Overview...................................................................................................................................................6

Warranty disqualifier.................................................................................................................................7

Quick reference checklist .........................................................................................................................8

General information ................................................................................................................................17

How to use this manual .....................................................................................................................17

Packing list ........................................................................................................................................17

The alignment jig ...............................................................................................................................19

The parallel jig ...................................................................................................................................20

Prerequisites...........................................................................................................................................22

Estimated installation time......................................................................................................................22

Special skills ...........................................................................................................................................22

Special jigs and tools..............................................................................................................................22

Pre-installation procedure ......................................................................................................................23

Verifying site preparation...................................................................................................................23

Marking the pressroom floor for press components..........................................................................23

Unpacking the boxes.........................................................................................................................23

Procedure ...............................................................................................................................................24

Installing the electrical cabinets ........................................................................................................24

Installing the printing engines............................................................................................................24

Mounting the turnbar .........................................................................................................................44

Mounting the PE1..............................................................................................................................45

Leveling the printing engines ............................................................................................................46

filename: CA294-03070-00.doc

HP Indigo Division Installation Instructions

Details

Modification available - performance/ Modification available -

reliability

HP Indigo press w3250

CA294-03070

As per press

13 Feb 07

N/A

HP confidential

page 1 of 153

Table of Contents

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Page 1: Table Of Contents
HP Indigo Division Installation Instructions Installation Manual Purpose To provide information and instructions for performing the installation of the HP Indigo press w3250. Installation instruction details Item Details Objective Modification available - performance/ Modification available - reliability Scope HP Indigo press w3250...
Page 2 Appendix A: Image placement parameters ..................151 Revision history ............................153 Confidentiality Notice..........................153 List of figures Figure 1 The HP Indigo press w3250 ....................6 Figure 2 The alignment jig ........................19 Figure 3 The alignment jigs mounted ....................19 Figure 4 Sections of the new Parallel jig ....................20 Figure 5 Mounting the v-section of the Parallel jig................21...
Page 3 Installation Manual Figure 11 Setting up the surveying tool ....................29 Figure 12 Focusing the surveying tool on the foresight stand target..........30 Figure 13 Leveling the surveying tool ....................30 Figure 14 Loosening the u-base connecting rods ................31 Figure 15 Installing the junction bars between the u-bases ...............31 Figure 16 Removing the front exit service door..................33 Figure 17 The lifting and positioning assembly ..................34 Figure 18 Positioning the link bar under the feed side ...............35...
Page 4 Installation Manual Figure 56 Connecting the UPS to the PDU ..................76 Figure 57 HVPS installation........................77 Figure 58 The HVPS cage assembly....................77 Figure 59 Installing the HVPS on the baseplate.................78 Figure 60 Installing the baseplate on the press..................78 Figure 61 Attaching the top cover to the baseplate ................79 Figure 62 Connecting the cables to the HVPS ...................79 Figure 63 ILP rollers..........................81 Figure 64 Distinguishing the ILP feed and exit stepping plate assemblies ........82...
Page 5 Installation Manual Figure 101 Adjusting the height of the utility cabinet ................120 Figure 102 The network configuration ....................121 Figure 103 The switchbox unit......................121 Figure 104 Identifying the slave computer connections ..............122 Figure 105 Mounting the slave computer and switchbox in electrical cabinet M2 ......123 Figure 106 Connecting a slave computer to its printing engine ............124 Figure 107 Connecting the master console computer..............127 Figure 108 Installing the monitor base....................128...
Page 6: Overview
Installation Manual Overview Figure 1 The HP Indigo press w3250 The procedure to install the HP Indigo press w3250 involves the following main steps: • Verifying site preparation • Marking the pressroom floor • Unpacking the boxes • Install the electrical cabinets •...
Page 7: Warranty Disqualifier
Installation Manual Warranty disqualifier The boxes addressed to the customer may be opened only by a qualified HP Indigo Customer Engineer. Any unauthorized opening of the boxes may void the warranty on the press and its parts. This manual and the corresponding Quick Reference Checklist are intended for use by the Customer Engineer.
Page 8: Quick Reference Checklist
Installation Manual Quick reference checklist The following procedure is a quick reference guide of the installation procedure intended for two integrators and extended over five days. Step Notes and Heading Reference Procedure check Pre-installation Site Verifying site Verify site preparation as per Site Site Preparation preparation preparation on page...
Page 9 Installation Manual Heading Step Reference Procedure Notes and check Install the electrical Install electrical cabinet M2 to cabinet M1 cabinet-to-cabinet cabling. cables on page 61 Install electrical cabinet M1 to cabinet M2 cabling. Install the electrical Install electrical cabinet M1 to PE1 and cabinet M1 cables to PE2.
