HP Indigo Division, w3250 Instruction For Use & Installation Instructions

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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

Scope

Document number

Kit number

Date

Related ECO

Security level

Modification available - performance/ Modification available reliability

HP Indigo press w3250

CA294-03070

As per press

13 Feb 07

N/A

HP confidential

Contents

Installation instruction details ...................................................................................................................1

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 page 1 of 153

Installation Manual

Securing the turnbar..........................................................................................................................54

Electrical cabling ...............................................................................................................................58

Installing the vacuum hoses..............................................................................................................70

Install the floor platform.....................................................................................................................72

Installing the chiller and cooling water hoses....................................................................................72

Install the UPS...................................................................................................................................75

Install the writing head.......................................................................................................................76

Install the HVPS (High Voltage Power Supply).................................................................................77

Install the roof covers ........................................................................................................................79

Install system components................................................................................................................80

Unpacking the ILP, unwinder, utility cabinets, and ink cabinets .......................................................80

Installing the ILP................................................................................................................................81

Installing the ILP web rollers .............................................................................................................97

Installing the unwinder.....................................................................................................................100

Unwinder electrical connections......................................................................................................104

ILP electrical connections................................................................................................................105

Connect the air supply.....................................................................................................................108

Install the ILP vacuum hoses ..........................................................................................................112

Installing the ink cabinets ................................................................................................................113

Adjusting the web guide ..................................................................................................................116

Install the utility cabinet ...................................................................................................................117

Connect the computers ...................................................................................................................121

Install the master console ...............................................................................................................127

Connecting the master computer ....................................................................................................128

Production flow................................................................................................................................130

Install the finishing components ......................................................................................................130

Installing the turnbar stepping plate ................................................................................................130

Install the main power connection and transformer ........................................................................130

Initial power-up ................................................................................................................................131

Emergency stop tests......................................................................................................................136

Threading the web...........................................................................................................................138

Configure the press software ..........................................................................................................139

Install PIP and blankets...................................................................................................................139

Testing and calibrating the press ....................................................................................................139

Customer acceptance test procedure (CATP) ................................................................................145

CATP specification checklist ...........................................................................................................147

Complete the installation.................................................................................................................150

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

Figure 6 Mounting the dial bracket on the extension..........................................................................22

Figure 7 Positioning the u-bases ........................................................................................................25

Figure 8 Remounting the u-base slip plates .......................................................................................26

Figure 9 Adjusting the u-base height..................................................................................................27

Figure 10 Placing the foresight on the PE2 u-base ............................................................................28

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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

Figure 19 Positioning the link bar under the exit side of the engine - view from rear.........................36

Figure 20 Positioning the lifting frames against the engine................................................................37

Figure 21 Leveling pad .......................................................................................................................38

Figure 22 Placing the leveling pads on the u-base.............................................................................38

Figure 23 Moving the raised engine to the u-base .............................................................................39

Figure 24 Press positioned over u-base .............................................................................................40

Figure 25 Lowering the engine on to the u-base and leveling pads...................................................41

Figure 26 Engine mounted on the u-base ..........................................................................................42

Figure 27 Final position of printing engine on u-base.........................................................................43

Figure 28 Identifying the turnbar components ....................................................................................44

Figure 29 Inserting the turnbar into the exit side of PE2 ....................................................................45

Figure 30 Using a level at the printing engine front ............................................................................46

Figure 31 Leveling at the printing engine input – PE2 shown ............................................................47

Figure 32 Mounting an alignment jig on the ITM end cap ..................................................................48

Figure 33 Aligning the printing engines - alignment jigs.....................................................................50

Figure 34 Identifying the u-base adjustment screws ..........................................................................51

Figure 35 Aligning the surveying tool crosshairs and sights ..............................................................51

Figure 36 Measuring the parallelism between rollers of opposing printing engines...........................52

Figure 37 The link brackets ................................................................................................................53

Figure 38 Mounting the front link bracket ...........................................................................................53

Figure 39 Inserting the rear connection bracket .................................................................................54

Figure 40 Securing the front connection bracket and input idler ........................................................55

Figure 41 Securing the rear connection bracket and input idler.........................................................56

Figure 42 Connecting the main electrical power in the electrical cabinet...........................................58

Figure 43 Securing the electrical cabinet cables ................................................................................59

Figure 44 Components of electrical cabinet M1 .................................................................................60

Figure 45 Components of electrical cabinet M2 .................................................................................61

Figure 46 The Unidrive assembly and components ...........................................................................65

Figure 47 The Unidrive unit ................................................................................................................66

Figure 48 Electrical cabinet M1 PLC, MPI, and Profibus connections ...............................................68

Figure 49 Routing the MPI (MODBUS) cable.....................................................................................69

Figure 50 Installing the vacuum hoses and adaptors .........................................................................70

Figure 51 Routing vacuum hoses to PE1 ...........................................................................................71

Figure 52 Routing vacuum hoses to PE2 ...........................................................................................72

Figure 53 Chiller pipe routing (Europe)...............................................................................................73

Figure 54 Chiller pipe routing (Japan) ................................................................................................74

Figure 55 The rear UPS panel............................................................................................................75

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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

Figure 65 Mounting the ILP stepping plate assemblies on the ILP ....................................................83

Figure 66 Installing the stepping plates to the ILP..............................................................................84

Figure 67 Installing the ILP exit cover on the exit-side stepping plate assembly ...............................85

Figure 68 Positioning the ILP next to PE1..........................................................................................86

Figure 69 Aligning the stepping plate to the PE1 front wall................................................................87

Figure 70 Unlocking the ILP alignment plates ....................................................................................88

Figure 71 Leveling and aligning the ILP ............................................................................................89

Figure 72 Adjust the ILP feet height ...................................................................................................90

Figure 73 Leveling the ILP..................................................................................................................91

Figure 74 Leveling the ILP at the rollers.............................................................................................92

Figure 75 Aligning the PE1 and ILP using the Parallel jig ..................................................................93

Figure 76 Aligning the ILP feed stepping plate rollers........................................................................94

Figure 77 Aligning the ILP feed stepping plate rollers - between stepping plate rollers.....................95

Figure 78 The priming unit rollers - position in the ILP .......................................................................97

Figure 79 Identifying the rollers ..........................................................................................................98

Figure 80 Installing the priming rollers - outer and inner stations.......................................................99

Figure 81 Moving the unwinder into its final position........................................................................100

Figure 82 Leveling the unwinder.......................................................................................................101

Figure 83 Checking the level at the unwinder exit............................................................................102

Figure 84 Aligning the unwinder with the ILP feed stepping plate assembly ...................................103

Figure 85 Aligning the unwinder with the ILP ...................................................................................104

Figure 86 Install cable securing clamps at the ILP ...........................................................................106

Figure 87 ILP rear connection panel.................................................................................................107

Figure 88 Connection the air supply at the ILP ................................................................................108

Figure 89 Routing the air hose from the ILP.....................................................................................109

Figure 90 Routing and connecting the air hoses at PE1 and PE2 ...................................................110

Figure 91 Installing the safety cover on the ILP rear panel ..............................................................111

Figure 92 Routing the vacuum hose to the ILP ................................................................................112

Figure 93 The 4-color configuration – front view ..............................................................................113

Figure 94 The 7-color configuration – front view ..............................................................................113

Figure 95 The ink cabinet – rear view...............................................................................................114

Figure 96 Mapping the BID hoses from the ink cabinet to the BIDs.................................................115

Figure 97 Removing the transport securing screws ..........................................................................116

Figure 98 Hinging the utility cabinet to the printing engine...............................................................117

Figure 99 Connecting the utility cabinet to the printing engine.........................................................118

Figure 100 Closing the utility cabinet on the sealing gasket ............................................................119

CA294-03070 rev 00 page 4 of 153

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

Figure 109 switching the UPS on .....................................................................................................132

Figure 110 The web feed system .....................................................................................................138

Figure 111 The image placement parameters..................................................................................151

CA294-03070 rev 00 page 5 of 153

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

• Install the printing engines and turnbar

• Install the In-Line Primer (ILP)

• Installing the unwinder

• Install the main electrical cabling

• Install the slave computers and switchboxes

• Install the printing engine vacuum hoses

• Install the cooling water hoses

• Install the floor platform

• Install system components such as ink cabinets, utility cabinets, and writing heads

• Install the master console and computer

• Powering up the press

• Installing the system electrical cabling

• Configuring the press software

• Testing and calibrating press systems

• Performing CATP

CA294-03070 rev 00 page 6 of 153

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. The engineer should obtain the manual prior to the installation of the press.

