a manual pump

● ink-resistant gloves

Refill the ink tank after either of the following operations:

● rebuilding the ink

● flushing the tank (for example, prior to long-term shutdown)

Figure 10-2. Draining the ink tank

Ink hose

Cap

Active filter

Active filter cap

ENWW Working with ink 167

Follow the instructions below to refill the ink tank.

WARNING! Electrical Hazard – Press an Emergency Stop button before beginning this procedure.

1 Access the Ink Properties window using one of the following methods:

• From the Diagnostics menu in the control panel, select the Ink option.

• Click the animated schematic diagram in the control panel to open the Schematic window. Click the required ink tank. The Ink Properties window opens.

2 Click the Flow tab.

3 On the press, remove the plug from the top of the ink tank.

Figure 10-3. The Ink Properties window

Figure 10-4. Refilling the ink tank

Plug


4 Insert one end of the manual pump hose into a container of clean imaging oil. Insert the other end of the pump hose into the hole on top of the ink container.Pump imaging oil into the ink container until the sensor on the Flow tab reaches the middle position (approximately 4 liters). If you add more imaging oil than required, the imaging oil will overflow when you add the solids.

5 Replace the plug in the hole on top of the ink tank.

6 To rebuild the ink, replace the ink concentrate can with a full new can. You can use the partially filled can at a later time.

7 From the Consumables menu, select the Ink Cans option.

8 Click the ink can that requires rebuilding. The ink can is selected.

9 Click Rebuild on the right side of the window. The word Yes appears in the Rebuild field. The next time the press is in the Getting Ready state, the ink concentrate will be added at the required density to the tank.

Replacing ink cansReplace an ink can when an ink concentrate can is empty (as indicated by the system warning indicator in the control panel) or when you want to change the color of ink in an ink tank.

Follow the steps below to replace an ink can.

1 Open the ink service door.

2 Grasp the empty ink concentrate can and lift up (you will feel a click). Pull out the bottom end first.

3 Dispose of empty cans in accordance with local regulations.

4 Locate a new can of the required color and shake it well.

5 With the nozzle facing down, insert in the holder. Push up and in. Fit the nozzle in the O-ring in the base.

6 Close the ink service door. The system injects the ink concentrate until the ink density in the ink container is up to the required level (1.7) and then stops automatically.

7 To update your system, select the Ink Can option from the Consumables menu. The Ink Cans window opens.

Figure 10-5. Replacing the ink can


8 If the Replace Ink Can tab is not already on top, click on it to bring it to the front.The ink can status appears as either OK or Empty.

9 Click on the ink can that you replaced. The ink can selected appears in the window.

10 In the Ink Cans window, click on the Replace button on the right side. The impression counter resets to 0. If the original can was empty, the status returns to OK.

Changing the color of an ink tank using the Install Ink wizardUse this wizard when you want to change the color of an ink tank.

Accessing the Install Ink Wizard Manager

1 From the Consumables menu, select the Install Ink option. The Install Ink Wizard Manager opens.

2 The Install Ink Wizard Manager walks you through all the procedures you perform when changing the color of an ink tank. The following wizards open from the Manager:

• Cleaning Cycle wizard

• Calibrate Ink Density wizard

• Color Adjust wizard

Using the wizard

1 In the Wizard Manager, click on the button for the required wizard. The selected wizard opens to the right of the manager.

2 Follow the instructions described at each stage in the selected wizard. Click Next to progress from stage to stage.

Note Explanations for procedures required for the wizards are provided in the wizards and in their corresponding help topics.

3 When you have performed all steps in a wizard, the wizard closes and the Wizard Manager remains on the window to allow you to select another wizard. A check mark appears beside all completed wizards within the manager.

Figure 10-6. Ink Cans window


Increasing ink conductivityPerform this procedure when the system prompts you to increase the ink conductivity level.

1 Bring the Press to Ready state so that the ink tank temperature is at the working level.

2 From the Diagnostics menu, select the Ink option. The Ink Properties window opens.

3 Click on the Conductivity tab.

4 Note the ink’s conductivity.

5 If conductivity reads lower than 70 pmho/cm3, add charge agent to the ink tank according to the following table:

Adding charge agent

1 Open the ink tank door.

2 Remove the plug from the top of the ink tank.

3 Add the charge agent as required.

4 When done, return the plug to the hole.

5 Make sure the press is at the Ready state.

6 Check ink conductivity again. If the conductivity is still lower than 70, call your HP Indigo customer engineer.

Decreasing ink conductivityPerform this procedure when the system prompts you to decrease ink conductivity.

1 Bring the press to Ready state so that the ink tank temperature is at the working level.

2 From the Diagnostics menu, select the Ink option. The Ink Diagnostics window opens.

3 Click the Conductivity tab.

4 Note the ink’s conductivity. If conductivity reads higher than 110pmho/cm3 replace the ink.

Note Try draining some of the ink and adding imaging oil until the correct conductivity is reached. If this does not work, replace the ink.

5 Check ink conductivity again. If the conductivity is still higher than 110pmho/cm3, call your HP Indigo customer engineer.

Measured conductivity[pmho/cm3]

Add charge agent [ml]

30-39 22

40-49 18

50-59 14

60-69 10


Viewing the ink logPerform this procedure to view ink can replacement history and the number of impressions per ink can.

Note The information in the Ink Log cannot be edited.

1 From the Consumables menu, select the Ink Cans option. The Ink Cans window opens.

2 Click Log (far right tab). On the Log tab, you can view the number of impressions per ink can and plan for ink can replacement.

Maintaining the blanket

OverviewThe function of the blanket is to entirely remove the ink from the Photo Imaging Plate (PIP) and to transfer it to the substrate. The blanket has two conflicting characteristics: the capacity to attract all the ink from the PIP and the capacity to repel all the ink and transfer it to the substrate. All the ink must be attracted and then repelled. The blanket’s capacity to perform these conflicting tasks diminishes with use.

Cleaning the blanket

The cleaner page option and the print cleaner function keep the blanket clean automatically. When a cleaner page does not clean the blanket properly, you need to use the print cleaner function, which is user defined. If the print cleaner does not achieve the desired effect, clean the blanket manually using a lint-free wipe.

Replacing the blanket

Although treating the blanket according to instructions guarantees its longevity, it will at some time lose its ink transfer capabilities, that is, it will attract ink but not transfer it to the substrate. When this happens, it is time to replace the blanket.

The blanket gets very hot and you must use heat resistant gloves when removing it. Apply the inch-safe-service method both for removing the old and mounting the new blanket. See "Inch-safe-service method" on page 25. In all cases, make sure the blanket and drum environments are spotlessly clean and that the blanket is taut.

Replacing the blanketPerform this procedure when the blanket is damaged, or if blank, non-inked areas appear on the printed output. Before beginning the procedure, make sure you have the following items:

● thermal gloves

● diagonal or needlenose pliers


Removing an old blanket

CAUTION The ITM drum is very hot and may cause injury if treated carelessly. Use thermal gloves.

1 Bring the machine to Standby state by clicking on Go to Standby in the control panel.

2 Lift the upper input service door above the input tray.

3 Lift the cover of the ITM drum.

4 Advance the ITM drum until the leading edge of the blanket is in view.

5 Cut the leading edge of the blanket along the edge of the metal fastener bar. To prevent the knife from penetrating the surface of the ITM drum, cut very close to the edge of the bar. The lower flap of the metal fastener bar protects the drum.

6 Gently pull the leading edge of the blanket using the needlenose or diagonal pliers (take care when the ITM drum is hot).

7 Advance the machine slowly and continue peeling off the blanket.

8 Lift up the metal fastener bar with the pliers.

Figure 10-7. Cut leading edge of blanket

Figure 10-8. Gently pull off leading edge of blanket

Figure 10-9. LIft up the metal fastener bar with the pliers

ENWW Maintaining the blanket 173

CAUTION Do not use a sharp object to peel off the blanket because this may scratch the ITM drum.

9 Roll the old blanket so that the adhesive side faces out. Advance the drum with the Inching button and use the sticky side of the blanket to clean the drum.

10 Clean the ITM drum with a lint-free wipe lightly soaked in imaging oil while advancing it with the Inching button. Change the cleaning pad when it becomes excessively dirty. Imaging oil dries rapidly. Clean off any remaining oil before it dries.

Installing the new blanket

Use the following items to install the new blanket:

● new blanket

● thermal gloves

Perform the following procedure after the old blanket has been removed and the ITM drum is clean.

1 After cleaning the ITM drum, advance the machine so that the ITM slot is in view (at a machine angle of 70o).

2 On the Consumables menu, select the Blanket option.

CAUTION The ITM drum is very hot and may cause injury if treated carelessly. Use thermal gloves.

3 Place the new blanket on the work table, adhesive side up. Remove the plastic covering from the adhesive side.

4 Pick up the blanket by its trailing edge, and press the edge of the adhesive side lightly on the housing of the writing head (above the ITM drum). Insert the pins of the metal fastener bar in slots in the ITM drum, and press the leading edge of the blanket against the drum so that it is flush with its surface.

5 Detach the trailing edge from the housing of writing head and hold it up. Advance the machine while pressing the blanket evenly against drum. Keep the trailing edge delicately stretched so that no air bubbles become trapped under the blanket.

6 Turn the ITM drum an additional revolution and check for evenness of the blanket.

Figure 10-10. Blanket window, Replace Blanket tab


7 Close the ITM drum cover and close the service doors.

8 Type the new serial number in the available Serial Number field.

9 Select the replacement cause using the drop down list. If you select Other, a field appears that enables you to enter the required information (this is for statistical purposes only).

10 Click the Replace button on the right side of the window.

11 The impression counter for the blanket is reset to zero.

12 A popup message box advises you to perform the color adjustment procedure. This procedure must be performed each time you replace the blanket.

13 Perform first transfer pressure adjustment procedure (below).

First transfer pressure adjustmentThe purpose of this procedure is to adjust the minimum required pressure between the PIP and ITM drums in order to achieve full ink coverage of the printed image.The adjustment is done on the front and rear controls.

Perform this procedure after changing the blanket or when ink coverage is partial and blank patches (in the shape of white clouds) appear on either side of the printed image.

Use the following to complete the first transfer pressure adjustment:

● Gray_20FN job (this job is supplied with the system)

● 5 mm Allen screw.

The first pressure transfer adjustment panels are located on the left and right sides of the exit side of the machine.

1 Open the exit door to locate the panels.

2 Adjust the drum pressure with the Allen screw so that the drum pressure slide is positioned at 75 percent (slightly after notch 4), as marked on the scale.

3 Loosen the ITM and PIP drums’ gap lock screws on each panel.

4 On the operator console, load and print Gray _20FN job.

Figure 10-11. First transfer pressure panel

Adjustment knob

Drum pressure slide

5 mm Allen screw

Lock screw


5 Adjust the rear and front knobs alternately in small increments (one-eighth to one-quarter turns).

6 Turn the knobs clockwise until inkless patches appear at both edges of the image.

7 Gently turn the knobs counterclockwise until full image ink coverage is achieved.

8 Print several sheets to make sure ink coverage is full and stable.

Viewing and modifying blanket temperaturePerform this procedure whenever you want to check the blanket’s current temperature or to adjust its set point.

Viewing current blanket temperature and set point

1 From the Consumables menu, select Blanket. The Replace Blanket window opens.

2 Click Temperature (second from left) at the top of the window. On the Temperature tab a temperature gauge shows the current blanket temperature (solid green line) and the current set point (broken line).

Changing the set point for the blanket temperature

1 Click on the Setup button on the right side of the Temperature tab. The Blanket Temperature Setting window opens.

2 Click on the Default button to use the default value for the set point, or define a new set point by using the spin buttons or dragging the lever.

3 The upper and lower temperature limits for the blanket are automatically defined according to the selected set point. If the blanket temperature exceeds the upper limit, a warning icon appears in the control panel and in the Schematic window. A warning message, with details about the problem, also appears in a pop-up Warning Message box.

Viewing the blanket logPerforming this procedure will help you keep track of the number of impressions made by each blanket and the cause for replacement.

Accessing the blanket log

1 Select the Blanket option from the Consumables menu. The Replace Blanket window opens.

2 Click Log (far right tab). The Blanket Log is displayed.

3 Use the scroll bar to view all information in the log.

Note The information in this log cannot be edited.