Page 10 Installation Manual Heading Step Reference Procedure Notes and check Installing the chiller Install chiller pipes adapters and Hoses from chiller on page 72 connections. should be prepared Install chiller according to specifications. Refer to the UltraFilter ultracool 0400 installation guide: Flow rate of 56 ±5 liters/minute Chiller and Temperature (measured at the press...
Page 11 Installation Manual Heading Step Reference Procedure Notes and check install the ILP exit Install the ILP exit stepping plate assembly stepping plate on to the ILP. page 83 align the ILP and Align the ILP and stepping plate assembly stepping plate with the press.
Page 12 Installation Manual Heading Step Reference Procedure Notes and check Connect on page 108 Connect the following air hoses at the ILP front: Input hose from mains air supply to Inlet connection. Long outlet hose from Outlet to PE connection to PE1. Long outlet hose from Outlet to UW connection to unwinder.
Page 13 Installation Manual Heading Step Reference Procedure Notes and check Production Production flow on Organize and install network cabling, RIP flow page 130 systems, HPPF units to aid production flow. Install the finishing Install the rewinder jig to test the press. Rewinder jig components on page After testing, install finishing components...
Page 14 Verify the writing head focus. Verify the accuracy of the front to back and side to side prints: a. Perform the natural web length calibration for duplex. See HP Indigo Service Instruction Calibrations, MNU-1633-01. b. Perform the eye mark sensor vertical positioning.
Page 15 Installation Manual Heading Step Reference Procedure Notes and check h. Click Next and Print. The color adjustment is performed. Make sure that the wizard completes all of its steps, and that all colors pass the color adjust procedure. Click Finish. Load the desired substrate on the press.
Page 16 Installation Manual Heading Step Reference Procedure Notes and check aa. Click Setup. The Setup OD of 100% Spec Values window opens. bb. Enter the optical density values noted in step l above in the appropriate color fields. cc. Click OK. A warning may appear.
Page 17: General Information
Installation Manual General information How to use this manual Read the manual carefully prior to installing the press. This manual is intended to guide the CE throughout the installation of the press. The packing list in the boxes takes priority over the list in this manual. Check off parts against the packing list in the boxes.
Page 18 Feed roller Unwinder book PX848AA#ABB Monitor Master Console MPT-7383-53 Console assy Emergency stop panel CA271-00263 Computer DD817AV Keyboard ps/2 hp MPT-7646-32 Working surface master console EHE-4069-51 Cable assy cc69 CA261-07420 Cable assy cc70 CA248-00230 PC software kit DD837AV Mouse PS/2 HP...
Page 19: The Alignment Jig
Installation Manual Box no. Part number Contents Name and weight (kg) Q5391-00680 Kit cons. Instl. W3250 Consumables kit MPR-1309-11 Pap. Roll condat 115 Paper roll condat 115 The alignment jig Figure 2 The alignment jig Figure 3 The alignment jigs mounted Sights increasing in height from PE1 to PE2 PE1 jig PE2 jig...
Page 20: The Parallel Jig
Installation Manual engines until all the sights are lined up with the crosshairs in the surveying tool (Figure 2 and Figure 3). The parallel jig The Parallel jig measures the variation in distance (parallel) along the length of two rollers. It is used to accommodate the various adjustments necessary to bring the rollers of all the press components (printing engines, ILP, unwinder) into parallel with the rollers of the adjacent one.
Page 21: Figure 5 Mounting The V-Section Of The Parallel Jig
Installation Manual The short configuration is used to align the remaining roller in each stepping plate to its companion roller aligned previously (Figure 4). To assemble the new Parallel jig to align two rollers (Figure 4): Insert the measuring gauge fixture into the desired extension (long, intermediate, short). Tighten the handle.
Page 22: Prerequisites
Installation Manual Figure 6 Mounting the dial bracket on the extension Dial bracket securing screw Positioning circle Dial bracket Center lines of roller Buffer Position of dial sensor tip Roller Dial Mount the gauged end of the jig on the specified roller needing to be aligned. Loosen the screw securing the gauge support on the fixture, and slide it back so it does not interfere with placing the wheel.
Page 23: Pre-Installation Procedure
Installation Manual Pre-installation procedure Verifying site preparation Verify that the pressroom has been equipped with the following per the HP Indigo press w3250 site preparation guide: Chiller input and output Power for press Air conditioning of work area Fast Ethernet networking...
Page 24: Procedure
Installation Manual Procedure NOTE: Two persons are required for this installation. Installing the electrical cabinets Place electrical cabinet M1 and electrical cabinet M2 in their positions. If any of the finishing components include electrical cabinets, position that cabinet opposite its corresponding finishing component and in line with the main electrical cabinets.
Page 25: Figure 7 Positioning The U-Bases
Installation Manual Figure 7 Positioning the u-bases PE1 u-base PE2 u-base CA294-03070 rev 00 page 25 of 153...
Page 26: Figure 8 Remounting The U-Base Slip Plates
Installation Manual Lay the u-bases on the floor at a distance of 6716 mm (1800+2450+2466 mm (264.4 ins)) from the wall at the unwinder end and at a distance of 693.0 mm (27.3 ins) apart (Figure 7). Measure a distance of XXX mm (XXX ins) from the rear of the u-base to the wall at the electrical cabinets.
Page 27: Figure 9 Adjusting The U-Base Height
Installation Manual Figure 9 Adjusting the u-base height U-base U-base slip plate Height of 200.00 mm Height adjustment screw Adjust the u-base feet to give a height of 200.0 mm from the floor to the u-base top side (Figure 9). CA294-03070 rev 00 page 27 of 153...
Page 28: Figure 10 Placing The Foresight On The Pe2 U-Base
Installation Manual Figure 10 Placing the foresight on the PE2 u-base 0.5 m m 0.5 m m PUB_1596 Sight Foresight stand PE2 u-base Position the foresight stand on the PE2 u-base at the front left corner (Figure 10). NOTE: The initial position of the foresight stand is used as the reference for leveling both u-bases.
Page 29: Figure 11 Setting Up The Surveying Tool
Installation Manual Figure 11 Setting up the surveying tool Position of surveying tool Surveying line NOTE: The surveying tool is setup on its tripod in accordance with its instruction manual at the position shown in Figure 11. Raise the height of the tripod and surveying tool to 1550.0 mm. CA294-03070 rev 00 page 29 of 153...
Page 30: Figure 12 Focusing The Surveying Tool On The Foresight Stand Target
Installation Manual Figure 12 Focusing the surveying tool on the foresight stand target 0.5 mm Height adjustment screws Crosshair target Position the surveying tool facing and parallel to the foresight stand (Figure 12). Figure 13 Leveling the surveying tool PUB_1346 Level bubble Adjust the level of the surveying tool until the bubble is centered in the level (Figure 13).
Page 31: Figure 14 Loosening The U-Base Connecting Rods
Installation Manual Tighten the lock nut to secure the height of the u-base foot at that corner. Move the foresight stand to the next corner facing the surveying tool. Adjust the height of the u-base foot at this corner so that the foresight cross target is centered in the crosshairs of the surveying tool.