CAUTION: The HP Indigo press w3250 printing engines,

unwinder and rewinder may be lifted or transported only by specially trained and qualified personnel using lifting bars, lifting straps, and other specialized equipment that meet HP Indigo specifications as well as any additional requirements imposed by central and local government regulations.

Improper lifting may cause serious personal injury

and/or damage to the press or other property.

Do not lift the printing engines (PE) from the paper

input or paper exit side.

When lowering the printing engines from the fork

lift, place wedges on the floor in front of the wheels to prevent slipping.

The press must be hard connected to the mains by a qualified local electrician in accordance with local safety regulations. The connection must be through a lockable mains supply disconnect switch rated at 32 A 5000 AIC type G. The cables must be protected by a conduit.

CA294-03070 rev 00 page 7 of 153

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

Heading

Reference Procedure

1st Day

Pre-installation

Site preparation

Measuring and marking

Unpacking 3. Unpacking the boxes

Installation

Electric cabinets

(20 mins)

U-bases

(40 mins)

Printing engines

(160 mins)

1. Verifying site preparation on page 23

2. Marking the pressroom floor on

e 23

pag

on page 23

4. Installing the electrical cabinets on pag

e 24

5. Position the u-bases on page 24

6. Position the foresight stand on page 28

7. Install the junction bars on page 32

8. Mount the PE2 on page 33

9. install the platform on page 43

10. Mounting the turnbar on page 44

11. Mounting the PE1 on page 45

12. level each printing engine on page 46

13. align the printing engines on page 49

14. Securing the turnbar on page 54

15. connect the printing

ines on page 56

eng

y site preparation as per Site

Verif Preparation Guide

Use marker pen to mark profile of press, cabinets, unwinder, ILP and Finisher on floor

Unp

ack the boxes and verify their contents

either with the BOM or Packing list on page

17.

Install electrical cabinet M1 and M2 in their marked position.

n the u-bases on the floor. Adjust

Positio distance between u-bases to 693.0 mm at a height of 200 mm. from the floor.

Use surve accurately. Raise the tripod and surveying tool to 1550.0 mm.

Install the junction bars between the two ubases.

Mount the PE2 on the u-base. Use the lifting and positioning assembly.

Install the platform between the printing engines.

Mount the turn

Mount the PE1 on the u-base. Use the lifting and positioning assembly.

Leve of 0.0 ± 0.1 mm

Accuratel horizontally using the surveying tool.

Mount the front brackets on the extended shaft of idler 3.

Install using M5 screws at front and rear. Install collar on idler at rear.

Recheck the alignment using the surveying tool.

Install front link Recheck alignment using surveying tool. Check parallelism between PEs using the parallel jig. Measure to an accuracy of

0.00 ± 0.01 mm

ying tool to align u-bases

bar assembly to PE1.

l each printing engine to an accuracy

y align the printing engines

and rear connection

brackets to attach two PEs.

Notes and check

Site Preparation check list

Marker pen

Cable meter

Packing list

Packed with PE2

CA294-03070 rev 00 page 8 of 153

Installation Manual

Step

Heading

Electrical wiring

(180 mins)

Vacuum hoses

(40 mins)

Reference Procedure

16. Install the electrical cabinet-to-cabinet cables on page 61

17. Install the electrical cabinet M1 cables to PE1, PE2 on page 62

18. Install the electrical cabinet M2 to PE1, PE2 on page 62

19. Install the electrical cabinet M1-to-master console cables on

e 63

pag

20. Install all Unidrive cables on page 66

21. Install the PE1-toPE2 cables on page 67

22. Install the PROFIBUS cables as on page 67

23. Install the CTNET cables on page 68

24. Route the MPI (MODBUS) cables on pag

e 69

25. Connect the ProfiBus and CT

Net cable connections on page 69

26. Installing the vacuum hoses on page 70

2nd Day

Floor platform 27. Install the floor

platform on page 72

Install electrical cabinet M2 to cabinet M1 cabling.

Install electrical cabinet M1 to cabinet M2 cabling.

Install electrical cabinet M1 to PE1 and PE2.

Install electrical cabinet M2 to PE1 and PE2.

Install the electrical cabinet M1-to-master console cables.

Leave the cables ends at the cabinet until installation of the raised floor and master console.

Install al electrical cabinets M1 and M2.

Install the PE1-

Install ProfiBus between electrical cabinets M1 and M2 and PLC in cabinet M1.

Install CT at electrical cabinets M1 and M2.

Route the MPI (MODBUS) cable through the ILP connection panel to the front of PE1 and connect JTBD of the cable to PTBD of the TBD.

Route the remaining connector JTBD to the exit are of PE2 and connect it to PTBD of the TBD.

Con cable connections at electrical cabinets M1 and M2

Remov

Install and route all vacuum hoses from electrical cabinets M1 and M2 to PE1, PE2 (short hoses 2-3 m), and ILP.

Wait for the raised floor and ILP to install long hose (3-4 m).

Reinstall lower under-panel

Install floor p specifications in Site Preparation Guide.

Start at unwinder and ILP area. For press, start at corners of press or wall.

l PE1 and PE2 Unidrive cables in

to-PE2 cables.

communication cable

Net cables between all Unidrives

nect the following ProfiBus and CTNet

e under-panel

latform according to

Notes and check

Wait for floor and ILP to connect.

CA294-03070 rev 00 page 9 of 153

Installation Manual

Heading

Chiller and chiller pipes

(60 mins)

UPS

(10 mins)

Writing head

(30 mins)

HVPS

(40 mins)

Roof

(15 mins)

Utility cabinet top cover

(15 mins)

Various components

(45 mins)

3rd Day

Lift ILP, unwinder, utility cabinets, ink cabinets

(20 mins)

ILP

(120 mins)

Step

Reference Procedure

Notes and check

28. Installing the chiller on page 72

29. Install the UPS on

e 75

pag

30. Install the writing head on page 76

31. Install the HVPS on page 77

32. Install the HVPS on page 77

33. install on page 117 Install utility cabinet top cover.

34. Install system

nents on page

compo 80

35. Lift and move the ILP, unwinder, utility cabinets, and ink cabinets on page 80

36. Installing the ILP on page 81

Install chi connections.

Install chiller according to specifications. Refer to the UltraFilter ultracool 0400 installation guide:

 Flow rate of 56 ±5 liters/minute

 Temperature (measured at the press

Make sure that the external filter supplied by the supplier is installed. The filter should be installed at the chiller return pipe.

Connect the cooling water hoses to the press as shown in Figure 53 and Figure 54 (dep

Install and connect the UPS cables.

Cables to be found in cabinet M1.

Check the installation of all UPS cables between the electrical cabinet M1, PE1, and PE2.

Connect the cables to the internal battery.

Remov

Remove under-plate at heater window.

Install and align writing head.

Install HVPS units and covers.

Install roof covers.

Install the foll

 PTE/air knife.

 Scorotron units.

 Cleaning station and wiper blade.

 ITM cover.

 BID units.

 Ametek filters.