Cleaning the blanketEven though all the ink on the blanket is transferred from the PIP to the substrate, a small amount of residue may remain on the blanket (this happens primarily as a result of a problem with the blanket). Perform this procedure whenever needed. Before beginning the procedure, make sure you have a lint-free wipe and imaging oil available.

1 Gently rub the blanket with a lint-free wipe.

2 If the blanket is still soiled, soak the pad in imaging oil and rub the blanket until the ink residue and other contamination are removed.

Blanket recoveryWhenever a web jam occurs, immediately check for substrate or ink residues on the blanket, and perform the procedure below. Before beginning, make sure you have the following items:

● A dry, lint-free wipe

● imaging oil (See HP Indigo part number in Chapter 13.)

CAUTION Dried ink particles and substrate shreds stuck to the blanket may damage it if not removed within a few minutes while the blanket is still hot.

1 Immediately remove any jammed substrate from the machine.

2 If any substrate remains stuck to the blanket, remove it with great care while the blanket is still hot. Peel off the substrate, gently rubbing with a dry lint-free wipe. If this does not work, soak the pad in imaging oil. Remove the substrate in one piece, if possible.

CAUTION The blanket is very hot and may cause injury if treated carelessly. Approach the blanket area with care. Avoid inhaling cleaning solution vapors.

CAUTION Never use IPA on a hot blanket

3 Wet persisting bits of substrate with imaging oil and remove.

4 Clean any ink residue and persistent bits of substrates very gently, using a lint-free wipe soaked in imaging oil. After removing visible ink spots, wipe off the rest of the blanket using the same method.

5 Check the impression film for dirt or damage. Replace it if necessary.


6 Visually inspect the blanket for any deformation. If there is no deformation, initiate the print cleaner wizard immediately. If Fast Recovery is enabled, select the Fast Recovery check box in the wizard window.

Note Fast Recovery is enabled only when the press state at the time of the web jam is Standby. This happens only when the substrate is stuck between the ITM and the impression drums.

7 After completing the wizard, click Go to Ready and then Print. Stop when prints show that the blanket is clean.

8 If a deformation exists, or if the print cleaner shows blanket defects, replace the blanket.

Enabling/disabling automatic blanket cleaner pageThe blanket cleaner page procedure is performed automatically if the cleaner page option has not been disabled. You may want to disable this automatic procedure if the substrate is costly or if you do not want to use it for cleaning the blanket. The cleaner page (when enabled) is automatically generated during a long cold start (at the start of the day) and after a predetermined number of separations (once the job being printed is complete).

The blanket cleaner page does not print when:

● The option is disabled by the operator.

● A system fault prevents the press cleaner from functioning.

To disable the blanket cleaner page function, use one of the methods below:

Method 1

1 From the Consumables menu, select Blanket.

2 Click on the Cleaner Page tab.

3 Click on the Bypass Cleaner Page check box at the bottom of the page.

Figure 10-12. Print Cleaner wizard with a Fast Recovery check-box


Method 2

1 From the Consumables menu, select Substrate.

2 Click the Replace Substrate tab.

3 Select the Bypass Cleaner Page check box at the bottom of the page.

Method 3

1 From the Diagnostics menu, select Bypass.

2 Click the Automatic Cleaner Page check box at the top of the page.

Enabling the automatic cleaner page

1 From the Consumables menu, select Blanket

2 Click the Cleaner Page tab.

3 Ensure that the Bypass Cleaner Page check box, at the bottom of the tab, is not selected.

4 Select or enter the number of cleaner pages that should be used.

Each time a blanket cleaner page is printed, the following message is displayed in a pop-up window:

Blanket Cleaner Page has been printed

A solid separation is printed in yellow. If the job does not use this color, a replacement color, predetermined by the system, will be printed.

Correcting misregistrations (supervisor only)To correct misregistrations that appear on the printed page, do the following:

1 Measure the misregistration on the printed page.

2 Verify the color order of the separations of the current job, as follows:

a From the System menu, select Job Manager.

b In the Loaded Jobs list, double-click the current job. The Job Properties window opens.

c Click the Color Order and Screening tab.


d Note the color order in the Separation Properties list.

e Click the Close button.

3 From the Consumables menu, select the Blanket option.

4 Click the Shift tab.

5 In the Separation Placement list, select the separation number that you want to adjust.

6 When printing, adjust Side A using the spin buttons or by typing the number of microns that you want to shift the image towards or away from the leading edge. A negative number will shift the image towards the leading edge. A positive number will shift the image towards the trailing edge.

7 Click the Apply or OK button.

8 Print a sample page, check the registration, and readjust again if necessary.

Figure 10-13. Job Properties window, Color Order and Screening tab

Figure 10-14. Blanket window, Shift tab


Maintaining the PIP

OverviewImages are written on the PIP and erased from it with each revolution. The PIP’s capacity diminishes with time. Periodically the system performs auto bias, which checks the state of PIP deterioration in order to compensate for it. This is performed automatically. Since the system calculates compensation as a function of the PIP’s age, let the system know when you replace a PIP.

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, the PIP has to be replaced. To prolong PIP longevity, handle it with care, keep it as clean as possible, avoid scratching it, and above all protect it from direct lighting. Direct lighting diminishes PIP capacity to receive and erase an image.

Use the inch-safe-service method (see "Inch-safe-service method" on page 25) when removing an old PIP or mounting a new one.

Keep the following in mind when you replace the PIP:

● Replace the PIP in dim light.

● After removing the used PIP, rinse the PIP drum thoroughly in imaging oil.

● Even the smallest dust particle affects print quality.

● While mounting the PIP on its drum, keep the PIP foil stretched and parallel to the drum shoulders.

● Load color adjust qualified substrate before replacing the PIP.

● Let the system know the reasons for PIP replacement and the new PIP serial number.

Color adjust

The purpose of the color adjust procedure is to adjust the press to guarantee color repeatability across the run and between runs. The procedure allows you to set 100 percent dot density and 50 percent dot density without altering the color reproduction curve.

PIP deterioration is reflected in inaccurate color. Automatic compensation due to PIP age is an approximate tool. Age (number of impressions) is not the only cause for PIP deterioration. The kind of images printed and the number of prints per image also influences the rate of PIP deterioration. The color adjust procedure fine tunes the compensation process for each PIP individually.

The system prompts you to perform the color adjust procedure every 4,000 impressions.

The color adjust procedure is triggered automatically when you turn the machine on after a break of several hours, or on replacement of the PIP.

Figure 10-15. PIP drum

PIP shoulder – front

ENWW Maintaining the PIP 181

Replacing the PIP

Removing the old PIP

CAUTION Use the "Inch-safe-service method" on page 25.

Before removing the PIP, make sure you have the following items:

● Developer stand

● lint-free wipes

● chemical-resistant gloves

To remove the old PIP, follow the instructions below:

1 Set the system to the Standby state by clicking on Standby in the control panel.

2 Lift up the upper exit door and open the front door.

3 At the press front, remove the scorotron.

4 Remove the cleaning station.

5 Disengage (do not remove) the squeegee by rotating the lock latch a half-turn (180o) counterclockwise.

6 At the press web exit side, pull the catch tray lever toward you.

Figure 10-16. Remove the scorotron

Figure 10-17. Remove the cleaning station


7 Raise the slit injector unit to its upper position and remove the developer drum.

8 Place the developer drum on a stand.

9 Wipe the slits at the bottom with a lint-free wipe soaked in imaging oil. Remove any dirt that may drop on the new PIP during installation.

10 Lift the electrometer away from the PIP drum.

11 Press the button on the control pad to advance the machine to the point where the PIP trailing edge is in view.

Figure 10-18. Raise the injectors

Figure 10-19. Remove the developer drum

Figure 10-20. Lift the electrometer

Rotate counterclockwise


12 Unlock the PIP latch.

13 Remove the leading edge of the used PIP from the slot and hold it away from the PIP drum.

14 Advance the machine and lift off the PIP as the drum turns. Dispose of the old plate in accordance with environmental regulations.

Installing the new PIP

Before installing a new PIP, you need to have the following items available:

● New PIP package.

● Developer stand.

● Plastic squeeze bottle with 500 mm (16 ounces) of clean imaging oil. The spout of bottle should be at 45º angle with nozzle size 1.5 - 2.0 mm (0.06 - 0.08 inches).

● Lint-free wipes.

● Chemical-resistant gloves.

You must keep the new PIP underlayer clean. Follow the instructions explicitly and make sure that your hands, the PIP, the PIP drum surface and all the surrounding environment are clean. It is particularly critical to remove all contamination from the PIP and the PIP underlayer surface. You should only open the new PIP package when you are ready to install the new PIP. After the package is open, you should be careful not to place the cartridge on a dirty surface. If you accidentally do, clean it thoroughly with a lint-free wipe.

Note Perform this procedure under dim lightning conditions to protect the PIP from exposure.

1 Verify that no residue or contamination remains on the PIP underlayer surface.

2 Open a new PIP package by tearing the tab labeled “Open here.”

Figure 10-21. Unlock the PIP latch

Figure 10-22. Opening PIP wrapping


3 Gently pull the PIP out of its protective cover. Wipe the cartridge clean with a lint-free wipe soaked in imaging oil. This prevents particles from being transferred from the cartridge to the PIP. Pull out the leading edge about 10 cm (4 inches). Remove the self-adhesive pull-tab.

Note Always protect the exposed PIP from direct light.

4 Insert the leading edge of the PIP into the slot all the way. Push it in until the edge is felt against the inner wall when sliding it from side to side. Center the PIP between the drum shoulders.

5 Lock the PIP latch.

Figure 10-23. Pull the PIP out

Figure 10-24. Insert PIP edge into PIP slot

Figure 10-25. Lock PIP latch

PIP slot

Press here to lock the PIP latch


6 Hold the PIP against the drum and check that its edges are parallel with the drum shoulders. If it is not parallel, remove the PIP and reinsert it properly.

7 Hold the PIP away from the drum. Using the squeeze bottle, apply imaging oil generously to cover the entire visible section of the PIP underlayer. Use the rinsing technique described below.

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 the imaging oil liberally. Drops dripping from the sides are good for the drum. However, make sure no drops reach the blanket.

Note Periodically flush sediment and contaminants from the imaging oil squeezer bottle using imaging oil.

8 Hold the PIP cartridge, green side down, with your right hand. To prevent damaging the PIP, make sure it does not touch the cartridge when being pulled out. Using the Inching control button, advance the PIP drum until the a new “dry” section of the PIP underlayer is in view. Make sure that there is no contact between the PIP foil and the reverse roller assembly.

Note When the exit door is open, the Inching control button on the feed door control pad is disabled.

9 Continue rinsing the exposed underlayer surface. Rinse all the dry sections until the entire drum has been thoroughly rinsed and the PIP’s holder is visible.

Figure 10-26. Make sure PIP is parallel to the drum shoulders

Figure 10-27. Apply the imaging oil generously

PIP cartridge

underlayer

Squeezer bottle


10 Pull the small blue removal-tab attached to the right edge of the protective paper for easy removal of the long adhesive strip.

11 Remove the protective paper and rotate the press one full revolution.

12 Place the PIP trailing edge over the leading edge.

13 Using a lint-free wipe soaked in imaging oil, wipe across the PIP leading edge. Press the trailing edge over the leading edge in order to attach the trailing edge to the leading edge.

14 Reengage the squeegee roller.

15 Rotate the drum another two full revolutions to stretch the PIP and for better contact with the PIP drum. Stop when the PIP trailing edge is in sight.

16 Lower the electrometer unit back into place.

17 Reinstall the developer drum. Lift up the developer drum handle and close.

18 Lower the slit injectors unit into place.

19 Reinstall the scorotron.

20 Reinstall the cleaning station.

Updating your system

1 From the Consumables menu, select PIP. The PIP window opens.

Figure 10-28. Remove protective paper

Pull here

PIP trailingedge


2 If the Replace PIP page is not already in front, click Replace PIP.

3 Enter the serial number for the new PIP.

4 Use the Replacement Cause drop-down list to select the reason for replacement. If none of the options are applicable, choose Other and enter your reason. Avoid using Other as much as possible; if you must use it, give a specific reason for the PIP replacement.

5 Click Replace to reset the counter and accept the information entered in this page.

6 A pop-up message box displays telling you to perform the color adjustment procedure.

7 Click on OK and continue with the Manual Color Adjustment wizard.

Preparing the PIP for printingIf your machine is not equipped with an in line densitometer, perform this procedure in order to prepare the PIP for printing. For presses equipped with an in-line densitometer, there is no need for any preparation.