Page 32 Installation Manual Install the junction bars (P/N MJX-1852-01) between the two u-bases using two M6 Allen screws, spring washers and flat washers to secure each bar (Figure 15). The distance between the u-bases is now fixed at 693.0 mm. NOTE: Make sure to mount each PE to the correct u-base.
Page 33: Figure 16 Removing The Front Exit Service Door
Installation Manual Figure 16 Removing the front exit service door Remove these screws Door lower hinge Front exit service door Mount the PE2 on the u-base as follows: At PE2 Remove the three screws securing the upper shaft of the front exit service door frame.
Page 34: Figure 17 The Lifting And Positioning Assembly
Installation Manual Remove the three screws securing the front exit door lower hinge (Figure 16). Keep the hinge and screws for later reinstallation. Figure 17 The lifting and positioning assembly Orientation labels Link bar Support wedges Maximum lifting weight label Pneumatic gun connector /adapter for wheel jack CE label Wheel jack...
Page 35: Figure 18 Positioning The Link Bar Under The Feed Side
Installation Manual Figure 18 Positioning the link bar under the feed side Engine rear Positioning label Base frame Feed link bar Support wedges Position the feed link bar under the base frame (Figure 18). Make sure to insert the support wedges under the engine feed base frame. CA294-03070 rev 00 page 35 of 153...
Page 36: Figure 19 Positioning The Link Bar Under The Exit Side Of The Engine - View From Rear
Installation Manual Figure 19 Positioning the link bar under the exit side of the engine - view from rear Rear electronic cabinet door Support wedge Support wedge Exit link bar Positioning label Exit base frame Rear engine frame Fully open the rear electronic cabinet door (Figure 19). Position the exit link bar under the exit engine frame (Figure 19).
Page 37: Figure 20 Positioning The Lifting Frames Against The Engine
Installation Manual Figure 20 Positioning the lifting frames against the engine Engine frame Metal securing peg Rear lifting frame Lifting frame slot securing end of exit link bar. Front lifting frame Metal securing peg Lifting frame slot securing end of feed link bar Position the front and rear lifting frames against the engine so that the feed and exit link bars are inserted in the lifting frame slots (Figure 20).
Page 38: Figure 21 Leveling Pad
Installation Manual Figure 21 Leveling pad Allen M10 screw Default height adjustment wedge position Height adjustment wedge Figure 22 Placing the leveling pads on the u-base Leveling pad slots Leveling pad slots U-base cover Leveling pads Allen M10 height adjustment screw Mount four leveling pads (Figure 21) at the four corner slots of the u-base (Figure 22).
Page 39: Figure 23 Moving The Raised Engine To The U-Base
Installation Manual The Allen M10 height adjustment screw (Figure 21) should be facing towards the outer sides of the press for easy access. Make sure that the leveling pads are at their default height (Figure 21-4). If not use an Allen M10 key to lower or raise the height adjustment wedges to their default level (Figure 21).
Page 40: Figure 24 Press Positioned Over U-Base
Installation Manual Figure 24 Press positioned over u-base Feed base frame underside slot Feed base frame underside slot Leveling pad Leveling pads U-base Exit base frame underside slot Carefully move the lifting jig and press over the u-base until the feed and exit base frame underside slots (Figure 30) are aligned correctly with the top surfaces of the leveling pads (Figure 23 and Figure 24).
Page 41: Figure 25 Lowering The Engine On To The U-Base And Leveling Pads
Installation Manual Figure 25 Lowering the engine on to the u-base and leveling pads Printing engine raised above u-base Printing engine correctly positioned on leveling pads and u-base Correct position of leveling pads Correct position of leveling pad Turn each wheel jack (Figure 17) an equal number of turns, in steps of 3-4 turns, to lower the engine on the leveling pads and u-base (Figure 32, Figure 25).
Page 42: Figure 26 Engine Mounted On The U-Base
Installation Manual Figure 26 Engine mounted on the u-base Position of link bar secured against Leveling pad press frame beam Frame slot Leveling pad U-base Frame slot Make sure that the pads are correctly aligned within their slots on the u-base and under the press (Figure 26).
Page 43: Figure 27 Final Position Of Printing Engine On U-Base
Installation Manual Figure 27 Final position of printing engine on u-base Securing bracket U-base Disassemble the lifting and positioning jig away from the printing engine. The printing engine and u-base should appear as shown in Figure 27. CAUTION: When transporting the printing engine, secure the engine to the u-base using the securing brackets (Figure 27).
Page 44: Mounting The Turnbar
Installation Manual Mounting the turnbar Figure 28 Identifying the turnbar components Turnbar end roller Front connection bracket Turnbar idler 1 Rear connection bracket Turnbar air pressure valve and dial Turnbar idler 2 Turnbar air vacuum control valve Turnbar idler 3 Turnbar lateral adjust control Turnbar cross lower roller Air pressure supply...
Page 45: Mounting The Pe1
Installation Manual Figure 29 Inserting the turnbar into the exit side of PE2 Notch for turnbar end roller shaft Turnbar end roller shaft Mount the turnbar in the exit side of PE2. The turnbar end roller shaft fits into the notches in the output assembly of the PE2 WHS (Figure 29).
Page 46: Leveling The Printing Engines
Installation Manual Reinstall the front exit door lower hinge using the original screws. Remount the front exit service door within its frame. Reinstall the top bracket to secure the door. Use the original screws to secure the bracket. Leveling the printing engines Figure 30 Using a level at the printing engine front PUBLISHER-1022 Front base...
Page 47: Figure 31 Leveling At The Printing Engine Input - Pe2 Shown
Installation Manual Figure 31 Leveling at the printing engine input – PE2 shown WARNING AVERTISSEMENT WARNING Level Idler Place the level at the following positions, and level the printing engine: • On the input idler (Figure 31) • Exit idlers. Remove the ILD securing bracket and place aside temporarily. If necessary, adjust the leveling pads until the printing engine is level.
Page 48: Figure 32 Mounting An Alignment Jig On The Itm End Cap
Installation Manual parallel jig to bring the centerlines of the printing engines into parallel. Both adjustments are then checked and repeated, if necessary, until the centerlines of the printing engines are collinear. Figure 32 Mounting an alignment jig on the ITM end cap ITM bearing housing plate Sights Alignment jig adapter...
Page 49 Installation Manual At the engine front To align the printing engines horizontally: (Figure 32): For each printing engine Remove three screws securing the ITM front bearing housing plate. Save the screws for immediate reinstallation. Install the alignment jig adapter on the plate. Insert the three screws previously removed in the same holes.
Page 50: Figure 33 Aligning The Printing Engines - Alignment Jigs
Installation Manual Figure 33 Aligning the printing engines - alignment jigs Surveying tool Line of sight Alignment jigs PE front CA294-03070 rev 00 page 50 of 153...
Page 51: Figure 34 Identifying The U-Base Adjustment Screws