Lift the ILP, unw ink cabinets to the raised platform floor.

Position ILP near PE1. Position ILP feed and exit stepping plate assemblies near ILP.

ller pipes adapters and

inlet) of 6°C

ending on country of installation).

e writing head from box 8.

owing in each engine:

Thoroughly clean the BID units.

inder, utility cabinets, and

Hoses from chiller should be prepared

CA294-03070 rev 00 page 10 of 153

Installation Manual

Heading

Unwinder

(60 mins)

ILP wiring and air hose connections

(160 mins)

Step

Reference Procedure

Notes and check

37. install the ILP exit stepping plate on pag

e 83

38. align the ILP and stepping plate assembly on page 86

39. Measure on page 87 Measure distance between stepping plate

40. Release on page 88 Release (do not remove) six ILP alignment

41. Lower on page 88 Lower four ILP feet until castors

42. level and align the ILP on page 89

43. align the ILP on page 93

44. level and align the ILP exit stepping plate rollers on page 94

45. Install the ILP feed stepping plate on pag

e 96

46. install the priming rollers on page 99

47. Installing the unwinder on page 100

48. align the unwinder on page 103

49. Unwinder electrical conn

ections on page

104

50. ILP electrical connections on page 105

51. Install on page 105 Install cables between cabinet M1and the

52. Connect on page 105 Connect air hoses and cables to the ILP

53. Install on page 106 Install the cable securing clamps on the

Install the ILP exit stepping plate assembly to the ILP.

Align the ILP and stepping plate assembly with the press. Verify gap between ILP exit cover and web entrance cover at PE1 is approximately 4-5 mm.

front edge and PE1 front wall. Distance should measure 30 mm.

plate locking screws.

approximately 5 mm above floor platform and feet touch floor.

Leve

l the the ILP

Align the ILP using the parallel jig.

Level and align the ILP exit stepping plate rollers.

Install the ILP feed stepping plate. Align and level the stepping plate to the ILP.

Install the ILP primin

n, install, level and align the

Positio unwinder.

Align the unwinder with the ILP feed stepping plate.

Install an and air hoses.

Install cab panel and cabinet M1.

ILP connections panel

connections panel

clamp rail.

d connect all appropriate wiring

les between the ILP connections

g rollers

CA294-03070 rev 00 page 11 of 153

Installation Manual

Step

Heading

Ink cabinets

(90 mins)

Web guide

(10 mins)

Utility cabinets

(20 mins)

Computers installation

(40 mins)

Reference Procedure

54. Connect on page 108 Connect the following air hoses at the ILP

55. Install the ILP rear panel safety cover on

e 111

pag

56. Install the ILP vacuum hoses on pag

e 112

57. Installing the ink cabinets on page 113

58. Place on page 116 Mount and install the corian working

59. Adjusting the web

de on page 116

gui

60. Install the utility

net on page 117

cabi

61. Connect the computers on page 121

62. Install the computer cables on page 126

63. Install the master

le on page 127

conso

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.

Install safety cover at the ILP front.

Connect the vacuum hose to the ILP.

Install eac order shown in Figure 93 on page 113 for four colors, and Figure 94 on page 113 for seven colors.

If more than four colors to be make sure that relevant calibration kit is ordered for extra colors.

surface.

Mount the mo on working surface.

Remov adjust the web guide.

Customer to save screws.

To troubleshoot, refer to w3200 service manual Calibrations.

Install the util hoses from utility cabinets to the printing engines.

 Cooling water in

 Cooling water out

 Solid add compressed air

 Impression drum cooling drain

 Vacuum

 Air flow

Connect control cable and power cable to utility cabinets.

Check the n Figure 103, and Figure 104 on page 121 -

122.

Install Slav electrical cabinet M2.

Install the com computers.

Install master c master computer.

h ink cabinet according to color

installed,

nitor, keyboard and mouse

e the two securing screws and

ity cabinets and connect

etwork diagrams in Figure 102,

es 1 and 2 computers in

puter cables to both slave

onsole, and connections to

Notes and check

CA294-03070 rev 00 page 12 of 153

Installation Manual

Heading

Production flow

4th Day

Rewinder jig and finishing components

Turnbar stepping plate

Transformer

Initial power-up

Thread web

Configure press

PIP and blankets

5th Day

ATP

Step

Reference Procedure

64. Production flow on page 130

65. Install the finishing components on page 130

66. Installing the turnbar

ng plate on

steppi

e 130

pag

67. Install the main power conn

ection and transformer on page 130

68. Initial power-up on e 131

pag

69. Threading the web on e 138

pag

70. Configure the press

software on page 139

71. Install PIP and

blankets on page 139

72. Testing and

calibrating the press on page 139

Emergency stop tests on page 139.

Checking the web flow on page 140.

Checking the ILP priming unit on page 140.

Testing the printing engine on page 141.

Testing printing engine voltages on page

Performing integration and testing on page

Organize and install network cabling, RIP systems, HPPF units to aid production flow.

Install the re

After testing, install finishing components according to customers design and Site Preparation Guide.

Install turnbar stepping plate.

A local qualified electrician should install and connect the transformer and electrical mains power connections.

Perform initial power up as detailed on page 131.

Local electrician to be present at startup to check mains power connections.

Mount a roll at unwinder and thread to finisher according to

Install latest version of press soft authorization codes.

Mount an relevant drums.

Test and calibrate press:

In the Diagnostics>Elements Ink Flow tab perform tests

142.

143:

2. Verify that the ink flows.

3. Verify that the second transfer

4. Install a new blanket and PIP foil.

5. Adjust the BID pressure.

6. Perform the first transfer pressure

7. Verify the writing head skew.

Changing the skew may affect focus.

winder jig to test the press.

ware with

d install PIP and blankets on

Build the inks.

pressure is correct.

calibration.

Notes and check

CA294-03070 rev 00 page 13 of 153

Installation Manual

Heading

Step

Reference Procedure

Notes and check

8. Verify the writing head focus.

9. 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. See HP Indigo Service Instruction Calibrations, MNU-1633-01.

c. Perform the eye mark sensor

lateral positioning. See HP Indigo Service Instruction Calibrations, MNU-1633-01.

d. Perform the eye mark distance to

nip adjustment. See HP Indigo Service Instruction Calibrations, MNU-1633-01.

e. Make sure that the substrate is

centered at PE1. Print and check.

f. Make sure that the substrate is

centered at PE2. Print and check.

10. Perform color adjustment using the paper roll supplied with the press.

If a different substrate is to be

installed on the press, perform the following:

a. Load glossy paper on the press.

b. From the Adjustments menu,

click Color Adjustment & Calibration.

The Color Adjustment Wizard

Manager window opens.

c. In the Automatic Color

Adjustment area, click Custom Color Adjustment.

The Custom Color Adjustment

wizard opens.

d. Select the desired matrix.

e. In the Electrode Voltage

Calibration field, select Include Velectrode Calibration.

f. Click Next. The OD step opens.

g. In the Select Method of Substrate

OD Usage field, select Read Substrate OD.

CA294-03070 rev 00 page 14 of 153

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.

i. Click Finish.

j. Load the desired substrate on the

press.

k. Print the CATP job.

l. In the 9th and 10th copy of the

CATP printout, measure the solid patches (J area), and calculate the average values.

Note the values.

m. Change the press software to

technician mode.

n. From the Options menu, click

Systab Editor.

The Systab editor window opens.

o. Expand the mmiCATopic tree.

p. In the right window, double-click

SpecOdLowerDeltaOsm.

The mmiCATopic

SpecOdLowerDeltaOsm window opens.

q. In the Saved field, type -0.7.

r. Click OK. The window closes.

s. Double-click

SpecOdLowerDelta5.