Initiate the Color Adjustment wizard by selecting the adjust color option from the Adjustment menu.

See the software help topic: "Using the Automatic Color Adjustment wizard."

Checking image uniformity

Perform this procedure to check the print for inkless white zones.

1 Bring the press to the Ready state by clicking on the Get Ready button in the control panel.

2 Select the Print Cleaner option from the Maintenance menu. The print cleaner wizard opens.

3 Print the required number of print cleaner pages.

4 Inspect the print for inkless white zones. These zones are caused either by unadjusted first transfer (PIP to ITM nip) or by a buckle on the PIP. Re-adjust the first pressure or reinstall the PIP. See "First transfer pressure adjustment" on page 175.

Figure 10-29. PIP window


Viewing the PIP Log

View the PIP log to keep track of PIP replacement and the number of impression made by the PIP.

1 Select the PIP option from the Consumables menu. The PIP window opens.

2 Click on the Log tab (far right tab).

3 View the PIP log. The information in this log cannot be edited.

Defining substrate type

The HP Indigo press ws2000 prints on a wide variety of substrates, including paper, carton, PVC and other thick, flexible materials. The HP Indigo press ws2000 supports substrates from a minimum thickness of 0.012 mm (0.0005 inches) to a maximum of 0.35 mm (0.0137 inches).

CAUTION Store glossy substrate away from direct sunlight.

Perform this procedure whenever you introduce a new substrate.

1 From the Consumables menu, select Substrate. The Substrate window opens.

2 If the Substrate tab is not already in front, click Substrate at the top of the window.

3 Click List. The Substrate List window opens.

Figure 10-30. The Substrate window

Figure 10-31. Substrate List

ENWW Defining substrate type 189

4 Click New. The Edit existing substrate definition window opens.

5 Enter a substrate name in the Substrate name field.

6 Measure the substrate and enter the values in the appropriate fields.

7 Set BKT Fan Level on Medium, and evaluate print wetness. For details on setting the blanket fan level see "Handling image wetness" on page 160. Click OK. The new substrate is added to the list.

8 Click Close to close the Substrate List window, and Close again to close the Substrate window.

9 Click on the Select Substrate button to select a new substrate.

10 For impression substrate thickness, select thin (0.1mm (0.004 inch)) for substrate thicker than 0.2 mm (0.008 inch), and thick (0.2 mm (0.008 inch)) for substrate thinner than 0.2 mm (0.008 inch).


Figure 10-33. Selecting a new substrate


11 If you do not want to use substrate to clean the blanket, click on the Bypass Cleaner Page check box. This cleaning option is usually chosen when substrate is limited or costly.

12 Click the Apply button to apply the change.

13 Perform appropriate hardware adjustments to load the new substrate.

Maintaining the separator

Replacing the separator waste bagThe waste bag periodically fills up and must be replaced with a new bag. Before beginning this procedure, you need to have a new, ink-proof, heavy plastic waste bag (recommended size: 30 by 50 cm (11.81 by 19.7 inches)).

1 Open the separator door.

2 Place a sheet of tissue paper under the unit to catch any waste particles that might come loose.

3 Lift up the waste basket by its handle.

4 Remove the used waste bag and replace it with a new one.

5 Put the basket back in place.

6 Remove the tissue paper, clean any waste and close the door.

Maintaining the separator imaging oil levelThis procedure drains a small amount of imaging oil from the separator in order to maintain the required level.

Viewing the level of imaging oil in the separator

1 From the Diagnostics menu, select the Imaging Oil option.

2 Click on the Imaging Oil tab.

Figure 10-34. Waste bag replacement

Separator

Waste basket

ENWW Maintaining the separator 191

The imaging oil page contains a gauge that indicates the current level of imaging oil in the separator. If the level is too high, you can drain a small amount of imaging oil from the separator. If the level is too low, you can add imaging oil (see "Adding separator imaging oil" on page 193).

Lowering the level of imaging oil

1 Click on the Separator tab in the Imaging Oil window.

2 Disconnect the reverse roller pipe and insert the end of the pipe into an empty container.

3 Click on the Drain button on the Separator tab of the Imaging Oil window. The imaging oil begins to drain into the empty container. The button remains depressed to indicate that the process is continuing.

4 Click on the Imaging Oil tab.

5 Note the level of the imaging oil in the gauge.

6 When the imaging oil reaches the correct level, click on the Separator tab.

7 Click on the depressed Drain button again to release it. The imaging oil stops draining.

8 Re-connect the reverse roller pipe.

Figure 10-35. Imaging Oil window


Adding separator imaging oilClean imaging oil must periodically be added to the separator. When replenishing is necessary, a warning indicator displays in the control panel and an imaging oil system warning message appears in the Warning Log. Use a 1.9 liter container of imaging oil.

1 Open the separator door under the operator console.

2 Pour up to 1.9 liters of imaging oil into the funnel at the top of the separator tank door. Do not pour in more than 1.9 liters.

3 Close the door.

Cleaning separator imaging oilPerform this procedure when the system indicates that the imaging oil requires cleaning.

1 From the Diagnostics menu, select the Imaging Oil option.

2 If the Imaging Oil tab is not already in front, click on Imaging Oil at the top of the window.

3 Note the level of the Dirtiness gauge in the center of the dialog box. When the dirtiness of the imaging oil is outside the acceptable level, the line in the gauge is red and is within the gray area of the gauge. You can check the dirtiness level only while you are printing.

4 Click on the Clean button on the Imaging Oil tab.

5 The separator cleans the imaging oil. If the dirtiness gauge continues to indicate that the level is unacceptable, inform your HP Indigo customer engineer.

Maintaining the scorotron

Stretching the coronaPerform this procedure if the corona wire is slack and requires stretching.

1 From the Consumables menu, select Corona. The Corona window opens.

2 Click the Corona tab.

3 Click Stretch Corona. The corona wire is stretched to the optimal tension.

Figure 10-36. Adding imaging oil to the separator

ENWW Maintaining the scorotron 193

Advancing the coronaPerform this procedure if the corona wire requires manual advancement. The corona wire is periodically advanced automatically to expose new wire.

1 From the Consumables menu, select Corona. The Corona window opens.

2 Click the Corona tab.

3 Click on the Advance Corona button. The corona wire advances to expose new wire.


Operator routines


● Introduction

● Start of day routines

● End of day routines

● Weekly routines

● Interlock check

● Long-term shutdown

ENWW 195

Introduction

This chapter and the next will help you become acquainted with the various maintenance procedures you will be performing to keep the machine at an optimum performance level. The information in this chapter is designed to be used while you are at work and in conjunction with the software help feature. Read this material before you start working with the press and as you perform the various operator procedures.

The software help contains detailed instructions for using various HP Indigo press ws2000 maintenance wizards. Use the wizards whenever possible. They are designed to save you time as you perform maintenance procedures.

Practical tips for performing maintenance routines

Backing up system files

Perform a system parameters backup once a month.

Breaks

If the press will be idle for more than two hours, perform the Print Cleaner wizard and change the press status to Standby. This will lengthen the life-span of your blanket.

When using ink cans

Ink cans which show signs of external damage should not be used. Shake the ink can well before installing it.

Print conditions

Periodically check the impression film for cleanliness and replace it if necessary.

196 Chapter 11 Operator routines ENWW

Start of day routines

There are several routines that you will be performing at the start of each day, and several others at the end of the day. The following checklists enumerate all these procedures in the order in which they should be performed.

Power upThe conditions shown below must be maintained throughout your work session to attain optimum print quality. To keep the substrate in ideal printing condition, store it in the same environment as the press.

● Set the room environment to the following values:Temperature: 20-25oC (68-77oF)Relative humidity (RH): 50-70 percent

● Verify that the end of day routines for the preceding day were performed. Repeat any of the routines if necessary.

To power up, switch on the Main Circuit Breaker on the rear of the machine. The system is initialized and the control panel appears with the status field displaying Off.

Perform this procedure without stopping between steps.

Activate the machinePress the Power Enable switch on the right side of the machine. The press status changes to Standby.

Prepare the pressClose all doors. Click Get Ready in the control panel and wait until the system reaches Ready state.

Perform color adjustColor adjust is performed automatically on presses equipped with an in-line densitometer.

ENWW Start of day routines 197

End of day routines

Perform the procedures below if the press will be idle for more than 12 hours.

Clean the blanketFrom the Maintenance menu, click Print Cleaner. Enter the number of blank pages and the number of cleaning pages to be used.

Note You can stop the cycle midway by clicking Stop in the wizard.

1 Click Print in the wizard. The printed sheets are ejected to the exit tray.

2 If the blanket is dirty even after your perform the print cleaner procedure, clean it with a lint-free wipe.

3 If the blanket develops defects that impair printing quality, you may have to reinstall it with a new blanket.

Clean the PIPWipe the PIP gently with a lint-free wipe and imaging oil.

Clean the cleaning station1 Remove the cleaning station.

2 Clean the blade.

3 Reinstall the cleaning station.

Check the impression filmReplace the impression film if it is dirty.

Set the press positionTurn the handwheel counterclockwise until the angle indicator points to 248o (+3o).

Clean the slit injectorsWipe the slit injectors unit with a lint-free wipe and imaging oil.

Replace the plastic waste bagUse a new ink-proof heavy plastic waste bag (recommended size 30 x 50 cm (11.8 by 19.7 inches).

1 Open the separator door.

2 Place a sheet of absorbent paper under the unit to catch any waste particles that might come loose.


3 Lift up the wastebasket by its handle.

4 Remove the used waste bag and replace it with a new one.

5 Put the basket back in place.

Cool the blanket1 From the Consumables menu, select Blanket.

2 Click the Temperature tab to display the temperature settings.

3 Verify that the blanket temperature is below 40o C (104°F [or 30 percent when viewed from the Schematic window]).

LubricateLubricate the following parts with machine oil:

● web exit roller (both ends)

● upper feed roller

● gripper shaft (both ends)

Follow the instructions below to lubricate the listed parts.

1 Turn the handwheel counterclockwise until the angle indicator points 170°.

2 Oil the gripper shafts and leave the handwheel in this position for at least one-half hour to allow the oil to penetrate.

3 Turn the handwheel counterclockwise until the angle indicator points to 248°.

Empty the drain coolerBefore carrying out this procedure, you need to have a 5-liter empty transfer container clearly labeled: “Drain Cooler Waste.”

CAUTION Do not confuse drain cooler waste, which contains water, with imaging oil. In case of contamination of imaging oil by drain cooler waste, contaminated imaging oil must be flushed out. If contamination occurred in the separator, contaminated imaging oil must be replaced.

Note Cooling unit liquids contain imaging oil and must be disposed of according to local waste disposal regulations.

1 Click Drain Cooler in the Maintenance menu. The Drain Cooler wizard opens.

2 Follow the step-by-step instructions in the wizard.

ENWW End of day routines 199

Shut down the machineBe sure to perform proper shutdown before switching the system off.

1 Click Shutdown in the System menu. The Shutdown window opens.

2 Click Shut down the press.

3 Click OK. The control panel closes and the press application shuts down.

4 In the lower left corner of your Windows desktop, click Start and select Shut Down.

5 Wait until you receive the message that it is safe to turn off your computer.

6 Switch off the Main Circuit Breaker at the rear of the machine.

7 Leave the lower feed and exit doors open to allow the press to cool down.

8 Close all other doors to avoid exposing the PIP to light.

Weekly routines

The procedures below should be performed at the end of every week. Weekly routines are performed after the regular end of day routine is performed.

For more information, see the software help topic “Accessing the weekly routine checklist.”

SafetyPress an Emergency Stop button. This keeps the machine in Off status.

Cleaning stationFor more information, see "Maintaining the developer station" on page 216.

To remove the cleaning station

1 Open the front service door.

2 Unscrew the knob on the cleaning station. Pull the cleaning station toward you, using the orange handle.

3 Slide the cleaning station out along rails while supporting the inner end. Place it on a work table.

To clean the cleaning station

1 Clean the gears with a semi-rigid brush and imaging oil.

2 Inspect the foam roller for deformation, signs of detachment from its metal core or holes. If you see a hole larger than 3 mm (0.12 inches), you can operate the press, but call your customer engineer to replace the foam roller.


Scorotron and dampersFor more information, see "Maintaining the scorotron" on page 229.