Installation Manual Figure 34 Identifying the u-base adjustment screws Inner screws - for aligning the PE accurately Figure 35 Aligning the surveying tool crosshairs and sights NOTE: When adjusting the u-base slip plates, tightening the inner screws moves the printing engine towards the rear and loosening them moves it towards the front.
Page 52: Figure 36 Measuring The Parallelism Between Rollers Of Opposing Printing Engines
Installation Manual Figure 36 Measuring the parallelism between rollers of opposing printing engines Parallel jig Align the printing engines as follows to make the rollers parallel: Place the V-section of the parallel jig on idler 9 of PE2 (Figure 36). Refer also to the section General information on page 17.
Page 53: Figure 37 The Link Brackets
Installation Manual Figure 37 The link brackets Front link bracket Rear link bracket Figure 38 Mounting the front link bracket Plate bracket Front corner bracket Joining screw M6 Allen screws 19 mm bolts NOTE: Use caution when installing the link brackets, as the printing engines can move if the link bracket is closed too tightly.
Page 54: Securing The Turnbar
Installation Manual Securing the turnbar Figure 39 Inserting the rear connection bracket Turnbar Rear connection bracket Turnbar idler 3 Idler extended shaft Turnbar idler 2 Mount the front and rear connection brackets on the extended shaft of idler 3 (Figure 39). Lower the turnbar towards PE2.
Page 55: Figure 40 Securing The Front Connection Bracket And Input Idler
Installation Manual Figure 40 Securing the front connection bracket and input idler Input idler PE2 input rollers front wall Front connection bracket Upper screw securing the idler Lower screw securing the front connection bracket Insert and slide the input idler to both the front connection bracket and the PE2 input rollers front side wall (Figure 40).
Page 56: Figure 41 Securing The Rear Connection Bracket And Input Idler
Installation Manual Figure 41 Securing the rear connection bracket and input idler Rear connection bracket PE2 input idler Lower screw securing the rear connection Collar spacer bracket Turnbar rear wall Upper screw securing the idler Turnbar input idler Install the rear collar spacer (Figure 41). Install two additional Allen M5 screw (P/N MBS-0840-10) to secure the rear connection bracket (Figure 41).
Page 57 Installation Manual Check the parallelism between the printing engine rollers using the parallel jig. Realign, if necessary. Tighten the joining Allen screw of the front link bracket. Tighten the screws securing the u-base connecting rods (Figure 14). CA294-03070 rev 00 page 57 of 153...
Page 58: Electrical Cabling
Installation Manual Electrical cabling Remove the four screws securing the floor-plates of both main electrical cabinets. Remove the floor-plates. Figure 42 Connecting the main electrical power in the electrical cabinet Locking bracket 2, 3 Main power connector Direction of closing locking bracket To install mains power connectors (Figure 42): Insert the cable connector to its female connection at the cabinet.
Page 59: Figure 43 Securing The Electrical Cabinet Cables
Installation Manual Figure 43 Securing the electrical cabinet cables PUB-485 Cable mounts here Support back-plate Cable bracket NOTE: Use the cable bracket (P/N MCC-0821-05) to secure the electrical cabinet-to-electrical cabinet and printing engine-to- electrical cabinet cables to the inner wall channel bracket attached to the wall of the electrical cabinets.
Page 60: Figure 44 Components Of Electrical Cabinet M1
Installation Manual Figure 44 Components of electrical cabinet M1 NOTE: Location of the connectors may vary. CA294-03070 rev 00 page 60 of 153...
Page 61: Figure 45 Components Of Electrical Cabinet M2
Installation Manual Figure 45 Components of electrical cabinet M2 NOTE: Location of the connectors may vary. Install the electrical cabinet-to-cabinet cables as follows (Figure 44, Figure 45): Cable From end point elect. cab. M2 To end point elec. cab. M1 Notes EHE-4405-51 3-phase 400VAC power supply for...
Page 62 Installation Manual Cable From end point elect. cab. M2 To end point elec. cab. M1 Notes CA261-10910 Signal interface between cabinets at X50 connector cable 10910 CC413 GND05 Ground connection cable M1b Ground connection cable M1b Route cable from cabinet M1 to M2 Install the electrical cabinet-to-cabinet cables as follows (Figure 44, Figure 45): Cable From end point elect.
Page 63 Installation Manual Cable From end point elect. cab. M2 To end point PE1 or PE2 Notes CC236 Electrical cabinet M2 X31.1 – WHS connector pins PE, 6, 5 CC54A Slave 1 compartment, Molex connection in M2A CC414 Electrical cabinet M2 X61 connector Junction box CC430 Electrical cabinet M2 x90...
Page 64 Installation Manual Cable From end point To end point Notes CC65 Slave 2 switchbox Master console switchbox (electrical cabinet M2 left connector J2 to plug 3X side) connector J4 top plug W190 From master console Master PC on-board See Figure 107, connect to switchbox connector P1 to Ethernet connection onboard network connection...
Page 65: Figure 46 The Unidrive Assembly And Components
Installation Manual Figure 46 The Unidrive assembly and components PUBLISHER-1133A UD75 interface module CTNET connection MODBUS connection Connector to UD51 second encoder feedback module Cable securing bracket UD51 second encoder feedback module Unidrive encoder connector Elec. cab.-to-elec. cab. power connectors nos. 1 - 11 Elec.
Page 66: Figure 47 The Unidrive Unit
Installation Manual Figure 47 The Unidrive unit PUBLISHER-1133 CTNET connection Encoder connection NOTE: UD51 second encoder feedback module is not installed on all Unidrives. In addition, the connector to the UD51 second encoder feedback module is not installed on all Unidrives. Install all Unidrive cables as follows: Remove the front lower covers from the Unidrives, and insert the following connections (see Figure 46 and Figure 47):...
Page 67 Installation Manual Install the PE2-to-Unidrive cables as follows: Cable From end point PE2 To end point FP2 encoder 26K0 CC440 Feed motor CC441 Feed motor power orange cable FP2 drive 26K9 pins PE, PE, 2, 4, 6 CC442 Impression engage motor IP2 encoder 27K0 CC443 Impression engage motor power orange cable...
Page 68: Figure 48 Electrical Cabinet M1 Plc, Mpi, And Profibus Connections
Installation Manual Figure 48 Electrical cabinet M1 PLC, MPI, and Profibus connections PLC (53A1 - 53A3) Mode selector Memory cartridge Cables cover Communications cable connection to PC Install the CTNET cables as follows: Cable From end point To end point Notes Unidrive 24U0 unwinder web Electrical cabinet M2 U029...
Page 69: Figure 49 Routing The Mpi (Modbus) Cable
Installation Manual Figure 49 Routing the MPI (MODBUS) cable Route the MPI (MODBUS) cables as follows (Figure 49): Route the ILP connection panel section to the electrical cabinets. The raised floor should be installed before connecting to the ILP. Route it to the front of PE1 and along bottom of the frame to the turnbar area. Connect JTBD of the cable to PTBD of the TBD.
Page 70: Installing The Vacuum Hoses
Installation Manual Installing the vacuum hoses Figure 50 Installing the vacuum hoses and adaptors V-junction adapters CA294-03070 rev 00 page 70 of 153...
Page 71: Figure 51 Routing Vacuum Hoses To Pe1
Installation Manual NOTE: All vacuum hoses are to be routed appropriately under the floor platform. Use metal ring screw clamps to connect all hoses to blowers, adaptors, and vacuum boxes. Remove the screws securing the feed panel. Remove the panel and save it and the screws for later reinstallation.