The mmiCATopic

SpecOdLowerDelta5 window opens.

t. In the Saved field, type -0.7.

u. Click OK. The window closes.

v. Close the Systab Editor.

w. From the Adjustments menu,

click Color Adjustment & Calibration.

The Color Adjustment Wizard

Manager window opens.

x. In the Automatic Color

Adjustment area, click Custom Color Adjustment.

The Custom Color Adjustment

wizard opens.

y. In the Electrode Voltage

Calibration field, make sure that Include Velectrode Calibration is not selected.

z. Click Next. The OD step opens.

CA294-03070 rev 00 page 15 of 153

Installation Manual

Step

Heading

COI 74. Complete the

Reference Procedure

Testing during normal operation on page

73. CATP on page 145 Perform CATP test procedure:

Printing CATP test on page 147.

Check CATP against CATP specification

installation on page 150

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

opriate color fields.

appr

cc. Click OK.

A warning may appear. Click OK

to close the warning.

dd. In the wizard, complete the wizard

steps.

Make sure that the color

calibration is completed successfully.

ee. From the Diagnostics menu,

click Writing Head.

The Writing Head window opens.

ff. Click the Laser Power tab.

gg. Check that the Laser Power

values do not approach the upper or lower limits (30 to 1).

If the values are at either

extremity, perform the Machine LUT Calibration wizard from

Adjustments > Machine LUT Calibration.

11. If necessary, perform the Machine LUT using 180 lpi.

145.

checklist on page 147.

Compl

ete installation as detailed on page

150.

Notes and check

CA294-03070 rev 00 page 16 of 153

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.

The Quick Reference Installation Guide at the end of the document is intended to provide the experienced installer with reminders of the key steps and information.

Packing list

The table below lists the main contents of each box. The full contents list provided with the boxes takes priority over this table.

Box no.

3 MPQ-0620-51 U-base assembly 2 U-base

6 CA290-0523X Vacuum hose pipes kit for

Part number Contents Qty Name and weight (kg)

CA254-01592

CA294-03070

CA254-00322

CA271-00263

EBC-3005-01

CA290-05140

MPQ-0024-33

MSQ-0017-02

MJX-2427-51

MZH-0328-02

CA290-05130

MPQ-0024-33

MSQ-0017-02

MZH-0328-02

MPT-3515-54

MPT-8636-51

EAS-2041-52

MPT-2609-55

MKT-3354-02

MPT-6787-53

MPQ-0028-01

MZH-0333-06

MPT-7387-52

WHS electrical cabinet M1b

Keys

Installation Manual

WHS electrical cabinet M2b

Keys

Computer Slave #1 and #2

Network Ethernet SW1

Printing engine 2 (PE2)

Working surface

Leveler 75x150-55 Airloc

Fixing bracket assembly

Pipe Insulation 1-1/8”

Printing engine 1 (PE1)

Working surface

Leveler 75x150-55 Airloc

Exit inverter roller

Pipe Insulation 1-1/8”

w3250

Back right cover assy

Roof top cover assy

HVPS assy

Utility cabinet

Kit ink cabinet- s3200

Cover t4

Cover guide closure (stage)

Pipe flex od-1+5/16

Bottom cover for pub

1 Vacuum pipes kit for w3250

Electric Cabinet

PE2 engine

PE1 engine

Miscellaneous PE2

CA294-03070 rev 00 page 17 of 153

Installation Manual

Box no.

Part number Contents Qty Name and weight (kg)

CA245-15320

CA290-00121

CA245-00132

CA245-00332

MPT-3989-51

CA245-09891

MPT-3515-54

MPT-8636-51

MPT-2609-55

MKT-3354-02

CA270-00101

CA290-06290

CA290-05260

CA297-00350

MPK-3072-05

MPQ-0028-01

CA244-05941

CA245-08182

CA245-08352

CA245-01234

CA240-47210

CA245-16791

CA245-04963

5188-1250

CA240-60860

5188-4872

PX848AA#ABB MPT-7383-53

CA271-00263

DD817AV

MPT-7646-32

EHE-4069-51

CA261-07420

CA248-00230

DD837AV

SRO-0070-01

MNU-1050-82

EMS-2008-81

CA290-05580

Air Knife

Kit S/P Cleaning station and wiper

Scorotron

BID unit

Filter box assembly

Arms, Cover holder assembly

Back right cover assembly

Roof top assembly

Utility cabinet

Kit ink cabinet

Writing head assembly for u\s

Kit acc. Installation For w3250

Kit access for w3250

Sp UPS w/extension cables

Skid pallet

Cover guide closure (stage)

Keyboard & mouse

Screws M8x40, flat

Washers, Spring Washers

Cover for left ramp

Left ramp assembly – ILP

Right ramp assembly -ILP

ILP

Air pipe black dia.=12

Upper rubber roller assy

ILP, lower roller assy

UW6 - Unwinder for w3250

Pipe air 8mm

Panel front

Perspex covers for uw6

Feed roller

Unwinder book

Monitor Console assy

Emergency stop panel

Computer

Keyboard ps/2 hp

Working surface master console

Cable assy cc69

Cable assy cc70

PC software kit

Mouse PS/2 HP

Siemens software

Machine system info

Mouse pad

Kit S/W 6.7 w3250

8 of each

1 1

Miscellaneous PE1

Ramp

ILP

Unwinder

Master Console

CA294-03070 rev 00 page 18 of 153

Installation Manual

Box no.

13 Q5391-00680 Kit cons. Instl. W3250 1 Consumables kit

14 MPR-1309-11 Pap. Roll condat 115 1 Paper roll condat 115

Part number Contents Qty Name and weight (kg)

The alignment jig

Figure 2 The alignment jig

Figure 3 The alignment jigs mounted

1 Sights increasing in height from PE1 to PE2

2 PE1 jig

3 PE2 jig

4 Highest sight

Alignment jigs are used to adjust the forward/rearward alignment of the printing engines.

The jigs are used with a surveying tool (scope). They are not identical. When mounted properly, the sights on the jigs increase in height going from PE1 to PE2. The increase in height allows all the sites to be visible in the surveying tool. Adjustments can then be made to the position of the printing

CA294-03070 rev 00 page 19 of 153

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. Adjustments can then be made to the press component position until the variation in distance is either zero or minimal.

Figure 4 Sections of the new Parallel jig

880

650

200

1 880 mm long extension 6 Dial

2 650 mm medium extension 7 Base

3 Extension securing screw 8 200 mm short extension

4 Dial bracket securing screw 9 V-section

5 Dial bracket

The jig may be extended between rollers of distances using the three extensions which are attached to the base. The v-section is suitable for rollers of diameter 50 - 79 mm, whereas the dial bracket, buffer and dial are suitable for rollers 79 - 80 mm in diameter (Figure 4).

The long

•

configuration is used to make the following alignments (Figure 4):

To align the ILP to PE1

• To align the unwinder to the ILP

The intermediate configuration is used to make the following alignments (Figure 4):

•

To align one of the rollers in the exit-side stepping plate of the ILP to PE1

• To align one of the rollers in the input-side stepping plate of the ILP to the ILP itself

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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 assem

ble 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.

2. Insert the extension into the base so that the V-section and the gauge are facing the same direction.

Tighten the two handles to secure the extension.

NOTE: Disassembly is the reverse of the above two steps.

Figure 5 Mounting the v-section of the Parallel jig

1 Base v-section 2 Roller

3. Mount the v-section on the first roller (Figure 5).

Make sure that the extension reaches the second roller and tighten the extension securing screws.

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Installation Manual

Figure 6 Mounting the dial bracket on the extension

1 Dial bracket securing screw 5 Positioning circle

2 Dial bracket 6 Center lines of roller

3 Buffer 7 Position of dial sensor tip

4 Roller 8 Dial

4. Mount the gauged end of the jig on the specified roller needing to be aligned.

5. Loosen the screw securing the gauge support on the fixture, and slide it back so it does not interfere with placing the wheel.