1 Open the scorotron lock bar.

2 Remove the scorotron and disassemble grids and bobbin cover.

3 Clean the grids, inside shield, wire path and metal guides, using a cotton swab and IPA (do not use imaging oil).

CAUTION IPA should be used to clean specified parts only. Such cleaning may be carried out only when the printing engine is off. It is essential that all parts be completely dry before they are reinstalled in the machine and printing is resumed.

4 Clean dampers gently using a lint-free wipe and IPA.

5 Test the damper for elasticity. It should rise a few millimeters when the tension on the corona wire is released.

6 Clean riding wheels and riding path on the PIP drum, using imaging oil.

7 Inspect the riding wheels for smooth motion. If the wheels appear to be malfunctioning, call a customer engineer.

8 Assemble the unit and reinstall it.

9 Close the scorotron lock bar.

CAUTION Ensure that all equipment, tools and materials are removed from the unit and that all doors are closed before operating the machine.

Developer drum For more information, see "Maintaining the developer station" on page 216.

1 Remove the developer drum.

2 Clean the drum’s gear.

3 Clean bias contacts on the machine and developer unit using a lint-free wipe and IPA.

Slit InjectorsFor more information, see "Cleaning the slit injectors" on page 210.

1 Remove the slit injectors.

2 Wash them thoroughly in the wash basin.

3 Clean inside the slits using the slit cleaning jig.

ElectrometerFor more information, see "Cleaning the electrometer" on page 224.

Clean the housing of the electrometer, using a lint-free wipe and imaging oil. Avoid touching the sensor.

WARNING! Do not clean the sensor.

ENWW Weekly routines 201

Developer station and catch trayFor more information, see "Maintaining the developer station" on page 216.

1 Remove the developer station and catch tray.

2 Clean the wipers in the wash basin. Inspect wipers for straightness and smoothness. Replace the wipers if damaged.

CAUTION Avoid wetting the wiper motors.

3 Inspect the wipers for waste accumulation twice a week. Clean them if needed.

Reverse rollersFor more information, see "Maintaining the reverse rollers" on page 224.

1 Remove the reverse rollers.

2 Clean the wipers and catch tray using a lint-free wipe and imaging oil.

3 Inspect the wipers for straightness and smoothness. Replace them if damaged.

4 Clean the gears with a semi-rigid brush and imaging oil.

5 Clean bias contacts on machine and Reverse Roller unit using IPA and a lint free wipe.

SqueegeeFor more information, see "Cleaning the squeegee" on page 222.

1 Remove the squeegee.

2 Clean the squeegee’s gear with a semi-rigid brush. If damaged, replace the squeegee.

3 Wipe the surface using a lint-free wipe and imaging oil.

4 Clean bias contacts on machine and squeegee using IPA and lint-free wipe.

ITM1 Clean the ITM area that comes in contact with the ITM temperature sensor.

2 Clean the ITM encoder gear with a semi-rigid brush.

Ink tanks For more information, see "Cleaning the imaging ink pump" on page 219.

1 Wash the pumps and filters in the wash basin.

2 Clean the density sensor slit using special paper supplied for the sensor’s cleaning (do not use the wash basin’s built-in brush).

3 Clean the density and conductivity sensors using clean imaging oil, sprayed from a bottle.


Substrate feed rollers

Feed rollers

Clean the feed rollers using IPA and a lint-free wipe.

Driving beltClean the main driving belt with IPA.

LubricationFor more information, see "Lubricating the press" on page 240.

Lubricate moving parts in input, output, front and rear sections, using machine oil.

Final check 1 Reinstall all stations.


3 Verify in the Schematic window that all parts are firmly in place.

4 Shut down the system and close all doors.

Interlock check

PurposeThe purpose of this procedure is to make sure all interlocks function correctly, thus providing the operator with a safe working environment.

FrequencyThis procedure should be performed at least once a month.

ENWW Interlock check 203

The following interlocks should be checked: front door, upper feed door, lower feed door, lower ink door, upper exit door, feed roller cover, web exit door, and tower (VME) door.

The following procedure should be carried out on all interlock doors.

1 Put the press in Standby state and check that all doors are closed.

2 Open front door.You should hear the RLD and RLE relays (behind the Motor Inverter cover) click as the interlock circuit is interrupted. The press is now in Off state and the front door on the Schematic window is open.

3 On the Diagnostics and Locks menu, select Diagnostics and Locks to display the Interlocks window. Check that the window conforms to door states.

Figure 11-1. Interlocked doors

Figure 11-2. Schematic with front door and rewinder cover opens

Tower door (rear side)

Microswitch doors

Interlocked doors

Feed rollers cover

Upper feed door

ITM cover

Lower feed door

Separator door

Rewinder top door

Ink cans door

Upper exit doorFront door

Ink tanks door


4 Make certain that the front door state on the Interlocks panel is listed as open.

5 Close the front door.

6 Listen to the RLD and RLE relay (behind the main motor inverter cover) click.

Figure 11-3. Interlocks window

Figure 11-4. Interlock interruption (Interlocks window) and warning (control panel)

Click here to see warning.

ENWW Interlock check 205

7 Check that the Schematic window indicates all doors as closed and that the three red spots are not present. When the red spots are on, the interlock system is not closed.

8 Check that the front door is no longer open in the Interlocks window.

9 Repeat procedure for upper and lower feed door, feed roller cover, upper exit door and web exit door.

Interlock fault conditionIf you do not hear the RLD relay click, or do not see a change in the Schematic window, or do not see a change in the door status in the Interlocks window, there is a fault in the interlock switch. Do not operate the press. Lockout the press and call your customer engineer.

Long-term shutdown

WARNING! Electrical/Mechanical Hazard Perform these functions with an Emergency Stop button pressed.

If the system remains inactive for four days or more, ink waste and dried ink may accumulate in the ink flow system. If this happens, you will have to dismantle components and hoses in order to clean and flush the press. To avoid this, follow the procedure described below any time the press will be shut down for an extensive period.

Shutting down the press for a long period1 Clean the developer catch tray and blades.

2 Remove the injectors unit. Perform a full cleaning procedure.

3 Drain the ink from the ink tanks into a clean container. Store this container if you wish to reuse the ink after shutdown.

4 Remove the ink pump. Clean the pump and filter.

5 Disconnect the heating plugs for each tank.

6 Remove each ink container by pressing two front pin-latches. Lower the container and pull it towards you to lift it out of its back-slot.

7 Clean the ink tanks.

8 Reinstall the ink tanks and reconnect the heating plugs.

9 Fill the ink tanks with imaging oil to the appropriate level.

Figure 11-5. Schematic - all doors closed


10 Select Install Ink in the Consumables menu. The Install Ink Wizard Manager opens.

11 Click Select Tank and Color in the Wizard Manager. The Select Tank and Color wizard opens.

12 Follow the steps presented in the wizard.

13 After flushing a selected tank, click Back if you wish to select the next tank. You do not need to perform the final step in the wizard in this procedure.

14 Shutdown the system as usual.

Initializing the press after a long shut downPerform this procedure after the press has been shut down with the long-term shutdown procedure. You can either replace ink you have stored before shutdown, or rebuild the ink in the tank.

Using stored ink

1 Remove the imaging oil in the ink tanks (you may reuse this to replenish the separator).

2 If the ink stored before shutdown is still in usable condition, fill the tank with it. Make sure that you shake the container well before pouring the ink in the tank.

Rebuilding ink

1 Rebuild ink in the ink tanks using new ink.

2 Start the system as usual.

ENWW Long-term shutdown 207

Maintaining the press


● Overview

● Cleaning the slit injectors

● Maintaining the cleaning station

● Maintaining the developer station

● Cleaning the imaging ink pump

● Cleaning the separator clean sensor

● Cleaning the squeegee

● Cleaning the electrometer

● Maintaining the reverse rollers

● Maintaining the scorotron

● Maintaining the PIP underlayer

● Mounting the impression film

● Web Maintenance

● Lubricating the press

ENWW 209

Overview

This chapter contains the procedures required for proper cleaning and maintenance of HP Indigo press ws2000 components.

Cleaning the slit injectors

The slit injectors unit requires periodic cleaning. Perform light cleaning at the end of each week, or when waste accumulates. Perform the full cleaning procedure when light cleaning is inadequate.

Light cleaning procedureThe purpose of the light cleaning procedure is to clean the build-up ink residue from the slit injectors. The procedure is generally performed once a week as part of the weekly routine. Before carrying out this procedure, make sure that you have the following items:

● imaging oil

● lint-free wipes

● slit cleaning jig

WARNING! Never print if the slit high voltage wire is not connected to the high voltage connector. Printing with an unbiased slit will affect the ink flow and seriously degrade print quality.

You do not have to remove the slit injectors to perform this procedure:

1 Make sure that the machine is turned off.

2 To protect the light-sensitive PIP, switch off the lights, leaving only the minimum of light necessary to assure safe operation.

3 Open the front and output doors.

WARNING! The developer drum is heavy. Lifting heavy weights can cause back and other muscular-skeletal injuries. Request assistance if necessary.

4 Remove the developer drum and place it on the stand.

Figure 12-1. Developer drum stand

210 Chapter 12 Maintaining the press ENWW

5 Raise the slit injectors unit as high as possible by turning the elevation knob counterclockwise.

6 Place a sheet of absorbent paper below the slit to absorb excess liquid.

7 Wipe the lower section of the slit injectors unit (where the slits are located) with a lint-free wipe soaked in imaging oil. Wipe the slit openings until all ink residue is removed.

8 Insert the cleaning jig into the slit closest to you. Slide the jig to the other end and pull it out. Wipe off the ink waste from the jig. Insert the jig into the same slit and repeat the action in the opposite direction. Repeat until the jig comes out clean. Proceed with the remaining slits in the same manner.

9 Reinstall the developer drum.

10 Return the slit injector unit to the lowest position.

11 Make sure that the slit injector unit is free of all tools and materials before restoring power.

Figure 12-2. The slit injector elevation knob

Figure 12-3. Removing waste

This is the elevation knob at its lowest position.

This is the elevation knob at its highest position.

Slide the jig along the slits.

ENWW Cleaning the slit injectors 211

Full cleaning procedureThis procedure completely cleans the slit injectors. Perform the full cleaning procedure when waste remains on the slit injectors after light cleaning. Before carrying out the procedure, make sure you have the following items:

● special catch tray for slit injectors

● ink resistant gloves

● wash-basin and fine brush

● density sensor cleaning jig

Perform the following procedure:

1 Make sure that the machine is switched to the Off state.

2 To protect the light-sensitive PIP, switch off the lights, leaving only the minimum of light necessary to assure safe operation.

3 Open the front and output doors.

4 Remove the developer drum and place it on the stand.

5 Unplug the high voltage connector.

6 Position the catch tray underneath the slit injectors unit. Hook it on the shaft behind the injectors and lock it with the spring catch on the stud.

CAUTION Be careful not to damage the PIP.

Figure 12-4. Catch tray for slit injectors

Figure 12-5. Positioning the catch tray

Stud

Spring catch

Hook

Shaft


7 Check that the catch tray is secure before proceeding to the next step. (When a unit is not firmly in place, it appears in red in the Schematic window.)

8 Put on ink-resistant gloves. Disconnect all hoses (including the imaging oil hose) from the top of the injectors unit by pressing their quick release buttons. Check that each hose and connector is marked with the color of its ink. This will help you return it to its correct connector later on. Push the hoses aside.

9 Loosen the left and right knobs of the slit injector unit, and lift up and away from the machine. Keep the catch tray level in order not to spill the accumulated ink.

10 Take the unit to the wash basin. Remove the catch tray. Stand the slit injectors on end in a vertical position to ensure that they will not be bent by contact with the wash basin.

CAUTION Never use fibrous (for example, paper) or hard (for example, metal) materials to clean the slits.

11 Spray the slits with imaging oil and clean them with a fine brush. Do not try to disassemble the unit.

12 Take the slit cleaning jig and slide it gently inside the slits to remove any ink residue.

13 Clean the slit injector housing and replace the catch tray on the slit injectors.

14 Return the slit injectors (with the catch tray) to the machine. Hang the unit on the hooks.

15 Insert the right side securing knob into the hole on the shaft bracket and tighten. Then tighten the left side knob (this one does not screw into the bracket).