Page 72: Install The Floor Platform
Install the floor platform At this point in the installation of the press, the customer should have the floor platform installed. The floor platform must meet the specifications detailed in the HP Indigo press w3250 site preparation guide. The customer engineer should inform the floor platform installers to start installing the floor at the unwinder and ILP positions.
Page 73: Figure 53 Chiller Pipe Routing (Europe)
(63 inches) operation. Open for chiller maintenance and inspection. 1" ball valve Barb fitting, 1" inside 1" pipe diameter 1" flexible tube installed by HP Engine No. 2 Engine No. 1 Blower Blower CA294-03070 rev 00 page 73 of 153...
Page 74: Figure 54 Chiller Pipe Routing (Japan)
1" ball valve Barb fitting, 1" inside diameter 1" pipe 1" flexible tube installed by HP Engine No. 2 Engine No. 1 Blower Blower To connect the cooling water hoses to the press use the following adapters and tools: Two hose 1.5"...
Page 75: Install The Ups
Installation Manual Install the UPS NOTE: Due to changes in the UPS manufacturer, the various UPS units may differ in their rear panel details. However, their general features will remain similar, as will their cable connections. Figure 55 The rear UPS panel UPS_R COM (SNMP) RS232 connection Output breaker button...
Page 76: Install The Writing Head
Installation Manual Figure 56 Connecting the UPS to the PDU PDU_CONN1 Neutral Three phases Main Breaker button Input from PC Install and connect the UPS cables as follows: Cable From end point To end point CC73A UPS No. 1 from slave 1 PC RS232 COM (SNMP) port at the 1 CC74A UPS No.
Page 77: Install The Hvps (High Voltage Power Supply)
Installation Manual Install the HVPS (High Voltage Power Supply) Figure 57 HVPS installation HVPS top cover HVPS rear cover Electrical cabinet side door Baseplate Electrical cabinet HVPS front cover Figure 58 The HVPS cage assembly Top cover Front cover Baseplate Rear cover CA294-03070 rev 00 page 77 of 153...
Page 78: Figure 59 Installing The Hvps On The Baseplate
Installation Manual Figure 59 Installing the HVPS on the baseplate Screws securing HPVS to baseplate Baseplate HVPS unit (upside down) Use four M6 × 16 Allen screws with washers and spring washers to install the HVPS on the baseplate (Figure 59). Figure 60 Installing the baseplate on the press Baseplate Screws securing baseplate to press (2 each side)
Page 79: Install The Roof Covers
Installation Manual Figure 61 Attaching the top cover to the baseplate Baseplate Screws securing top cover to baseplate (4 places) Use four MBG 4 × 10 conic screws to attach the top cover to the baseplate (Figure 61). Install the HVPS front cover. Figure 62 Connecting the cables to the HVPS WARNING 24VDC...
Page 80: Install System Components
Installation Manual Install system components For each printing engine, unpack the section and perform the following: Install the PTE/air knife. Install the scorotron units. Install the cleaning station and wiper blade. Install the ITM cover. Thoroughly clean the BID units with imaging oil and a lint-free cloth. Install the BID units.
Page 81: Installing The Ilp
Installation Manual Installing the ILP Figure 63 ILP rollers Inner station duplex primer No. 5 (DP5) Lower drive roller Idler No. 5 Lower nip roller Outer station simplex primer No. 5 (SP5) Lower buffer roller Outer station simplex primer No. 4 (SP4) Inner station duplex primer No.
Page 82: Figure 64 Distinguishing The Ilp Feed And Exit Stepping Plate Assemblies
Installation Manual Idler No. 14 Inner station duplex primer No. 3 (DP3) Idler No. 15 Inner station duplex primer No. 4 (DP4) Idler No. 12 Idler No. 6 Idler No. 11 The following ILP installation procedure is performed (Figure 63): Install the exit stepping plate.
Page 83: Figure 65 Mounting The Ilp Stepping Plate Assemblies On The Ilp
Installation Manual NOTE: Both stepping plate assemblies are secured to the ILP. They are not identical. The ILP exit-side stepping plate assembly has four mounting holes for the ILP exit cover. The ILP input- side stepping plate assembly does not have these holes. See Figure 64.
Page 84: Figure 66 Installing The Stepping Plates To The Ilp
Installation Manual Figure 66 Installing the stepping plates to the ILP ILP EXIT EXIT STEPPING PLATE ASSEMBLY Lower bracket Upper securing screw Lower securing screws Upper frame Stepping plate assembly Upper securing screw Install the exit stepping plate assembly to the ILP using four Allen M5 screws, washers, and spring washers (Figure 66).
Page 85: Figure 67 Installing The Ilp Exit Cover On The Exit-Side Stepping Plate Assembly
Installation Manual Figure 67 Installing the ILP exit cover on the exit-side stepping plate assembly Exit cover Exit-side stepping plate assembly Mount the ILP exit cover on the ILP exit-side stepping plate assembly (Figure 67). NOTE: Make sure that the PE1 web entrance cover is installed before proceeding with the ILP alignment.
Page 86: Figure 68 Positioning The Ilp Next To Pe1
Installation Manual Figure 68 Positioning the ILP next to PE1 4 - 5 mm At the PE1 feed Mount the cover on the end of the ILP exit stepping plate assembly (Figure 67). Push the cover mounting studs in the holes at the exit end. To align the ILP and stepping plate assembly with the press (Figure 68): Move the ILP closer to the PE1 feed.
Page 87: Figure 69 Aligning The Stepping Plate To The Pe1 Front Wall
Installation Manual Figure 69 Aligning the stepping plate to the PE1 front wall Exit-side stepping plate PE1 chassis 30 mm from straight edge to PE1 chassis Remove the cover. Place aside temporarily. Align the center of the stepping plate rollers with the PE1 input rollers. Remount the ILP exit cover.
Page 88: Figure 70 Unlocking The Ilp Alignment Plates
Installation Manual At the ILP exit stepping plate assembly Adjust the stepping plate gas spring arm so that the plate lifts without touching the ILP exit side (Figure 64). Figure 70 Unlocking the ILP alignment plates Alignment plate locking screws (x6) Open the front and rear ILP doors.
Page 89: Figure 71 Leveling And Aligning The Ilp
Installation Manual Figure 71 Leveling and aligning the ILP W3250_ILD_ALIGNMENT_2971 ILP external frame Securing nut Feed pull screw (similar at exit) ILP internal frame Feed push screw (similar at exit) ILP frame securing screw ILP internal frame ILP external frame ILP rear foot Position of ILP front frame securing screws ILP feed stepping plate assembly...
Page 90: Figure 72 Adjust The Ilp Feet Height
Installation Manual Figure 72 Adjust the ILP feet height ILP feet Stepping plate assembly feet (shown raised; 2 each assy) Use a 20 mm wrench to release the upper nut securing the lower height adjustment nut (Figure 72). Turn the 20 mm height adjustment nut clockwise to lower the feet until the ILP wheels are just raised by 2-3 mm.
Page 91: Figure 73 Leveling The Ilp
Installation Manual Figure 73 Leveling the ILP ILP feed frame Leveler Place a leveler at the feed and exit frames and measure the deviation from true level (Figure 73). Measure the level to an accuracy of 0.0 ± 0.1 mm. Repeat step d above at the exit ILP.
Page 92: Figure 74 Leveling The Ilp At The Rollers
Installation Manual Figure 74 Leveling the ILP at the rollers ILP idler No.3 Leveler Roller securing jig At the ILP feed Mount the roller securing jig on the idler No.3. Make sure that the roller is secure. Place the level on the roller. While one person measures the level at idler No.