6. Loosen the lock nut for the handle securing the gauge fixture in the extension.

7. Adjust the position of the gauge fixture in the extension so that the wheel rests on the roller and coincides with the vertical centerline of the roller.

Tighten the handle and the lock nut.

8. Slide the gauge support back until the contact touches the roller.

Continue sliding the gauge until the needle makes one complete turn.

Tighten the screw to secure the gauge support in place.

Prerequisites

Completion of site preparation.

Estimated installation time

4 days

Special skills

Only specially trained personnel should perform this installation.

Special jigs and tools

All special jigs and tools required for the installation of the press are included in the installation kit. Confirm the contents of the installation kit with the Bill of Materials (BOM).

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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



Parts cleaning station



External densitometer



Lockable main switch



Electrical outlets installed near pluggable equipment and are easily accessible

The printing engines may be mounted on the u-bases on-site or off-site. Make sure that the entrance to the site is large enough to allow an object 2200 mm high to enter.

Marking the pressroom floor for press components

1. Open the installation kit and select the marking pen.

2. Use the marking pen to mark the pressroom floor with the profile of the main press components and indicate their placement. Refer to the HP Indigo press w3250 site preparation guide for details of the floor area.

Unpacking the boxes

1. Before opening the boxes, check that the shock and tilt sensors have not changed color to red. If either of the sensors has changed color to red, then the boxes were mishandled. Notify the Regional Service Manager or Installation Manager immediately.

2. Unpack the box containing the accessories kit.

Open the accessories kit, and remove the System Information File.

Remove the customer letter about residual ink (P/N SV8-0039-00) from the System

Information File.

3. Give the letter to the customer.

4. The boxes are opened in the order of installation. At each stage of the installation open each box carefully and inspect the part for damage before installing. If any part shows signs of damage, immediately notify the Response Center or Regional Service Manger.

Verify the contents of each box according to the contents list included with the boxes.

5. Notify the Regional Manager or Installation Manager regarding any installation problems or damage found when unpacking the boxes.

CA294-03070 rev 00 page 23 of 153

Installation Manual

Procedure

NOTE: Two persons are required for this installation.

Installing the electrical cabinets

1. Place electrical cabinet M1 and electrical cabinet M2 in their positions.

2. 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.

Installing the printing engines

Positioning the printing engines

1. Position the u-bases as follows

a. Unpack the u-bases and loosen the front two securing screws to remove the u-base

slip plates.

Place the slip plates aside for later use.

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Figure 7 Positioning the u-bases

1 PE1 u-base

2 PE2 u-base

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b. 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.

Figure 8 Remounting the u-base slip plates

1 U-base slip plate 4 Securing screws (2)

2 U-base 5 Adjustment screws

3 Grease applied here

d. Remount the u-base slip plates on the u-bases (Figure 8).

Grease the u-bases before mounting the u-base slip plates.

The grease facilitates easy adjustment during the aligning procedure.

e. Secure the slip plates with the outer screws.

NOTE: The inner screws are for adjusting. They move the slip plate

from front to rear a total of 10.0 mm.

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Installation Manual

Figure 9 Adjusting the u-base height

1 U-base

2 U-base slip plate

3 Height of 200.00 mm

4 Height adjustment screw

f. Adjust the u-base feet to give a height of 200.0 mm from the floor to the u-base top

side (Figure 9).

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Figure 10 Placing the foresight on the PE2 u-base

1 12 23 34 45

0.5 mm

PUB_1596

1 Sight

2 Foresight stand

3 PE2 u-base

g. 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.

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Figure 11 Setting up the surveying tool

XXX

(125in)

3175 mm

693.0 mm

1 Position of surveying tool

2 Surveying line

NOTE: The surveying tool is setup on its tripod in accordance with

its instruction manual at the position shown in Figure 11.

h. Raise the height of the tripod and surveying tool to 1550.0 mm.

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Installation Manual

Figure 12 Focusing the surveying tool on the foresight stand target

1234

0.5 mm

1 Height adjustment screws

2 Crosshair target

i. Position the surveying tool facing and parallel to the foresight stand (Figure 12).

Figure 13 L

1 Level bubble

eveling the surveying tool

PUB_1346

j. Adjust the level of the surveying tool until the bubble is centered in the level

(Figure 13).

Focus the surveying tool so that the cross target on the foresight is clearly seen and centered with the crosshairs of the surveying tool (Figure 11).

If necessary, adjust the height of the cross target on the foresight stand.

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Installation Manual

l. Tighten the lock nut to secure the height of the u-base foot at that corner.

m. 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.

n. Repeat step m for all the corners of the u-bases.

Tighten the u-base foot lock nuts at each corner after it is leveled.

o. Recheck all the corners to confirm the heights. Re-adjust if necessary.

p. Use a marker pen to mark the position of the u-base feet on the floor.

Figure 14 Loosening the u-base connecting rods

PUB_455

1 Connecting rod

q. Loosen the four screws securing the connecting rod of each u-base (Figure 14).

Figure 15 Installing the j

unction bars between the u-bases

1 Junction bars 3 Junction bar securing screws

2 PE1 u-base 4 PE2 u-base

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Installation Manual

r. 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).

NOTE: Make sure to mount each PE to the correct u-base. PE1 has

The lifting jig should only be used if a forklift is either

The distance between the u-bases is now fixed at 693.0 mm.

a web feed door. PE2 has a web exit door.

unavailable or the site does not allow entry to a forklift.

CAUTION: Each section of the lifting jig has a diagram label

describing the position of the section when lifting the press. Use each specific section in its correct position as labeled.

Make sure to adhere to all the safety warnings

labeled on the lifting jig. The lifting jig should only be used on horizontal surfaces and the maximum lifting weight for the jig is 1800 Kg.

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Figure 16 Removing the front exit service door

1 Remove these screws

2 Door lower hinge

3 Front exit service door

2. Mount the PE2 on the u-base as follows:

At PE2

a. Remove the three screws securing the upper shaft of the front exit service door

frame.

b. Remove the door by lifting it out of its frame.

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Installation Manual

c. 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

1 Orientation labels 6 Link bar

2 Support wedges 7 Maximum lifting weight label

3 Pneumatic gun connector /adapter for wheel jack 8 CE label

4 Wheel jack 9 Support wedges

5 Warning label

For use on horizontal surfaces only

CAUTION: Do not use a pneumatic gun to raise or lower the

wheel jack.

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Figure 18 Positioning the link bar under the feed side

1 Engine rear 4 Positioning label

2 Base frame 5 Feed link bar

3 Support wedges

d. Position the feed link bar under the base frame (Figure 18).

Make sure to insert the support wedges under the engine feed base frame.

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Figure 19 Positioning the link bar under the exit side of the engine - view from rear

1 Rear electronic cabinet door 5 Support wedge

2 Support wedge 6 Exit link bar

3 Positioning label 7 Exit base frame

4 Rear engine frame

e. Fully open the rear electronic cabinet door (Figure 19).

Position the exit link bar under the exit engine frame (Figure 19).

Make sure to insert the support wedges under the exit base frame (Figure 19).

CA294-03070 rev 00 page 36 of 153

Installation Manual

Figure 20 Positioning the lifting frames against the engine

1 Engine frame 5 Metal securing peg

2 Rear lifting frame 6 Lifting frame slot securing end of exit link

bar.

3 Front lifting frame 7 Metal securing peg

4 Lifting frame slot securing end of feed link bar

g. 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).

Make sure that the link bars are inserted sufficiently to the lifting frame slots so that metal securing pegs can be fully inserted to the holes between the link bars and the lifting frames.

i. Insert the metal securing pegs to the holes between the link bars and the lifting

frames.

j. Turn each wheel jack (Figure 17) at the four corners of the lifting frames an equal

numbe

r of turns, in steps of 3-4 turns, to raise the engine 20 cm.