16 Connect the ink hoses to their respective places, and connect the imaging oil hose. Make sure that the female ink hose connector pin is pushed in. This will prevent damage to the male connector O-ring. Since the injectors unit moves during printing, provide enough slack to allow the slit injectors to slide freely all the way down. Arrange the hoses so as not to obstruct the path of the laser beam.

Figure 12-6. Removing the slit injectors

Right side knob

Left side knob

PIP

Figure 12-7. Slit injector hooks

Tighten this knobHang the injectors unit here.

ENWW Cleaning the slit injectors 213

17 Reconnect the high voltage connector.

18 Remove the catch tray and reinstall the developer drum.

19 Raise and let go of the elevation knob and check that the injectors unit is free to slide up and down. Leave the slit injectors unit at its lowest position.

Maintaining the cleaning station

When ink streaks appear on your printed output, the wiper on the PIP cleaning station needs to be cleaned or replaced.

1 Press the Stop button on the control panel to stop printing.

2 Resume printing.

3 If ink streaks still appear, remove the cleaning station and clean the wiper.

Removing the cleaning station1 Open the front service door.

2 Unscrew the locking knob on the cleaning station.

3 Grasp the orange handle and pull the cleaning station towards you.

4 Slide the cleaning station out along the rails while supporting the inner end. Place it on a work table.

Figure 12-8. The cleaning station

Locking knob

Handle


Cleaning the wiperBefore cleaning the wiper, make sure that you have the following items:

● Imaging oil

● lint-free wipes

Wipe along the wiper with a lint-free wipe soaked in imaging oil.

Replacing the wiper1 Hold the plastic wiper blade in your hand. Loosen three locking screws by at least four

full turns. This will help you avoid scratching the wiper when sliding it out of its housing.

2 The wiper has four numbered edges. Turn it to the next unused edge. For example, if edge #1 was used, turn to #2, and so on. If edge #4 was used, replace wiper.

Reinstalling the cleaning station1 Reinstall the cleaning station by feeding it into the slot in rails, and push until it

contacts the end. You must turn the handwheel slightly to ensure that the gears of the cleaning station fit properly with the gears of the ITM.

2 Lock the unit with the locking knob.

3 Check the Schematic window to see if you installed the cleaning station properly. If the unit appears in red it has been installed improperly.

Figure 12-9. Locking screws and wiper

Locking screws

Wiper

ENWW Maintaining the cleaning station 215

Maintaining the developer station

Clean the developer station weekly and whenever ink residue builds up significantly. Use the short cleaning procedure regularly and the full cleaning procedure when the buildup of the ink residue in the developer station catch trays and blades is heavy.

Short cleaning procedure

CAUTION Be careful. The wipers are sharp.

Perform this procedure in order to clean the wipers. Using this procedure, you can clean the wipers without removing the developer station from the machine.


2 Wipe the blades and holders with a wet, lint-free wipe. Take care not to exert excessive force on the blades. Make sure that the draining grooves in the wiper holder are clean.


Figure 12-10. Developer station

Warning label

Screw jigs

Wiper harness bracket

Knob screws

Wiper motor connector

Figure 12-11. Developer station (blade holder)

Keep areas marked by arrows especially clean.

The developer station


Full cleaning procedurePerform this procedure when the short procedure is inadequate.

1 Press an Emergency Stop button to bring the machine to the Off state before disconnecting and reconnecting the wiper system cables.


3 Disconnect the developer station connector.

4 Disconnect the catch tray hoses.

5 Remove the catch tray.

6 Remove the developer station.

7 Thoroughly clean the developer station in a wash basin.

8 Reinstall the developer station.

9 Reinstall the catch tray.

10 Reconnect the hoses and connectors.


12 Reinstall the developer drum

Replacing the wiper bladeReplace the wiper blade when it is damaged.

1 Press an Emergency Stop button to bring the machine to the Off state before disconnecting and reconnecting the wiper system cables.

2 Release the long knob screws on the developer station and remove the wiper assembly from the machine.

CAUTION Wiper blades are sharp. Handle them with care.

3 Thoroughly clean the wiper assembly with a lint-free wipe and imaging oil. Pay special attention to the wiper holder and threaded holes.

CAUTION Use only the original, specially designed jigs. Use of other screws may cause irreversible deformation of the holder.

Figure 12-12. Developer station jigs

Jigs

Screws are mounted on a jig holder next to the developer station main connector.

Jigs

ENWW Maintaining the developer station 217

4 Carefully screw all five jigs all the way into the five threaded jig holes in the wiper holder. Do not use excessive force.

5 Loosen and remove the old blade.

6 Make sure that the holder slot is completely clean and free of foreign particles. Pass the old wiper blade back and forth through the slot to make sure that it is clean.

7 Slide a new wiper blade into the holder slot from the end of the holder opposite the motor. Inserting the blade with a sliding motion ensures that the slot is cleared of any foreign objects and that the blade is properly inserted.

8 Gently and firmly push the blade into the holder and make sure it fits properly.

9 Starting at the center and then alternating from left to right, remove the jigs from the wiper.

10 Return the jigs to the jig holder.

CAUTION Wiper blades are easily damaged. Do not allow them to come in contact with any hard surfaces.

11 Carefully install the wiper and motor assembly in the wiper frame. Make sure the wiper blade does not touch any metal surface.

a Insert the end of the wiper shaft into the plastic bushing at the back of the wiper frame.

b Slide the gear shaft into the keyhole on the front of the wiper frame.

c Push the bushing into place. The bushing should be fully inserted into the frame wall and the gear adapter plate should be flat against the front wall of the frame.

12 Secure the gear to the wiper frame with the long knob screw.

13 Connect the wiper motor cable to the wiper developer board (WDB).

14 Release the Emergency Stop button to bring the machine to Standby status.


16 Select Ink from the Diagnostics menu. The Ink window opens.

17 Click the Flow tab at the top of the window.

18 Click the Wiper Home button in the bottom right corner of the page.

19 Check that the wiper has moved to its home location.

Figure 12-13. Inserting the jigs in the wiper holder

Jig

Figure 12-14. Inserting a new wiper blade in the wiper holderBladeHolder


Cleaning the imaging ink pump

The imaging ink pump needs to be cleaned on a weekly basis or when you have flow rate problems. A flow rate problem is indicated by white (inkless) bands along the length of the printed sheet. The following procedure cleans the imaging ink pump.

Before performing this procedure, make sure that you have the following items:

● wastebasket or tray lined with plastic

● wash basin and fine cleaning brush

● density sensor cleaning paper

1 Bring the machine to Standby state.

2 Press an Emergency Stop button. This brings the machine to the Off state.

3 Loosen the locking knob on the top plate of the imaging ink tank.

4 Disconnect the air hose from the imaging ink can holder by pressing the quick-coupling ring.

5 Pull the unit by the front handle until it comes free. Lift it out.

Figure 12-15. Releasing ink pump unit

Figure 12-16. Removing ink pump

Press the quick coupling ring air hose connection.Loosen the

locking knob.

ENWW Cleaning the imaging ink pump 219

6 Place the unit in a wash basin or in plastic-lined tray.

7 Extract the filter from the pump by pulling out, and remove the filter cap.

8 Clean the filter in imaging oil.

9 Return the filter cap.

10 Take cleaning paper sheet from the plastic wallet. Fold the paper along the perforated line to form a cleaning wedge. Do not use the same paper twice.

11 Insert the paper into the density sensor slit at the back of the electronic board on the pump unit. Remove the paper. Rinse the density sensor by squirting clean imaging oil into the density sensor slit. Check the density sensor.

12 Reinsert the filter in the ink pump. Make sure it is secured tightly in its place.

13 Reinstall the ink pump unit into the ink tank.

14 Tighten the locking knob.

15 Connect the air hose to the quick-coupling connection on the imaging ink can.

Figure 12-17. Ink pump filter

Figure 12-18. Cleaning density sensor

Ink pump filter

Filter cap


Cleaning the separator clean sensor

Cleaning the separator clean sensor is necessary to ensure precise readings of oil cleanliness and purity. You must clean the separator clean sensor when the press issues the error message dirty separator fluids.

Before performing this process, make sure you have a separator clean sensor brush. One is provided with the press.

1 Change machine status to Standby.

2 Open the peripheral cabinet door.

3 Unscrew the clean sensor cap which is located above the separator (Figure 12-20).

4 Insert the brush into the clean sensor, clean the sensor, and remove the brush.

5 Replace the cap.

6 Clean the brush by rinsing with clean imaging oil before returning it to storage.

Figure 12-19. Separator clean sensor brush

Figure 12-20. Clean sensor cap

Separator housing

Clean sensor cap

Substrate lift motor

ENWW Cleaning the separator clean sensor 221

Cleaning the squeegee

Perform this procedure at the end of every week, according to the order of procedures recommended in the weekly routines checklist. Weekly routines are performed after the end of day routine is performed.

Before performing this procedure, you will need the following:

● IPA

● Imaging oil

● Lint-free wipe

1 Open the front and upper exit doors.

2 Raise the slit injectors unit.

3 Remove the developer drum and reverse roller unit.

Figure 12-21. Squeegee unit

Figure 12-22. Squeegee lock

SQUEEGEE

Squeegee roller

Squeegee gear

Squeegeelock

Squeegee lock


4 Release the squeegee lock by turning the latch a half turn (180°) counterclockwise.

5 Lift up the squeegee roller unit with both hands and place it on a worktable.The squeegee lock is located on the front of the machine, behind the handwheel.

6 Stand the roller on its end with the gear at the top. Wipe the roller clean with a lint-free wipe soaked in imaging oil.

7 If the squeegee surface appears to be damaged, replace the roller.

8 Clean the gear.

9 Clean the bias contacts with IPA, both on the machine wall (on the left side of the squeegee) and on the squeegee unit. Be careful not to damage the contacts.

10 If any of the parts of the squeegee are damaged, call your customer engineer.

11 Reinstall the squeegee roller with the gear end on the left side.

12 Lock by turning the latch a half turn (180°) clockwise.

13 Reinstall the reverse rollers and developer drum.

14 Lower the slit injectors unit.

Figure 12-23. Removing the squeegee

ENWW Cleaning the squeegee 223

Cleaning the electrometer

Clean the outer housing of the electrometer at the end of every week, in accordance with the weekly routines checklist.

1 Open the upper exit door.


3 Lift the electrometer.

CAUTION Do not touch or clean the sensor.

4 Clean the electrometer outer housing using a lint-free wipe soaked in imaging oil.

Maintaining the reverse rollers

Perform this procedure at the end of every week, in accordance with the weekly routines checklist (see the software help topic: "Accessing the weekly routine checklist"). Clean the reverse rollers weekly and replace blades only if they are buckled, nicked, or rusty.

Dark bands along the length of the sheet indicate a number of possible problems, including poor adjustment or faulty wetting roller blades or reverse roller blades.

Cleaning the reverse rollersThis procedure cleans the reverse rollers. Before performing this procedure, make sure that you have the following items:

● 8 mm open wrench

● 2.5 mm Allen key

● wetting roller blade (doctor blade wetting)

● reverse roller blade (doctor blade cleaning)

To clean the reverse rollers:

1 Open the front and upper exit doors.

2 Raise the slit injectors unit.


Figure 12-24. Electrometer with slit injectors


4 Unscrew the reverse roller feed hose by unscrewing the knob and pulling away from the microswitch. Pull out the hose unit.

5 Face the PIP drum. The reverse roller unit is beneath it, sitting on two rails and held in place by one pin on each side.

Note When removing or inserting the reverse roller, press the developer cradle down with your arms to prevent the reverse roller rear spring stud from interfering with the developer drive gear.

6 Release the pins by pushing in on both sides. Give them a half turn and lock them open.

7 Slide the reverse roller unit out from under the PIP drum (block the drain hole at the bottom of the catch tray on the right side to avoid leakage of imaging oil).

8 Drain the imaging oil into a container.

9 Place the unit on work table.

CAUTION Take care not to scratch the PIP or squeegee unit when removing the reverse roller.

10 Unscrew the two 8 mm cylinder screws (holding lock pins), one on each side of the unit with an 8 mm open-end wrench. Lift up the roller unit from the catch tray.

CAUTION Be very careful while cleaning the blades. They are very sharp.

11 Place the roller unit in a wash basin. Use a lint-free wipe soaked in imaging oil to clean the catch tray. Wipe clean both the wetting and the reverse rollers and blades.

12 Check the blades for nicks, buckling, or rust spots. If you find any, replace the blades in accordance with the procedures that follow.