Page 93: Figure 75 Aligning The Pe1 And Ilp Using The Parallel Jig
Installation Manual At the ILP feed While one person places a leveler on the idler No. 3 (Figure 75), and then idler No. 10 (Figure 63), another person should adjust the pull/push screws at the feed and exit of the rear lower frame: Turn the push screw counterclockwise to release the internal frame.
Page 94: Figure 76 Aligning The Ilp Feed Stepping Plate Rollers
Installation Manual Place the Parallel jig (P/N CA045-07192) between the PE1 drive roller and the ILP Idler No. 10 (Figure 75). Move the Parallel jig from front (of press) to rear and back to front (Figure 75). Make sure that the difference in distance between PE1 and ILP at both the front and rear of the press, between the parallel jig readings is 0.00 ±0.01 mm.
Page 95: Figure 77 Aligning The Ilp Feed Stepping Plate Rollers - Between Stepping Plate Rollers
Installation Manual Tighten the front and rear adjustment bracket locking screws. Figure 77 Aligning the ILP feed stepping plate rollers - between stepping plate rollers Stepping plate roller (previously aligned and Stepping plate roller (to be aligned and leveled) leveled) Parallel jig (shortened) Allen M5 rear adjustment bracket locking screw...
Page 96 Installation Manual Tighten the front and rear adjustment bracket locking screws (Figure 77). Install the ILP feed stepping plate between the Unwinder position and the ILP as described in step 2 on page 83. Repeat step 4 on page 86 to align the ILP feed stepping plate rollers. Repeat step 12 on page 94 to level the ILP feed stepping plate rollers.
Page 97: Installing The Ilp Web Rollers
Installation Manual Installing the ILP web rollers Figure 78 The priming unit rollers - position in the ILP Priming unit Simplex station Duplex station Simplex priming roller 5, SP5 (impression roller) Duplex priming roller 1, SP1 (reservoir roller) Simplex priming roller 4, SP4 (upper rubber Duplex priming roller 2, SP2 (lower rubber roller) roller) Simplex priming roller 3, SP3 (intermediate...
Page 98: Figure 79 Identifying The Rollers
Installation Manual Figure 79 Identifying the rollers SP1 or DP1 steel roller with ends recessed SP4 or DP4 rubber roller with a narrow priming surface SP2 or DP2 rubber roller with a wide priming SP5 or DP5 steel roller surface SP3 or DP3 steel roller The installation for the inner and outer station rollers is similar.
Page 99: Figure 80 Installing The Priming Rollers - Outer And Inner Stations
Installation Manual Figure 80 Installing the priming rollers - outer and inner stations Clamp SP2 or DP2 rubber roller Bearing SP4 or DP4 rubber roller To install the priming rollers (Figure 80): Open the ILP feed door. Remove the outer station priming roller mount clamps. Place them aside on a flat clean surface.
Page 100: Installing The Unwinder
Installation Manual Installing the unwinder Positioning the unwinder Place the unwinder on the floor platform at the input side of the ILP. Figure 81 Moving the unwinder into its final position Unwinder v6 Pallet jack Use a pallet jack to move the unwinder into position near the input side of the ILP to a distance of between 30 - 40 cm from the ILP feed stepping plate assembly.
Page 101: Figure 82 Leveling The Unwinder
Installation Manual Position the unwinder so that the front surface of the unwinder is approximately 215 mm in front of the front surface of the stepping plate assembly. Align the center of the ILP rollers with the center of the unwinder rollers. Figure 82 Leveling the unwinder Leveler Unwinder...
Page 102: Figure 83 Checking The Level At The Unwinder Exit
Installation Manual Figure 83 Checking the level at the unwinder exit Unwinder exit panel ILP feed stepping plate assembly Leveler Unwinder Unwinder exit upper roller At the unwinder exit Secure the two unwinder exit rollers by tighten the screws securing the unwinder exit panel (Figure 83).
Page 103: Figure 84 Aligning The Unwinder With The Ilp Feed Stepping Plate Assembly
Installation Manual Figure 84 Aligning the unwinder with the ILP feed stepping plate assembly Unwinder exit upper roller Stepping plate roller Parallel jig Parallel jig dial bracket To align the unwinder with the ILP feed stepping plate assembly (Figure 84): Adjust the length of the Parallel jig to measure the variation in distance between the unwinder exit upper roller and the stepping plate roller shown in Figure 84.
Page 104: Unwinder Electrical Connections
Installation Manual Figure 85 Aligning the unwinder with the ILP Top unwinder exit roller ILP input idler No.3 Unwinder v6.0 Parallel jig Reconfigure the Parallel jig to align the unwinder with the ILP. Mount the Parallel jig between the ILP input idler No. 3 (Figure 63-8, Figure 85) and the top unwinder exit roller as shown in Figure 85.
Page 105: Ilp Electrical Connections
Installation Manual Connect the interface cable (P/N GW Art. NR.8110.00361) to X4 in the unwinder electronics compartment. Connect the other end to JX66 in electrical cabinet M1. ILP electrical connections Install the following cables between the ILP connections panel and cabinet M1: End point Cable Origination point ILP...
Page 106: Figure 86 Install Cable Securing Clamps At The Ilp
Installation Manual Cable end point Origination point Notes Inlet hose from air valve Main compressor pump outlet. at wall. Outlet hose to unwinder ILP compressor pump. Figure 86 Install cable securing clamps at the ILP Rear inner ILP Securing clamps Cables from ILP assemblies to cabinet M1 ILP rear panel and PE1...
Page 107: Figure 87 Ilp Rear Connection Panel
Installation Manual Figure 87 ILP rear connection panel Rear ILP Cable securing panel Top Allen M3 securing screw Securing screw Securing screw Top Allen M3 securing screw ILP rear panel Make sure that the connections to the ILP appear as shown in Figure 87: Slide the cable securing panel on top of the cables and tighten the two securing screws.
Page 108: Connect The Air Supply
Installation Manual Connect the air supply NOTE: All air supply hoses are to be routed appropriately under the floor platform. Figure 88 Connection the air supply at the ILP ILP front Air outlet to PE connection Air Input connection Air outlet to unwinder At the ILP front Connect the following air hoses at the ILP front: Input hose from mains air supply to Inlet connection.
Page 109: Figure 89 Routing The Air Hose From The Ilp
Installation Manual Figure 89 Routing the air hose from the ILP Air hoses PE2 ILD air pressure dial PE1 air manifold PE1 ILD air pressure dial PE2 air manifold Route the Outlet to the PE1 air supply manifold as follows (Figure 89): Around the back of the ILP Under the PE1 to the front of the engine air manifold CA294-03070 rev 00...
Page 110: Figure 90 Routing And Connecting The Air Hoses At Pe1 And Pe2
Installation Manual Figure 90 Routing and connecting the air hoses at PE1 and PE2 Air input from ILP Web guide air pressure dial T-junction ILD air pressure dial Air output to PE2 Web guide air input connection V-junction adapter Air manifold At the PE1 air manifold Install the hose to the PE1 air manifold (Figure 90): Fit a T-junction to the end of the hose.
Page 111: Figure 91 Installing The Safety Cover On The Ilp Rear Panel
Installation Manual Insert the air hose from the PE2 engine to the parallel outlet of the T-junction. Route the hose to the PE2 air manifold. Insert two short hoses to the v-junction adapter and route the hoses as follows: To the input at the ILD dial regulator To the PE1 air manifold rear input to the Web Guide At the PE2 air manifold Repeat step 3 above at the PE2 engine.