This will allow mounting of the engine on the u-base (Figure 17).

CAUTION: Do not tilt the press, as this could cause the press

to fall and become damaged.

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Installation Manual

Figure 21 Leveling pad

1 Pad 3 Allen M10 screw

2 Default height adjustment wedge position 4 Height adjustment wedge

Figure 22 Placing the leveling pads on the u-base

1 Leveling pad slots 4 Leveling pad slots

2 U-base cover 5 Leveling pads

3 Allen M10 height adjustment screw 6

k. Mount four leveling pads (Figure 21) at the four corner slots of the u-base (Figure 22).

Make sure that the pads are mounted centrally on the slotted areas of the u-base cover as shown in Figure 22.

CA294-03070 rev 00 page 38 of 153

Installation Manual

The Allen M10 height adjustment screw (Figure 21) should be facing towards the

outer si

des of the press for easy access.

l. 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).

Figure 23 M

oving the raised engine to the u-base

1 Front lifting frame 3 Leveling pads

2 U-base 4 Direction of lifting jig and engine over u-base

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Installation Manual

Figure 24 Press positioned over u-base

1 Feed base frame underside slot 4 Feed base frame underside slot

2 Leveling pad 5 Leveling pads

3 U-base 6 Exit base frame underside slot

m. 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 pad

If necessary, move the u-base to correctly align the underside slots with the leveling

s (Figure 23 and Figure 24).

pads top surfaces.

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Installation Manual

Figure 25 Lowering the engine on to the u-base and leveling pads

1 Printing engine raised above u-base 3 Printing engine correctly positioned on leveling

pads and u-base

2 Correct position of leveling pads 4 Correct position of leveling pad

n. Turn each wheel jack (Figure 17) an equal number of turns, in steps of 3-4 turns, to

lowe

r the engine on the leveling pads and u-base (Figure 32, Figure 25).

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Installation Manual

Figure 26 Engine mounted on the u-base

1 Position of link bar secured against

press frame beam

2 Frame slot 5 Leveling pad

3 U-base 6 Frame slot

4 Leveling pad

o. Make sure that the pads are correctly aligned within their slots on the u-base and

under the press (Figure 26).

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Installation Manual

Figure 27 Final position of printing engine on u-base

1 Securing bracket 2 U-base

p. 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).

3. To install the platform between the two printing engines:

a. Insert the platform between the two engines.

b. Use two bolts, washers, and nuts to install the platform at each engine side.

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Installation Manual

Mounting the turnbar

Figure 28 Identifying the turnbar components

1 Turnbar end roller 7 Front connection bracket

2 Turnbar idler 1 8 Rear connection bracket

3 Turnbar air pressure valve and dial 9 Turnbar idler 2

4 Turnbar air vacuum control valve 10 Turnbar idler 3

5 Turnbar lateral adjust control 11 Turnbar cross lower roller

6 Air pressure supply 12 Turnbar air pressure cross upper roller

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Installation Manual

Figure 29 Inserting the turnbar into the exit side of PE2

1 Notch for turnbar end roller shaft

2 Turnbar end roller shaft

1. 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).

Mounting the PE1

At the PE1

1. Repeat step 2. on page 33 for the PE1.

Make sure to move PE1 close to PE2, but leave a gap of at least 1 cm between the engines.

3. Use an Allen M6 key to verify the tightness of the junction bar securing screws between PE1

4. Tighten all other securing screws of the two u-bases.

CA294-03070 rev 00 page 45 of 153

Use a manual forklift to move the presses and u-bases to their fixed marked positions on the floor

and PE2 u-bases.

Installation Manual

5. Reinstall the front exit door lower hinge using the original screws.

6. Remount the front exit service door within its frame.

7. 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

1 Front base

2 Level

3 Leveling bar jig

8. To level each printing engine, do the following (Figure 30):

Remove the grounding cable screws at the front base.

Place the jig and level on the flat surface of the front base.

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Installation Manual

Figure 31 Leveling at the printing engine input – PE2 shown

1 Level

2 Idler

WARNING AVERTISSEMENT

WARNIN G

b. 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.

Use a 19 mm wrench to turn the nut at the front of the pads to adjust the level.

If necessary, use the following to adjust the position and level of the engine:

• A long crow-bar to slightly adjust the position of the engine.

• 2 mm spacers placed between the pads and the engine frame. Use a

lift-jack to slightly raise the engine and insert the pads.

Level to an accuracy of 0.00 ± 0.01 mm.

c. After the printing engine is level, make sure that the four wheels are not in contact

with the ground.

If not, use the pads to lift the wheels evenly off the ground.

d. Make sure that the printing engine is still level. Re-level if required.

e. Repeat steps a through d to level the remaining printing engine.

NOTE

: There are two parts to the printing engine alignment

procedure. The first part uses the alignment jigs to align both printing engines horizontally. The second part uses the

CA294-03070 rev 00 page 47 of 153

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

1 ITM bearing housing plate 3 Sights

2 Alignment jig adapter 4 Alignment jig mounted on ITM end cap

CAUTION: When installing the alignment jigs, make sure not

to damage the ITM lamp or any wires exiting from the lamp.

NOTE: See General information on page 17 for details on mounting

and using the jigs.

CA294-03070 rev 00 page 48 of 153

Installation Manual

At the engine front

9. To align the printing engines horizontally: (Figure 32):

For each pri

nting engine

a. Remove three screws securing the ITM front bearing housing plate.

Save the screws for immediate reinstallation.

b. Install the alignment jig adapter on the plate. Insert the three screws previously

removed in the same holes.

Make sure of the following:

• The ITM heater cable is routed through the adapter inner groove.

• The adapter is suitable for the plate and there is no gap between the plate

and the adapter. On some engines, three of the plate securing screws protrude, and only the specific adapter suitable should be used.

c. Mount the PE1 alignment jig (P/N MJX-3055-51) on the ITM end cap of PE1.

Make sure that the jig is oriented as shown in Figure 32.

Secure the jig using four screws.

d. Repeat step c for PE2 using its alignment jig (P/N MJX-3056-51).

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Figure 33 Aligning the printing engines - alignment jigs

1 Surveying tool

2 Line of sight

3 Alignment jigs

4 PE front

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Installation Manual

Figure 34 Identifying the u-base adjustment screws

1 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.

Each turn of the u-base slip plate inner screws moves the

printing engine by 0.3 mm.

e. Adjust the inner screws on the u-base slip plate of each printing engine until the

sights on both alignment jigs are aligned with the crosshairs in the surveying tool (Figure 33 - Figure 35).

They should be aligned such that the crosshairs of the surveying tool are located at the center of the four sights.

f. Adjust the printing engines until each one is aligned to ±0.1 mm.

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Installation Manual

Figure 36 Measuring the parallelism between rollers of opposing printing engines

1 Parallel jig

10. Align the printing engines as follows to make the rollers parallel:

a. Place the V-section of the parallel jig on idler 9 of PE2 (Figure 36). Refer also to the

ction General information on page 17.

Place the gauged end of the jig on idler 3 of PE1.

c. Move the jig along the length of the rollers (Figure 36).

Note the difference in the readings between the front and the rear.

If the readings differ by more than 0.02 mm, then adjust the u-base slip plate screws

shown in Figure 34 to correct the alignment.

d. Rep

eat step c until the difference between the front and rear readings is less than

0.01 mm.

Check the level of each printing engine.

Readjust it, if necessary.

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Installation Manual

Figure 37 The link brackets

1 Front link bracket

2 Rear link bracket

Figure 38 Mounting the front link bracket

1 PE2 5 Plate bracket

2 PE1 6 Front corner bracket

3 Joining screw 7 M6 Allen screws

4 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.