Figure 12-25. Reverse roller feed hose

Locking knob

Feed hose

Figure 12-26. Reverse roller with catch tray

8 mm screw

ENWW Maintaining the reverse rollers 225

Replacing the wetting bladeBefore replacing the wetting blade, make sure that you have the following items:

● 8 mm open-end wrench


● wetting roller blade (doctor blade wetting)

Perform this procedure in order to clean and/or replace the reverse roller blades.

1 Using a 2.5 mm Allen key, loosen the spring collars on both ends of the blade holder to release the spring tension.

Note Take notice of the position of the screw hole in the spring collar relative to the blade holder. To properly reinstall the spring collar, you must restore it to its original position.

WARNING! The blade is sharp. Be careful not to cut yourself.

2 Slightly loosen the seven Allen screws that hold the wetting blade and remove the old blade.

3 Insert a new blade halfway into the blade holder (either side of the blade can be inserted).

4 Gently screw in all seven screws so that the blade is locked firmly in place.

5 Loosen the screws again, very slightly, just enough to allow the blade to slide in with a tiny bit of pressure. Gently push the blade into the slot until it reaches the end stop.

6 Center the blade with the blade holder equidistant from both ends.

7 Tighten the screws slightly, starting with the center screw. Alternate between tightening screws on the left and the right of center until all are gently tightened.

Figure 12-27. Wetting roller blade

Wetting roller Wetting blade

Spring collar

Wetting bladeAllen screws

Spring collar

Roller gear (on right side)

Blade holder


8 Align the hole on each spring collar (back to the position they were in before you loosened them) with the pin holes on the wetting roller blade holder. Do this by inserting an Allen key in the set screw hole in the spring collars and turning the spring collars. Tighten both spring collars.

9 Rotate the wetting roller and verify the pressure of the blade.

Replacing the reverse roller bladePerform this procedure to replace the reverse roller blades.


● 8 mm open end wrench


● reverse roller blade (doctor blade wetting)

1 Note the position of the screw hole in the spring collar relative to the blade holder. Loosen the Allen screws on the reverse blade spring collars

2 Twist the reverse blade holder to bring the blade out.

WARNING! Be careful not to cut yourself; the blade is sharp.

Figure 12-28. Tighten both spring collars

Figure 12-29. Reverse blade

Figure 12-30. Reverse blade after spring tension release

Insert Allen key here

Align screw with this pinhole to tense the spring

Spring collar

Left side gear Reverse roller

Reverse roller blade

Spring collar

Blade roller holder

Blade holder upper edge

Allen screws holding blade

Reverse roller blade

Blade roller holder

ENWW Maintaining the reverse rollers 227

3 Slightly loosen the seven Allen screws holding the reverse blade and remove the old blade.

4 Insert a new blade halfway into the blade holder (either side of the blade can be inserted).

5 Gently screw in all seven screws so that the blade is locked firmly in place.

6 Loosen the screws again, very slightly, just enough to allow the blade to slide in with a tiny bit of pressure. Gently push the blade into the slot until it reaches the end stop.

7 Center the blade with the blade holder so that it is equidistant from both ends.

8 Tighten the screws slightly, starting with the center screw. Alternate between left and right of center until all the screws are gently tightened.

9 Align the hole on each spring collar with the pin holes on the reverse roller blade holder (back to their position at the first step of this procedure) by inserting the Allen key in the set screw holes in the spring collars.

10 Tighten both spring collars.

Reassembling the reverse roller unitPerform this procedure as necessary:

1 Reinstall the roller unit in its catch tray.

2 Insert the 8 mm cylinder screws and tighten. Make sure the cylinder is screwed into the holes completely.

3 Taking care not to scratch the PIP or squeegee unit, slide the reverse roller unit into slots under the PIP drum.

4 Release the locking pins to engage the unit. Press the roller unit until they click into place.

5 Install the reverse roller feed hose by sliding it into place and twisting the holder under the screw knob.

6 Engage the microswitch and gently turn the screw know clockwise until it is slightly more than finger-tight (check that it is pressing against the microswitch).

7 Reinstall the developer drum and lower the injectors unit.

8 Collect and dispose of all contaminated cleaning materials.

Figure 12-31. Align spring collars with pin hole on

Insert Allen key here.

Align screw with this pinhole to tense.


Maintaining the scorotron

Because the scorotron creates the electrical charge that transfers the image, it is essential that the scorotron be kept clean and in good working order. If the corona wire tears, replace it. Otherwise, at the end of every week, according to the order of procedures recommended in the Weekly Routines checklist, clean the corona wire and grid and change the corona wire if necessary.


● corona bobbin with wire

● empty PVC bobbin

● two corona grids

● Phillips screwdriver

● cotton swabs

1 Open the front door.

2 Remove the scorotron unit by lifting the latch and pulling out. Place the unit on a work table.

3 Remove the grid by pressing the springy grid latch towards the grid and releasing the grid from the latch hook.

4 Release the grid from the fixed hood on the other end and then slide the grid all the way out.

5 Repeat the steps above for second grid.

6 Using a Phillips screwdriver, open the bobbin cover to expose the corona wire mechanism.

Figure 12-32. Scorotron unit

Figure 12-33. Sliding out the grid

Bobbin cover with Phillips screw

Fixed hooks

Grids

Grid latch

ENWW Maintaining the scorotron 229

7 Remove the bobbin and place the stainless steel bobbin and the PVC bobbin aside, lifting both up and releasing the corona wire loop from the idler pulley at the other end of the unit.

CAUTION Use IPA to clean specified parts only. Such cleaning may be carried out only when the printing engine is off. It is essential that all parts be completely dry before they are reinstalled in the machine and printing is resumed.

8 Clean the unit thoroughly along the corona wire path using cotton swabs soaked in IPA. Clean the compartment housing. Verify that the unit is completely dry before proceeding.

9 Mount a new stainless steel corona wire bobbin and fit it on the pin in the shaft.

10 Pick up the wire and place it over the idler pulley at the other end of the scorotron.

11 Thread the wire into the empty PVC bobbin shaft hole and return via the second hole. Secure by knotting. Loop wire around the bobbin a few turns to ensure that it is secured. Cut off the loose end.

12 Mount the PVC bobbin on the shaft and fit it on the pin in the shaft.

13 Set the wire in the path.

14 Close the bobbin cover and screw it on (Phillips screw).

15 Rotate the plastic gear by hand to tighten the wire and ensure free movement. The spring-loaded idler pulley retracts.

CAUTION Do not use imaging oil to clean the grids.

16 Clean the grids carefully with a cotton swab and IPA.

Figure 12-34. Corona wire routing

Figure 12-35. Plastic gear

Steel bobbin

PVC bobbin

To tension pulley

From tensionpulley


17 Return the grids to their slots by sliding each in its rails, hooking up the first on the inner end and then pressing the latch and hooking up the outer end. Return the grid it to its previous position. The grid side that used to face out should be mounted face out.

CAUTION Make sure that you remove all tools and materials from the unit and that all doors are closed before you operate the machine.

18 Insert the scorotron unit in its slot in the machine and engage the latch.

Maintaining the PIP underlayer

The PIP underlayer is wrapped around the PIP drum. Its function is to soften the surface under the PIP foil.

Before removing or mounting the PIP underlayer, make sure that you have the following items:

● Imaging oil

CAUTION Use clean imaging oil for this procedure. Make sure that no foreign particles are present in the imaging oil bottle. Using dirty imaging oil will cause considerable print quality problems.

● Lint-free wipes

● IPA bottle

● Scraper (window scraper)

● Impression film

Removing the PIP underlayer1 Set the press to Standby.

2 Remove the following:

a scorotron

b cleaning station


4 Turn the electrometer probe vertically.

5 Remove the reverse roller.

6 Remove the squeegee.

7 Remove the slit injectors.

8 Remove the PIP from the drum.

9 Remove the developer station tray:

a Remove the wipers connector.

b Remove the developer station tray.

c Remove the paper exit strip.

10 Move the seventh catch tray ink return tube to the inner front side and press the other ink tubes into the opening at the inner front section.

ENWW Maintaining the PIP underlayer 231

11 Remove the PIP underlayer. Remove a corner at the PIP holder slot and pull the PIP underlayer from the drum while slowly rotating the drum in a counterclockwise direction.

12 Insert a sheet of paper below the PIP drum to catch the removed glue from the drum.

13 Wet the drum surface with a lint-free wipe soaked in imaging oil.

14 While slowly rotating the drum counterclockwise, use the scraper to remove the remaining glue from the drum (see Figure 12-36). Keep the drum wet with imaging oil.

CAUTION Take care not to damage the PIP drum surface.

15 When all the glue has been removed, wipe the drum with the lint-free wipe soaked in imaging oil.

16 Carefully wipe and clean the PIP drum thoroughly using a lint-free wipe soaked in IPA.While holding the wet wipe against the drum, inch the press forward. Move the wipe in a forward diagonal direction. If the drum is still not completely clean of glue, clean the drum with imaging oil, and then wipe the drum with the wipe soaked in IPA.

17 Using an A4 sheet of photocopy paper, dry the PIP holder slot. Make sure that no imaging oil and glue residues remains on the drum and PIP holder slot. This will prevent adhesion of the new PIP underlayer.

18 Manually rotate the press until the machine dial reads 90°. At this position, the PIP holder slot will be directly in front of the PIP underlayer jig's pressure roller (when installed).

Figure 12-36. Cleaning the PIP drum

PIP drum

Scraper

Insert paper sheet under drum to collect glue droppings.


Installing the PIP underlayer jigThe figure below illustrates the PIP underlayer jig.

19 Use a 2.5 mm Allen key to turn the set screw and push the rear frame bar away from the front frame bar. Make sure that the set screw touches the rear frame bar, then turn the Allen screw six turns clockwise to create a gap between the front and rear frame bars.

20 Push the pressure roller to its set position as shown in Figure 12-38.

21 Mount the jig in the press in the position of the reverse roller as shown in Figure 12-38.

22 Clean the pressure roller. Turn the roller slowly holding a lint-free wipe soaked in IPA.Move the wipe on the roller in forward strokes from the press rear to the front.

a Push the pressure roller to its mount position as shown in Figure 12-37.

b Unscrew the set screw and make sure that the screw does not touch the rear frame bar.

Figure 12-37. PIP underlayer jig

Figure 12-38. Mounting the PIP underlayer jig

Rear frame bar

Mount position

Set position

Front frame barSet screw

Pressure roller

PIP drum

PIP holder slit

Pressure roller

PIP underlayer jig


Mounting the PIP underlayer

1 Mount an impression film as shown in Figure 12-39.

2 Hold the PIP underlayer with the mounting strip facing towards the drum and the transparent protective coating (see the white mounting tab) on top (Figure 12-40).

3 Insert the PIP underlayer mounting strip entirely in the PIP holder slot (Figure 12-41).Make sure that the strip is inserted completely along the width of the PIP underlayer.

Note Verify that the PIP underlayer is centered between the PIP drum shoulders.

4 Lock the PIP holder.

Note Recheck that the PIP underlayer is centered between the PIP drum shoulders.

5 Use the handwheel to turn the drum so that the PIP holder slot (nip) is aligned slightly above the jig’s pressure roller (Figure 12-41). The PIP underlayer is now held firmly on the drum.

Figure 12-39. Mounting the PIP underlayer jig and impression film

PIP drum

PIP underlayer jig

Impression film

Figure 12-40. Removing the protective coating from the PIP underlayer

PIP drum

PIP holder slot

PIP underlayer jig pressure roller

Press front

PIP underlayer

Impression filmTransparent protective coatingPeel white tab diagonally


6 Peel the transparent protective coating from the PIP underlayer surface.From the top right corner, peel the coating diagonally downwards to left side using the white tab. Then peel straight downwards until you reach the tail end at one side. Peel the final section diagonally to completely remove the coating.

Note Take care when peeling the final section. Peel this section slowly to avoid allowing the PIP underlayer to fold upon itself or contact any parts within the area.

7 Make sure that the top section of the PIP underlayer rests completely on the pressure roller.

8 Turn the handwheel continuously and very slowly counterclockwise to stick the PIP underlayer on the drum. Turn the drum one complete rotation without stopping.

CAUTION The PIP underlayer should not overlap the drum shoulders. Make sure that no particles stick to the PIP underlayer.

9 Turn the drum a second complete rotation.

10 Make sure that the set screw touches the rear frame bar, then turn the Allen screw six turns clockwise to create a gap between the front and rear frame bars.