Page 112: Install The Ilp Vacuum Hoses
Installation Manual Install the ILP vacuum hoses Figure 92 Routing the vacuum hose to the ILP W3250_ILD_VACUUMHOSE_8363 ILP vacuum hose Hose securing band ILP vacuum hose adapter Install the ILP vacuum hose adaptor to the ILP using four screws (Figure 92). Route the hose connected to the lower blower in electrical cabinet M1 to the vacuum hose connection at the rear of the ILP (Figure 92).
Page 113: Installing The Ink Cabinets
Installation Manual Installing the ink cabinets Figure 93 The 4-color configuration – front view INK_FRONT-1 Figure 94 The 7-color configuration – front view CA294-03070 rev 00 page 113 of 153...
Page 114: Figure 95 The Ink Cabinet - Rear View
Installation Manual Figure 95 The ink cabinet – rear view IN OUT Screws for securing the working surface Cooling water OUTPUT J21 - not in use Cooling water INPUT Imaging oil add J31 - Not in Use Grounding cable Guard bracket Install each ink cabinet as follows: Fill the ink tanks with imaging oil and install the ink pumps.
Page 115: Figure 96 Mapping The Bid Hoses From The Ink Cabinet To The Bids
Installation Manual Remove the outer screw securing the guard bracket, and turn the bracket counterclockwise to expose the cooling water connections (Figure 95). Connect the two cooling water hoses to the ink cabinet (Figure 95). Connect the black plastic imaging oil tube to the ink cabinet (Figure 95). Connect the solid add compressed air tube to the ink cabinet (Figure 95).
Page 116: Adjusting The Web Guide
Transport screws in post-installation position Original position of transport screws Remove the transport securing screws (Figure 97-2). Insert the transport screws to their post-installation position. Adjust the web guide. See HP Indigo Service Instruction Calibrations, MNU-1633-01. CA294-03070 rev 00 page 116 of 153...
Page 117: Install The Utility Cabinet
Installation Manual Install the utility cabinet For each utility cabinet Mount and install the top cover on the utility cabinet. Figure 98 Hinging the utility cabinet to the printing engine BLR-CAB Printing engine Cooling water from chiller Utility cabinet Cooling water to chiller Hinge Move the cabinet into position, and connect the lower hinge (Figure 98).
Page 118: Figure 99 Connecting The Utility Cabinet To The Printing Engine
Installation Manual Figure 99 Connecting the utility cabinet to the printing engine OUTLET INLET SOLID ADD POWER CONTROL COMP AIR CABLE CABLE OUTLET INLET HOSE HOSE Connect the following hoses from the utility cabinet to the printing engine (Figure 99): •...
Page 119: Figure 100 Closing The Utility Cabinet On The Sealing Gasket
Installation Manual Figure 100 Closing the utility cabinet on the sealing gasket VOC-484ng Sealing gasket Utility cabinet Carefully close the utility cabinet. The utility cabinet should close smoothly and press against the sealing gasket to create a proper seal (Figure 100). CA294-03070 rev 00 page 119 of 153...
Page 120: Figure 101 Adjusting The Height Of The Utility Cabinet
Installation Manual Figure 101 Adjusting the height of the utility cabinet VOC-429 Locking nut Adjusting nut If the utility cabinet does not seal properly with the gasket, adjust the castors as necessary to create the seal and align the unit with the printing engine (Figure 101). Install the utility cabinet top cover.
Page 121: Connect The Computers
Installation Manual Connect the computers Figure 102 The network configuration POPI POPI POPI POPI WHIF WHIF 192.168.101.14 192.168.101.13 192.168.101.23 192.168.101.24 Switch Switch Slave 2 Slave 1 On Board ON BOARD 192.168.101.22 192.168.101.12 To Slave 2 To Diva Master 192.168.112.1 Cross 192.168.111.2 Cross To Diva Master...
Page 122: Figure 104 Identifying The Slave Computer Connections
Installation Manual Figure 104 Identifying the slave computer connections HP C ompute r xw42 00-5 000 Customer LAN Mouse VCORN III Power COM 2 port Keyboard VGA graphics (monitor) COM 1 port Internal LAN USB ports Audio out RIP server LAN...
Page 123: Figure 105 Mounting The Slave Computer And Switchbox In Electrical Cabinet M2
Installation Manual Figure 105 Mounting the slave computer and switchbox in electrical cabinet M2 Mouse and keyboard connections Software dongle (master computer only) Monitor connection Writing head J10 RS-232 G-Link connector Switchbox Computer shelf Modem connection External LAN connection On-board network connection Audio connection COM 1 connection COM 2 connection...
Page 124: Figure 106 Connecting A Slave Computer To Its Printing Engine
Installation Manual Figure 106 Connecting a slave computer to its printing engine MON_CABLES Keyboard cable Mouse cable Monitor video cable Monitor power supply cable Audio cable Monitor power supply unit Connector bracket Each printing engine is connected to a networked computer, which is installed in electrical cabinet M2. Each computer acts as a slave within the internal network of the press.
Page 125 Installation Manual Route and connect the following cables to the slave 1 computer: Cable From end point To end point CC45 PE1 ECN POP-I J4 RJ45 connection Electrical cabinet M2 slave 1 PC switchbox J3 connection Connection to 3X on switchbox CC46 PE1 writing head J11 LAN RJ45 Electrical cabinet M2 slave 1 switchbox...
Page 126 Installation Manual Cable From end point To end point CC44 PE2 ECN POP-I J7 connection Electrical cabinet M2 slave 2 PC COM1 port (Figure 103 – 11) CC47 PE2 writing head POP-I J10 RS232 Electrical cabinet M2 slave 2 PC cable connection COM2 port (Figure 103 –...
Page 127: Install The Master Console
Installation Manual Install the master console Figure 107 Connecting the master console computer Computer side frame release screw SCSI connection port Computer frame lock USB connection port Mouse connection Sound card connections Onboard Intel network connection to COM 2 port customer network Monitor connection LPT1 and dongle connection port...
Page 128: Connecting The Master Computer
Installation Manual Connecting the master computer Connect the following cables to the computer (Figure 107): Port Master console cable Slave 1 cable Slave 2 cable Keyboard CC52 CC52 CC52 Mouse CC53 CC53 CC53 COM1 RS232 cable- to UPS CC44 CC44 COM2 CC47 CC47...
Page 129 Installation Manual CC68 RJ45 from the WHS PLC 53A3 to J6 W190 from the onboard Ethernet at master PC to J5 Connect the gray X54 power enable/emergency stop cable from electrical cabinet M1 as follows: One connector to the power enable switch connector inside the master console cabinet at CC439.
Page 130: Production Flow
Installation Manual Production flow Organize in conjunction with the customer administrator the installation and connection of the following: • RIP systems • HPPF units • Cables and network Install the finishing components Install the Rewinder jig to test the operation of the press. When completed perform the finisher installation according to the customers design and Site Preparation Guide.
Page 131: Initial Power-Up
Installation Manual Initial power-up Initial web handling system power-up tests CAUTION: A qualified and certified local electrician should verify the following: Correct power up voltage and current for the press as described in the customer’s site preparation guide. Earth continuity at the electrical cabinets and the press.
Page 132: Figure 109 Switching The Ups On