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Installation Manual

Securing the turnbar

Figure 39 Inserting the rear connection bracket

1 Turnbar 4 Rear connection bracket

2 Turnbar idler 3 5 Idler extended shaft

3 Turnbar idler 2

1. Mount the front and rear connection brackets on the extended shaft of idler 3 (Figure 39).

Lower the turnbar towards PE2.

Make sure that the rear and front connection brackets face towards the PE2 input rollers.

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Figure 40 Securing the front connection bracket and input idler

1 Input idler

2 PE2 input rollers front wall

3 Front connection bracket

4 Upper screw securing the idler

5 Lower screw securing the front connection bracket

3. Insert and slide the input idler to both the front connection bracket and the PE2 input rollers front side wall (Figure 40).

Secure the idler with two M5 wide head bolts (P/N MBS-0820-10 – upper screw, P/N MBS-0816-10 – lower screw) at the upper screw holes (Figure 40).

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Figure 41 Securing the rear connection bracket and input idler

1 Rear connection bracket 5 PE2 input idler

2 Lower screw securing the rear connection

bracket

3 Turnbar rear wall 7 Upper screw securing the idler

4 Turnbar input idler

6 Collar spacer

5. 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).

NOTE

: Before tightening all the screws to secure the turnbar, make

sure that all of the turnbar rollers move without friction.

7. Holding the turnbar in position, tighten the screws.

8. Connect the turnbar air hose to the turnbar air pressure air valve.

9. To connect the printing engines to each other:

a. Mount the front link bracket (Figure 37 and Figure 38).

Install the two

19 mm bolts and the two M6 Allen screws.

Do not tighten the joining M10 Allen screw yet. It remains loose for final adjustments.

b. Repeat step a above for the rear link bracket (Figure 37).

Check the horizontal alignment of the printing engines using the surveying tool.

Realign, if necessary.

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d. Check the parallelism between the printing engine rollers using the parallel jig.

Realign, if necessary.

e. Tighten the joining Allen screw of the front link bracket.

f. Tighten the screws securing the u-base connecting rods (Figure 14).

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Installation Manual

Electrical cabling

1. 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

1 Locking bracket

2, 3 Main power connector

4 Direction of closing locking bracket

2. To install mains power connectors (Figure 42):

Insert the cable connector to its female connection at the cabinet.

b. Pull and turn the locking bracket until the mains power connector is locked.

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Figure 43 Securing the electrical cabinet cables

PUB-485

1 Cable mounts here

2 Support back-plate

3 Cable bracket

NOTE: Use the cable bracket (P/N MCC-0821-05) to secure the

electrical cabinet-to-electrical cabinet and printing engine-toelectrical cabinet cables to the inner wall channel bracket attached to the wall of the electrical cabinets. (Figure 43).

Use the support back plate to support the rear of the cable.

Insert the cable bracket at the front of the cable.

IMPORTANT: Where a cable consists of a number of wires, the

black wires are labeled 1, 2, 3, 4 etc. in white on the wire at the insertion ends.

Some cables are labeled U, VV, WWW, XXXX

instead of 1, 2, 3, 4.

Wires should be inserted in the order labeled at the

connection point.

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Installation Manual

Figure 44 Components of electrical cabinet M1

NOTE: Location of the connectors may vary.

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Figure 45 Components of electrical cabinet M2

NOTE: Location of the connectors may vary.