11 Move the pressure roller to the set position.

Figure 12-41. Mounting the PIP underlayer

PIP holder slot

White stripJig pressure rollerPIP underlayer

Peel PIP underlayer protective sheet this way

Mounting tab

PIP underlayer

Figure 12-42. Preparing the PIP underlayer

PIP drumPIP holder slot

PIP underlayer jig pressure roller

Press frontPIP underlayer


12 Remove the jig.

13 Unlock the PIP holder.

14 Remove the mounting strip from the PIP holder slot as shown in Figure 12-43.

CAUTION Make sure that you keep your fingers from touching the pinch points.First, peel the strip away from the PIP underlayer. Then pull the strip completely out of the slot.

15 Firmly press down the edges of the PIP underlayer around the holder slot.Press down from the PIP underlayer center outwards towards the edges.

16 Turn the handwheel and firmly press down the side edges of the PIP underlayer.

17 Visually inspect the PIP underlayer on the drum. Look carefully for air bubbles, or other particle adhesions causing bumps in the PIP underlayer. If air bubbles or bumps are present on the PIP underlayer, remove the air bubbles by pressing fingers firmly on the PIP underlayer towards slit, and then towards the drum shoulders. See "Performing troubleshooting" on page 237.

18 Remove the impression film used with this installation (see Figure 12-39).

19 Reinstall the squeegee.

20 Reinstall the reverse roller. Make sure that the roller edges do not touch the PIP underlayer.

21 Lower the squeegee position latch.

22 Reinstall the slit injectors.

23 Reinstall the developer station.

24 Reconnect the cable connector to the catch tray.

25 Turn the press on.

26 Mount a new PIP. See "Replacing the PIP" on page 182.

Figure 12-43. Removing the PIP underlayer tab

PIP underlayer

PIP holder slot

PIP underlayer tab


Running a test procedureThe following test procedure reveals problems in the PIP underlayer. If cleaning the PIP and the surrounding area fails to remove noticeable print defects, perform this test procedure:

1 Print the Print Cleaner job. Adjust the first transfer pressure if necessary.

2 Print the Gray_20 job and verify that full format of the image is achieved. Check the print quality for the following:

• full format uniformity

• no defects such as white spots, or white areas

If the above problems appear during the test, use the following table to solve the problem.

Performing troubleshootingRefer to the following table to solve problems found during the visual inspection of the PIP underlayer.

Problem Suggested Treatment

Particle trapped between PIP and PIP underlayer

Locate the particle and remove it.

Bubble trapped under PIP underlayer in printing area

First, try to squeeze the bubble out with fingers.If necessary, pierce the bubble with a needle.If these actions fail, replace the PIP underlayer.

Particle trapped between PIP underlayer and PIP drum

Replace the PIP underlayer.

Problem Suggested Treatment

PIP underlayer is freed from PIP drum

If freed near a corner:Clean the exposed drum area with IPA and reattach the PIP underlayer to the surface.Do not use any glue.If this procedure fails to reattach the PIP underlayer area, replace the PIP underlayer.

Threads tail from PIP underlayer Gently cut the thread with a sharp knife.Take care not to damage the fabric.

Particle is captured between PIP underlayer and PIP drum

Replace the PIP underlayer.

Air bubbles are trapped under PIP underlayer near PIP holder slit edge

Remove the air bubbles by pressing fingers firmly on PIP underlayer towards slit, and then towards drum shoulders.

Bubble is trapped under PIP underlayer in printing area

First, try to squeeze the bubble out with fingers.If necessary, punch the bubble with a needle.If these actions fail, replace the PIP underlayer.


Mounting the impression film

The impression drum protective film (HP Indigo part number in Chapter 13) isolates the impression drum from the ITM drum. Whenever an old impression film has moved out of place, or has been damaged, the impression drum must be coated with a new impression film.

Note The impression film must be replaced approximately every 100,000 impressions.

To change the impression film:

WARNING! Use the Inch-Safe-Service method (see "Inch-safe-service method" on page 25). You must activate an Emergency Stop button before performing this procedure.

1 Put the machine in the standby mode.

2 Open the upper and lower input doors.

3 Open the ITM cover.

4 Inch the machine until you see the leading edge of the old impression film.

5 Detach the impression film leading edge.

6 Hold the leading edge with one hand while inching the machine with the other.

7 Remove the old impression film.

8 Clean the drum using a lint-free wipe soaked in isopropyl alcohol.

9 Inch the machine to 60°, as indicated in the PIP angle indicator.

Figure 12-44. Angle indicator

PIP axle

PIP arm

Angle indicator


10 Attach the impression film jig (HP Indigo part number in Chapter 13) to the PIP–ITM NIP.

11 Using a felt-tipped pen, mark the jig’s edge on the impression drum surface.

12 Glue the impression film leading edge to the impression drum. Make sure the leading edge is aligned with the jigs’ markings and that the film is centered laterally.

Note Make sure the leading edge is parallel to the drum’s axis.

13 Using the inching button, slowly advance the press, and with your second hand, press the impression film to the impression drum.

14 Glue the trailing edge of the impression film to the impression drum.

15 Check the impression film placement each time you change the substrate to make sure it has not moved. If the impression film has shifted, you will notice a bright strip of glue above the impression film leading edge.

Make sure that all equipment, tools and materials are removed from the unit and that all doors are closed before operating the press.

Web Maintenance

Clean the front sides of the transmitter and receiver every 500K impressions with a dry brush or wipe.

Perform a visual inspection of the grounding contact (Every 500K impressions). If erosion is detected then replace the contact (see Chapter 13 ).

Figure 12-45. Impression film jig

ITM

Impression drum

ITM connector bar

Impression film jig

Impression film

xx

Adhesive tape

ENWW Web Maintenance 239

Lubricating the press

General informationLubrication of the mechanical system is essential for proper operation of the press. When you lubricate components at scheduled intervals they will last longer and function more efficiently. Unless otherwise indicated, perform lubrication procedures every week.

Unlabeled arrows in the following illustrations indicate lubrication points that require gear oil. See Chapter 13 for specifications and sources of gear oil.

The arrows marked with a G in the following illustrations indicate lubrication points that require mechanical grease. See Chapter 13 for specifications and sources of mechanical grease.

Keep the following in mind whenever you perform lubricating procedures:

● Press an Emergency Stop button to change the machine state to the Off state before performing any lubrication procedures.

● Perform lubrication procedures only if you are trained and thoroughly familiar with safety and maintenance procedures.

● Do not over apply lubricants.

● A number of lubrication points are protected by spring bearings. To lubricate these points you must apply pressure on the bearing, then apply the oil. Use an oil can with a long spout for this purpose.

CAUTION Make sure you have removed all tools and materials from the unit and that you have closed all doors before resuming operation of the machine

Figure 12-46. HP Indigo press ws2000 lubricating areas

Rear

Input

Output

Front


Lubricating the front sectionFollow these procedures to lubricate the lubrication points located in the front section of the press.

All moving parts in the machine are covered either by doors or by guards.

Figure 12-47. Front wall lubrication points—new presses

2X

2X

ENWW Lubricating the press 241

Lubrication points behind the front upper doorPress the Stop button to change the machine state to the Off state before performing these procedures.

Open the front door.

The lubrication points in the front section of the press, behind the ink concentrate cans, are protected with a transparent guard. This guard has to be removed in order to gain access to the lubrication points.

Removing the guard

1 Release the 3 mm Allen screws.

2 Push the guard up and pull out.

Lubricating the substrate input sectionPress the Emergency Stop button to change the machine state to the Off state before performing these procedures.

Accessing the ITM gear

Insert the oil can spout between the guard and the gear.

Figure 12-48. Front wall lubrication points—older presses


Accessing the encoder gearInsert the oil can spout into the slot.

Lubricating the bushing on the inner rear wall

Push the oil can spot under the ITM gear guard.

Lubricating the substrate exit sectionPress the Emergency Stop button to change the machine state to the Off state before performing these procedures.

Accessing the exit rollers lubrication points

1 Open the upper and lower exit doors.

2 Lower the catch tray.


4 Place the injectors at the lowest possible point.

5 Insert the oil can from above the catch tray, between the catch tray and PIP drum and access the exit roller’s lubrication points.

CAUTION Make sure that all equipment, tools and materials are removed from the unit, and that all doors are closed before operating the machine.

Figure 12-49. Encoder cover

ITM and Encoder gears behind guard


Figure 12-50. Reverse roller station and PIP gear

Figure 12-51. Exit side, right

Figure 12-52. Web exit, rear inside wall

Lubrication points

Lubrication points

Lubrication points


Lubricating the rear sectionPress an Emergency Stop button to change the machine state to the Off state before performing this procedure.

1 Release the 3 mm Allen screw.

2 Press latch and open computer cabinet.

The rear section of the press includes the drums, the gripper solenoid, and the vacuum valve. The vacuum valve is located at the machine’s rear behind ITM air duct.

Figure 12-53. HP Indigo press ws2000 rear wall


Accessories


● Imaging products

● Parts

● Disposable parts

ENWW 247

Imaging products

Additional imaging products

Item Part number

HP photo imaging plate (4 per pkg.) for PIP underlayer MPS-2177-42

HP photo imaging plate (1 per pkg.) for PIP underlayer MPS-2176-41

HP PIP underlayer (2 per pkg.) MCH-1390-42

HP imaging oil (carton of six 1.9 liter containers) MPS-2017-43

HP ElectroInk - Cyan (EI Mark 3.1) (carton of 10 cans) MPS-2132-42

HP ElectroInk - Magenta (EI Mark 3.1) (carton of 10 cans) MPS-2133-42

HP ElectroInk - Yellow (EI Mark 3.1) (carton of 10 cans) MPS-2134-42

HP ElectroInk - Black (EI Mark 3.1) (carton of 10 cans) MPS-2131-42

HP ElectroInk - Violet MPS-2465-42

HP ElectroInk - Orange MPS-2401-42

HP thin impression film (10 per pkg.) MPS-2018-46

HP thick impression film (10 per pkg.) MPS-2031-45

HP imaging agent (for ink conductivity) MCH-0061-41

HP image transfer blanket kit (15 per pkg.) MPS-4016-46

Description Part number

HP pure oil 1.9 liter MPS-2034-41

248 Chapter 13 Accessories ENWW

Parts

Additional parts

Item Part number

HP squeegee roller MPJ-0171-44

Corona wire bobbin set(one full and one empty)

MKT-1106-46

Corona grid and damper MKT-0630-01

Cleaning station wiper-short (20 per package) MKT-1038-41

Suction finger (24 per package) MKT-1032-41 (B1429)

Doctor blade cleaning (for reverse roller and developer 7th blade [10 per package])

MKT-1036-42

Doctor blade wetting (for reverse roller [10 per package])

MKT-1037-42

Doctor blade colors (developer wiper blades [10 per package])

MKT-1035-42(4 pcs)

Ground contact MPY-2001-01

Item Part number

Slit cleaning jig MJX-0200-01

Density sensor cleaning paper MJX-0221-51

Developer stand MJX-0006-01

Squeegee base MJX-0029-01

Impression drum film jig MPJ-0755-01

Press roll cart MJX-0500-01

ENWW Parts 249

Supplies

For lubricants, contact your local HP supplier.

Always use clean, lint-free wipes for cleaning and applying imaging oil to print surfaces. Fibers remaining on internal surfaces degrade print quality.

Item Indigo part number

Supplier

Teflon tape (10 cm wide)

MTP-0003-01

Waste bags MPK-0043-01 Heavy plastic, dimensions (mm):300w x 500h t=0.05

IPA, 1 liter MCH-0027-01 Available at any pharmacy

Disposable gloves, nitrile MTS-0006-01 Available at any pharmacy

Synthetic cleaning wipes, lint-free

MTS-0016-01 Global Logistic 21902-985,TEXWIPE TX1009 Alpha wipeor equivalent

Cotton swabs MTS-0007-01 Available at any pharmacy

Cleaner, liquid organic (for removing ink stains from wipe)

MCH-0045-01 Global Logistic LC02-1017or equivalent


Disposable parts

Can be purchased in general purpose stores.