Installation Manual Figure 109 switching the UPS on Power button At each UPS, to switch the UPS units on: Make sure that the relevant cables are connected to the two UPS systems. Switch the UPS on at the rear switch. Turn on the input breaker switch shown in Figure 109.
Page 133 Installation Manual Proc. Electrical cabinet M1 Notes Switch the following circuit breakers and power isolators ON: 22Q5 22Q3 26F1 Switch the following circuit breakers ON: Make sure that the LEDs at the front of the Mains Cabinet M1 15F1 remain lit. 15F3 15F1.1 15F3.1...
Page 134 Installation Manual Proc. Electrical cabinet M1 Notes At the unwinder Close all doors and Covers and make sure that the Control on button works correctly Check the Unidrive connections at 24F1- 29F1 Make sure that the Boards are inserted correctly Check the Unidrive connections at 24U0 Make sure that the Boards are inserted correctly Make sure that the Unidrives turn on...
Page 135 Installation Manual Proc. Electrical cabinet M1 Notes Turn the writing head main power on. Proc. Printing Engine 1 (PE1) Notes Inside the PFU, turn the following on: Fan on EMR on Green LED lit CBR1.1 CBS1.1 CBR2.2 CBTS CBT0.1 CBT1.1 CBT1.2 Motor driver red LED lit CBT0.3...
Page 136: Emergency Stop Tests
Installation Manual Important: Before beginning the next section of tests, make sure that the following cables are connected to the in-line finisher interface cables: Cable CC71 from the printing engine 2 junction box to the interface cable from the inline finisher. Cable 261 10180 from the cabinet M1 X52/53 interlock cable to the interface interlock cable from the finisher.
Page 137 Installation Manual Release the emergency stop button at the Hunkeler finishing unit. IMPORTANT: Before beginning the following tests, make sure that the following cables are connected to the in- line finisher interface cables: Cable CC71 from the PE2 junction box to the interface cable from the inline finisher.
Page 138: Threading The Web
Installation Manual Threading the web Figure 110 The web feed system Unwinder ILP (web routed through primer and web guide sections) Web handling system for PE1 Turnbar Web handling system for PE2 Finishing system (dependent on customer choice) Output assembly Input assembly Output assembly Input assembly...
Page 139: Configure The Press Software
To configure HP IndigoServe, see HP Indigo Service Instruction HP IndigoServe 2.0 (P/N CA293-01270). Configuring Norton anti virus To configure the anti-virus for daily updates and file scans, see HP Indigo Service Instruction Norton anti virus 8.1 (P/N CA293-00660). Install PIP and blankets For the PE1 and PE2 Install PIP and blankets to the PIP and IMP drums.
Page 140 Installation Manual Press the Emergency Stop button at the Hunkeler finishing unit, and verify that all the following occur: At the press MMI and Hunkeler finishing unit touchscreen panels, the touchscreen panels display that the units are switched to the OFF/ Stopped status. At electrical cabinet M1, all LEDs of relays 33K0, 33K2 33K3, 33K5 and M1K1 should be OFF.
Page 141 Installation Manual At the ILP touchscreen, feed the web through the press with priming as follows: Press RUN. After the light goes off, press RUN again. The system initializes including the filling up of the priming trays and the engage and rotation of the priming rollers.
Page 142 Installation Manual Click On Engage and Disengage and make sure that the scorotron moves smoothly up and down Fans Air Suction should be always ON and the ITM suction fan should be working Click ON Feed Fan and make sure that the input air fan is working Click ON Exit Suction and make sure that the exit air knife is working Main Motor...
Page 143 Ensure that the eye mark sensor lateral positioning is accomplished before performing the eye mark distance to nip adjustment. Perform the eye mark distance to nip adjustment. See HP Indigo Service Instruction Calibrations, MNU-1633-01. Make sure that the substrate is centered at PE1. Print and check.
Page 144 Installation Manual The Color Adjustment Wizard Manager window opens. In the Automatic Color Adjustment area, click Custom Color Adjustment. The Custom Color Adjustment wizard opens. Select the desired matrix. In the Electrode Voltage Calibration field, select Include Velectrode Calibration. Click Next. The OD step opens. In the Select Method of Substrate OD Usage field, select Read Substrate OD.
Page 145: Customer Acceptance Test Procedure (Catp)
Installation Manual Enter the optical density values noted in step l above in the appropriate color fields. Click OK. A warning may appear. Click OK to close the warning. In the wizard, complete the wizard steps. Make sure that the color calibration is completed successfully. From the Diagnostics menu, click Writing Head.
Page 146 If the print test quality is uncertain, compare it to the reference master CATP job. CATP qualification procedure Load the CATP job and print duplex images using the customer substrate (per HP Indigo qualifications) according to the following table: Repeat...
Page 147: Catp Specification Checklist
Installation Manual Use Run no. 1 prints to evaluate the quality of 10 successive printed copies according to the CATP described in "CATP specification checklist" on page 147. All the tests should be related to Run no. 1. It is specified in the test if related to another run. Use Run no.
Page 148 Installation Manual Item Description Pass/Fail/Waiver Registration In order to check the Registration between separations, look at the lines above and next to the three cross marks (D, D1, & U) on the left border, and the three parallel cross marks on the right border. Each of the lines is composed of 4 colors.
Page 149 Installation Manual Item Description Pass/Fail/Waiver Overdraft Visually check that there is no severe overdraft, smearing, or fog below each of the seven lines. Compare to the reference master CATP job. White overdraft check The colored row consists of white text on color. The text row consists of colored text on white background.
Page 150: Complete The Installation
Close/reinstall all open panels, doors, and covers. NOTE: An envelope in the System Information File contains the interlock bypass keys for the HP Indigo press w3250. WARNING: These keys may be used only by authorized service personnel when required for servicing and maintenance procedures.
Page 151: Appendix A: Image Placement Parameters
Installation Manual Appendix A: Image placement parameters Figure 111 The image placement parameters Value Designation Image length Image width Repeat length Skew Side position Leading edge marks Trailing CA294-03070 rev 00 page 151 of 153...
Page 152 HP Indigo Division Installation Feedback Complete this form immediately after installation, fax it to the address below, and file it in the press logbook. Att: Technical Marketing Ronen Yaniv Hewlett-Packard Company, Indigo Division Fax: +972-8-938-5517 e-mail Ronen.Yaniv@hp.com Use e-mail if fax unavailable.
Page 153: Revision History
Revision history Revision Description Initial document Responsible engineer Ronen Yaniv Group manager Aaron Lubelski Product engineering manager Documentation manager Ronit Shugal Configuration control Charles Margy Written by Gershon Levy Confidentiality Notice This document contains valuable trade secrets and confidential information of Hewlett-Packard Company. Nothing herein may be copied, reproduced or distributed in any form or medium, or disclosed to any third party in any manner, without prior written authorization of Hewlett-Packard Company.

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