Description Part number Quantity

Plastic waste bags MPK-0043-01 500

Liquid organic cleaner MCH-0115-51

Isopropyl alcohol (IPA) MCH-0116-51 1ltr

Heat resistant gloves MTS-0003-01

Lint-free wipes MTS-0009-01

Disposable nitrile gloves MTS-0006-01

Manual pump MTS-0008-01

Cotton swabs MTS-0007-01

ENWW Disposable parts 251

Glossary

This glossary contains terms and definitions found throughout the HP Indigo press ws2000 documentation package.

Term Definition

blanket A fabric coated with natural or synthetic rubber which is clamped around the blanket cylinder and which transfers the ink from the press plate to the substrate.

catch tray Collects excess ink from the developer drum for recycling on HP Indigo presses.

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.

density A measure of the relative difference between a white area and a toned or black area. Can be applied both to black and white and color. Or, the ability of a material to absorb light. It is inversely proportional to the amount of light reflected or transmitted through the sample.

developer drum An HP Indigo press subsystem that, along with the PIP drum, generates the electric field that drives ink particles towards the image area and away from the non-image areas.

densitometer A device that measures the density and dot size of ink to make certain they are consistent throughout the run. If they are not consistent, it adjusts the press to compensate for deviation.

ENWW 253

eye-mark A short black strip printed as part of the first pass image. It is used for registering second pass image to the first pass image previously printed. Size and position are detailed below.

image The computerized representation of a picture or graphic.

imaging oil The liquid carrier of the pigment.

Impression drum Impression cylinder, the cylinder of a printing press which brings the paper into contact with the printing plate or blanket cylinder.

ITM drum (the intermediate transfer media)

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 intense light beam with a very narrow band width that can produce images by electronic impulses. It makes possible imaging by remote control from computers or facsimile transmissions.

look-up-table (LUT) A set of values in tabular form for input or output relationships. Such tables are most often associated with color calibration issues and determining how a color system translates from one color space to another.

non-image A non-inked area of the printed sheet.

one-shot The method whereby the press transfers all separations of the image onto the blanket—one separation per revolution—and then, in one revolution, transfers the image to the substrate.

photo imaging plate (PIP) In digital printing, the redefinable photo-sensitive image carrier.

PIP drum The drum around which the PIP is wrapped.

Term Definition

254 Chapter 14 Glossary ENWW

PostScript A Page Description Language (PDL) created by Adobe Systems for describing graphic information.

print cleaner An HP Indigo press function that cleans the blanket without manual intervention.

process The printing from a series of four or more separations in order to produce intermediate colors, shades and tones.

register In printing and image assembly, the exact fitting of two or more images, ensuring exact alignment with each other.

reverse roller An HP Indigo press subsystem that cleans the non-image areas on the PIP.

raster image processor (RIP) The part of an output device that converts mathematical and digital information into a series of dots.

scorotron unit An HP Indigo press subsystem that charges the PIP prior to exposure to laser beams.

screen The breaking down of an image into variable-sized dots that facilitate the reproduction of shades in monochrome printing.

screen ruling The number of lines per inch of a screen. Screen rulings are available from 65 lines per inch to 350 lines per inch.

separation In color printing, the outcome of the breakdown of color images to CMYK.

signature A single physical sheet of paper composed of several imposed pages.

simplex One-sided printing.

spread One side of the printing sheet.

squeegee An HP Indigo press subsystem that compresses the ink layer while reducing its imaging oil content.

Term Definition

ENWW 255

substrate types Printing media such as paper.

web The continuous substrate used in the press.

writing head An HP Indigo press subsystem composed of laser diodes that defines the image on the PIP.

Term Definition

256 Chapter 14 Glossary ENWW

Service and support

To obtain service, please contact the customer care center (CCC) within your country/region:

North America

Hewlett-Packard CompanyIndigo Division400 Unicorn Park DriveWoburn, MA 01801USA

Tel: +1 781 937 8800Fax: +1 781 937 8810

International

Hewlett-Packard CompanyIndigo DivisionLimburglaan 56221 SH MaastrichtThe Netherlands

Tel: +31 43 356 5656Fax: +31 43 356 5600

Israel

Hewlett-Packard CompanyIndigo DivisionKiryat WeizmannP.O. Box 150Rehovot 76101, Israel

Tel: +972 8 938 1818Fax: +972 8 938 1338

ENWW 257

258 Appendix A Service and support ENWW

Index
Aaccessing
job editor 45schematic 40subsystem 40

accessories 247adding, separator imaging oil 193adjust, color 181adjustment procedures 114advancing

corona 194system 58

angle indicator 61archiving 44automatic blanket cleaner page, enabling/disabling 178

Bblanket

cleaning 172, 177, 198cooling 199installing new 174log 176maintaining 172recovery 177replacing 172temperature, viewing and modifying 176transferring image to 17

blanket cleaner page, automatic enabling/disabling 178

Ccalibration

duplex eye-mark sensor 149eye-mark sensor 144simplex eye-mark 146

centering the web 105changing

color of an ink tank, using Install Ink wizard 170print queue order 43

charging and discharging PIP 16checking

image placement accuracy 111image uniformity 188impression film 198

cleaningblanket 172, 177, 198cleaning station 198electrometer 224imaging ink pump 219PIP 198reverse rollers 224separator clean sensor 221separator imaging oil 193slit injectors 198, 210squeegee 222wiper 215

cleaning stationcleaning 198maintaining 214reinstalling 215removing 214

coating 238

the impression drum 238color

adjust 181match 57

configuring, HotFolder 46consumables, handling 165– 194control pads 59control panel, using 38conventions 10cool the blanket 199corona

advancing 194stretching 193

correctingimage skew 86misregistrations 179

customizing job properties field display 43

Ddefining

substrate type 66, 189designing

duplex job 130duplex job with rewind 135duplex job without rewind 138first and second pass jobs 130simplex job with rewind 131simplex job without rewind 133

deskew, image 106developer drum 201developer station and catch tray 202developer station, maintaining 216devices, safety 23disposable parts 251double S threading procedure 68drain cooler, emptying 199draining ink tank 166duplex eye-mark sensor calibration 149duplex job

designing 130with rewind 135without rewind 138

Eediting job properties 55electrometer, cleaning 224emergency

power cut-off 26stop 59stop buttons 24

empty drain cooler 199enabling/disabling automatic blanket cleaner page 178end of day routines 198ending current job 159end-of-roll indicator 115eye-mark

placement 124placement and size 128sensor calibration 144

ENWW 259

Ffind mark 60first and second pass jobs, designing 130first transfer pressure adjustment 175front section, lubricating 241full cleaning procedure 212, 217

Gglossary 122, 253

Hhandling image wetness 160handwheel, using 60help 33– 36

help topics window 35operation guide 34printing help topics 35reference guide 33

HotFolder, configuring 46HP ElectroInk 166HP Imaging ink 166HP Indigo Press

navigating the interface 32online help 33operator 140warning signs to post 22

HP Indigo RIP, working with 154

Iimage

checking placement accuracy 111deskew 106placement 57printing 17uniformity, checking 188wetness, handling 160

imaging ink 166pump, cleaning 219

imaging oil 166imaging products 248impression drum 238impression film, check 198inching 60injectors, slit 201ink

HP ElectroInk 166HP Imaging Ink 166imaging oil 166removing excess 17working with 166

ink can, log 172ink cans, replacing 169ink log 172ink tank 202

changing color 170draining 166refilling 167

inking the PIP 17installing

new blanket 174new PIP 184

interface navigation 32interlock check 203interlock fault condition 206introduction 14ITM 202

Jjob editor

accessing 45functions 45using 45

job handling 153job imposition 47job manager 42

window 42job properties, editing 55jobs

designing first and second pass jobs 130ending current 159maintenance 55managing 42pausing or stopping print jobs 158printing 52, 157retained 44second pass reinsertion 54to HP Indigo press ws2000 operator 140to QuarkXpress operator 141

Llight cleaning procedure 210loaded jobs list 43long term shutdown 206look-up tables (LUTs) 57lubricating 199

front section 241press 240rear section 245substrate exit section 243

LUTs 57

Mmachine state indicator 39maintaining

cleaning station 214developer station 216PIP 181PIP underlayer 231press 209– 245reverse rollers 224scorotron 193, 229separator 191separator imaging oil level 191

maintenanceblanket 172cleaning station 214developer station 216jobs 55lubricating 199press 209– 245safety and emergency procedures 25scorotron 193separator 191tips 196web 239

managing jobs 42mechanical reset option 61misregistrations, correcting 179

Oonline help 33operating the press 49– 61operation guide 34operator

260 Index ENWW

HP Indigo press ws2000 140QuarkXpress 141routines 195– 207setting the press 141

options, mechanical reset 61overview 14– 18

Pparts 249

disposable 251pausing or stopping a print job 158performing troubleshooting 237PIP

charging and discharging 16cleaning 198inking 17installing new 184maintaining 181preparing for printing 188removing old 182replacing 182

PIP underlayermaintaining 231removing 231

placementeye-mark 124image 57

preparing the press 51press

lubricating 240maintaining 209– 245operation 49– 61preparing 51set position 198setting, operator 141

presses supported 11pressure adjustment, first transfer 175pre-threading procedure 68, 90print cycle 16print queue, changing 43printing

help topics 35image 17jobs 52preparing PIP for 188second pass 119– 152the job 157

proceduresadjustment 114double S threading 68full cleaning 212, 217light cleaning 210pre-threading 68, 90safety 19– 29short cleaning 216straight path threading 89test 237threading 65, 73web replacement 108

products, imaging 248pump flow rate, setting 110

QQuarkXpress operator 141

Rrear section, lubricating 245reassembling reverse roller unit 228recovery, blanket 177reference guide 33refilling ink tank 167reinstalling the cleaning station 215removing

cleaning station 214old PIP 182PIP underlayer 231

repeat length matching verification wizard 150replacing

blanket 172ink cans 169PIP 182reverse roller blade 227wetting blade 226wiper 215wiper blade 217

retained jobs 44reverse roller blade, replacing 227reverse roller unit, reassembling 228reverse rollers 202

cleaning 224maintaining 224

RIP, HP Indigo 154rollers, reverse 202routines

end of day 198operator 195– 207start of day 197tips 196weekly 200

Ssafety

air conditioning precaution 22devices 23electrical hazard 21emergency power cut-off 26emergency stop buttons 24entanglement hazard 21hazardous voltage 22hot surface hazard 21ink pump hazard 22laser 20maintenance and emergency procedures 25open gears hazard 22pinch hazard 21procedures 19– 29symbols 20warning signs to post 22

schematic window 40scorotron

maintaining 193, 229scorotron and dampers 201

screening 57second pass jobs, designing 130second pass printing 119– 152

introduction 120system description 120

second pass reinsertion jobs 54selecting threading mode 67separator clean sensor, cleaning 221separator imaging oil

adding 193

ENWW 261

cleaning 193maintaining level 191

separator, maintaining 191service and support 257setting

press position 198pump flow rate 110repeat length 86, 106the press operator 141

short cleaning procedure 216shutdown, long term 206simplex eye-mark calibration 146simplex job

with rewind, designing 131without rewind, designing 133

slit injectors 201cleaning 198, 210

squeegee 202cleaning 222

start of day routines 197starting-up 16straight path threading procedure 89stretching the corona 193substrate exit section, lubricating 243substrate feed rollers 203substrate type, defining 189supplies 250support 257supported presses 11symbols 20system

advancing 58description, web transport system 64update 187

Ttemperature, blanket 176test procedure, running 237threading 73

mode, selecting 67procedures 65

transferring image to blanket 17troubleshooting

performing 237web jams 110

Uuniformity, image 188updating system 187user guide

about 10conventions used in 10

usinghandwheel 60job editor 45web pump 109

Vviewing

blanket log 176ink log 172

viewing and modifying blanket temperature 176

Wwarning signs to post 22web

feed 59maintenance 239motion 121replacement procedure 108

web pump, using 109web transport system 63– 117

description 64weekly routines 200wet jams, troubleshooting 110wetness, image 160wetting blade, replacing 226wiper

cleaning 215replacing 215

wiper blade, replacing 217wizard, repeat length matching verification 150working with ink 166

262 Index ENWW

copyright © 2002Hewlett-Packard Company

*MNU-1651-51**MNU-1651-51*

reorder #: MNU-1651-51MNU-1651-20

www.hp.com/go/indigo

This is an HP Indigo digital print.

mnu-1651-51 (x51121_e)

Documents

dripping prevention

dripping prevention

main circuit

backfeed drive

weekly routine

indexer drive

spiral tension

lateral adjustment