3. Install the electrical cabinet-to-cabinet cables as follows (Figure 44, Figure 45):

Cable

EHE-4405-51 CC405

EHE-4400-51 CC400

CA261-10950

EHE-4438-51 CC438

CA261-10930

CA261-10940

From end point elect. cab. M2 To end point elec. cab. M1 Notes

3-phase 400VAC power supply for electrical cabinet M2 at JX4

400 VAC 3-phase power cable for PE1 at JX8

20F8 connector, pins 1,3,PE to cabinet fans

400 VAC 3-phase power cable for PE2 at JX9

X31 connector, pins 1,3, PE at 15F1 UPS connection for PE1 JX31,

X32 connector, pins 1,3, PE at 15F3 UPS connection for PE1 JX32

X4 connector, pins L1,L2,L3,PE

X8 connections 1,2,3.N.PE

1-phase 24 V power supply for electrical cabinet M2 at JX36

X9 connections 1,2,3,N,PE

Pins 1, 2, 3

Pins 4, 5, 6

Old cable EHE-4406-51 CC406

Old cable EHE-4401-51 CC401 To UPS 1 G5 power input

Old cable EHE-4437-51 CC437 To UPS 2 G5 power input

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Installation Manual

Cable

CA261-10910 cable 10910 CC413

GND05 Ground connection cable M1b Ground connection cable M1b Route cable from

From end point elect. cab. M2 To end point elec. cab. M1 Notes

Signal interface between cabinets at

X50

X50 connector

cabinet M1 to M2

4. Install the electrical cabinet-to-cabinet cables as follows (Figure 44, Figure 45):

Cable

CA261-10190

From end point elect. cab. M1 To end point elec. cab. M2 Notes

JX15 connection Pins 1, 2 X15 connection at Pins 1, 2

X8 connector, pins 1,2,3,N,Pe

X9 connector, pins 1,2,3,N,Pe

3-phase power supply for PE1 at JX8

3-phase power supply for PE2 at JX9

5. Install the electrical cabinet M1 cables to PE1, PE2 engines according to the following:

Cable

CA261-10630 3-phase power supply for PE1 at

CA261-10640 3-phase power supply for PE2 at

From end point elect. cab. M1 To end point PE1 or PE2 Notes

JX8

JX9

PE1 3 phase 400 VAC power

cable connection. Main AC power to line filter in PDU

PE2 3 phase 400 VAC power cable connection. Main AC power to line filter in PDU

6. Install the electrical cabinet M2 to PE1, PE2 engines according to the following:

Cable

CA261-10550

CA261-10560

CC424 Encoder to WHS green cable

CC415 Interlock dark gray cable

CC426 WH signal to PE gray cable

CC425 PE signals to WH gray cable

CA261-10790

CA261-10800

CC73A Interface panel UPS Com UPS COM connection -

W141

From end point elect. cab. M2 To end point PE1 or PE2 Notes

Cable from JX31 Pins L, N, PE Power cable to PF1 PDU

Cable from JX32 Pins L, N, PE Power cable to PF2 PDU

Electrical cabinet M2 x89 Interface panel J4

Electrical cabinet M2A x75 Interface panel J3

Electrical cabinet M2 x73 Interface panel J2

Electrical cabinet M2A x71 Interface panel J1

Mains power cable to PE1 UPS at JX31

Main power cable to PE2 +MC UPS at JX32

Electrical cabinet M2 JX8.1 quick connector

Connection at PE1 UPS Pins L, N, PE

Connection at PE2 UPS Pins L, N, PE

PDU -

15F1 control switch

15F3 control switch

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Installation Manual

Cable

CC236

CC54A Slave 1 compartment, Molex

CC414

CC430 Encoder to WHS green cable

CC431 Interlock white cable

CC432 WH out to PE gray cable

CC433 PE signals to WHS gray cable

CC74A UPS Com connection Interface panel UPS Com -

W142

CC237

CC54A Slave 2 compartment Molex

CC434

From end point elect. cab. M2 To end point PE1 or PE2 Notes

Electrical cabinet M2 X31.1 – WHS connector pins PE, 6, 5

connection in M2A

Electrical cabinet M2 X61 connector

Electrical cabinet M2 x90 Interface panel J4 -

Electrical cabinet M2 X76

Electrical cabinet M2 X74

Electrical cabinet M2 X72

Electrical cabinet M2 JX9.1 quick connector

Electrical cabinet M2 X32.1 – WHS connector pins PE, 5, 6

connection in electrical cabinet M2

Electrical cabinet M2 X62 connector

PDU -

Junction box -

Interface panel J3 -

Interface panel J2 -

Interface panel J1 -

PDU -

Junction box -

7. Install the electrical cabinet M1-to-master console cables as follows:

Cable

CC77A RS 232 control for UPS Master console PC -

CC27B UPS power connection for

CC439 Interlock interface to

CC68 Communication between

CC60 Slave 1 Ethernet card in

CC61 Slave 2 Ethernet card in

CC64 Slave 1 switchbox

From end point To end point Notes

master console at electrical cabinet M1 X30, pins 3,4,5

master (e-stop) electrical cabinet M1 X54

master computer and PLC at electrical cabinet M1 53A3

electrical cabinet M2

(electrical cabinet M2 right side) connector J4 to plug 4X

Master console cabinet, power-in multiple sockets

Master console power enable switch and Emergency Stop button connectors

Master console switchbox connector J6 to plug 6X

Master console two port Ethernet board

Master console switchbox connector J1 to plug 2X

See Figure 107, connect to right side to modem port No. 1

See Figure 107, connect to left side to modem port No. 1

CA294-03070 rev 00 page 63 of 153

Installation Manual

Cable

CC65 Slave 2 switchbox

W190 From master console

CC70 LAN from master network

CC69 Modem from master

From end point To end point Notes

(electrical cabinet M2 left side) connector J4 top plug 4X

switchbox connector P1 to plug 1X

interface card

computer

Master console switchbox connector J2 to plug 3X

Master PC on-board Ethernet connection

Customer wall -

See Figure 107, connect to

oard network connection

onb No. 4

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Installation Manual

Figure 46 The Unidrive assembly and components

PUBLISHER-1133A

1 UD75 interface module

2 CTNET connection

3 MODBUS connection

4 Connector to UD51 second encoder feedback module

5 Cable securing bracket

6 UD51 second encoder feedback module

7 Unidrive encoder connector

8 Elec. cab.-to-elec. cab. power connectors nos. 1 - 11

9 Elec. cab.-to-elec. cab. power connectors nos. 21 - 31

10 Unidrive main unit

11 Mains power connector

12 Mounting bracket and break resistor unit with thermal switch

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Installation Manual

Figure 47 The Unidrive unit

PUBLISHER-1133

1 CTNET connection

2 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.

8. Install all Unidrive cables as follows:

a. Remove the front lower covers from the Unidrives, and insert the following

connections (see Figure 46 and Figure 47):

For both p

rinting engines, there are two 8 mm power and encoder motor cables.

b. Install the PE1-to-Unidrive cables as follows:

Cable

CC418 Drive motor, encoder connection

CC419 Motor drive power connector orange cable

CC420 Impression engage motor encoder

CC421 Motor drive power connector blue cable

From end point PE1 To end point

FP1 encoder at 24U0

FP1 drive at 24K9, pins 2,4,6, PE, PE

IP1 encoder at 25U0

IP1 drive at 25K9, pins 2,4,6, PE, PE

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c. Install the PE2-to-Unidrive cables as follows:

Cable

CC440 Feed motor

CC441 Feed motor power orange cable

CC442 Impression engage motor

CC443 Impression engage motor power orange cable

CC422 Exit nip feed motor

CC423 Exit nip feed motor power orange cable

CC444 Turnbar feed motor

CC445 Turnbar feed motor power blue cable

From end point PE2 To end point

FP2 encoder 26K0

FP2 drive 26K9 pins PE, PE, 2, 4, 6

IP2 encoder 27K0

IP2 drive 27K9 pins 2, 4, 6, PE, PE

FE encoder 28K0

FE drive 28K9 pins PE, PE, 2, 4, 6

FX encoder 29K0

FX drive 29K9 pins PE, PE, 2, 4, 6

9. Install the PE1-to-PE2 cables as follows:

Cable

CC9B

CC114A PE2 service door interlock PE1 service door interlock

PE1 ECN Electronic engage cable PE2 ECN Electronic engage cable

From end point To end point

Electronic gearing PE2 ESBPRO J53 connector

PE1 ESBPRO J65 connector

10. Install the PROFIBUS cables as follows:

Cable

From end point To end point Notes

CC428 Purple

Electrical cabinet M2 80A7 connection

Electrical cabinet M1 53A5 connection

Purple cable terminator should be turned off

Connection is on top of cable CC408

CA294-03070 rev 00 page 67 of 153

Installation Manual

Figure 48 Electrical cabinet M1 PLC, MPI, and Profibus connections

1 PLC (53A1 - 53A3)

2 Mode selector

3 Memory cartridge

4 Cables cover

5 Communications cable connection to PC

11. Install the CTNET cables as follows:

Cable

From end point To end point Notes

Unidrive 24U0 unwinder web motor controller 5 pin connection at UD75 in electrical cabinet M1

Electrical cabinet M2 U029 turnbar feed (FX)

Electrical cabinet M2 U028 exit nip feed (FE)

Electrical cabinet M2 U027 IMP engage of PE2 (IP2)

Electrical cabinet M2 U026 PE2 feed (FP2)

Electrical cabinet M2 U025 IMP engage of PE1 (IP1)

NOTE: All electrical cables are to be routed appropriately under the

floor platform.

Electrical cabinet M2 U029 turnbar feed (FX) controllers 5-pin connection at UD75

Electrical cabinet M2 U028 exit nip feed (FE) controllers 5-pin connection at UD75

Electrical cabinet M2 U027 IMP engage of PE2 (IP2) controllers 5pin connection at UD75

Electrical cabinet M2 U026 PE2 feed (FP2) controllers 5-pin connection at UD75

Electrical cabinet M2 U025 IMP engage of PE1 (IP2) controllers 5pin connection at UD75

Electrical cabinet M2 U024 PE1 feed (FP1) controllers 5-pin connection at UD75

Green CTNET cable connects between all Unidrives from UW to FX to FE to IP2 to FP2 to IP1 to FP1

CA294-03070 rev 00 page 68 of 153

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Figure 49 Routing the MPI (MODBUS) cable

TBD

12. 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.

b. Route it to the front of PE1 and along bottom of the frame to the turnbar area.

c. Connect JTBD of the cable to PTBD of the TBD.

d. Route the remaining connector JTBD to the exit are of PE2.

Connect it to PTBD of the TBD.

13. Connect the ProfiBus and CTNet cable connections at electrical cabinets M1 and M2 as follows:

Cable

CA294-11200

CC428 Purple

Profibus

CA294-11200

CC428 Purple

Profibus

CA294-11200

CC428 Purple

Profibus

CA294-11200

CC428 Purple

Profibus

CA294-11200

CC428 Purple

Profibus

CA294-11200 CC428 Purple

Profibus

CTNet 10960 Green

CTNet Green 09190

Origin point End point Notes

Cabinet M2 80A7 connection

Cabinet M2 PLC connection 60A2

Cabinet M2 PLC connection 80A2

Cabinet M2 PLC connection U3/VB2

Cabinet M2 PLC connection U5/VBX

Cabinet M2 PLC connection 60A7

CTNET cable connection JX57at M1

Unidrive 24U0 FB encoder 5-pin connection at UD75 in Cabinet M1

Cabinet M1 53A5 connection

Purple cable terminator should be turned off.

Cabinet M1 53A5 connection

Connection at Unidrives

Cabinet M2 U029 turn bar feed (FX) controllers 5-pin connection at UD75

Connection is on top of cable

11190.

Verify connection

NOTE: All electrical cables will be routed under the floor platform as

necessary.

CA294-03070 rev 00 page 69 of 153

Installation Manual

Installing the vacuum hoses

Figure 50 Installing the vacuum hoses and adaptors

1400 mm

600 mm

1350 mm

BLOWER

ELECTRONIC

COOLER

UNIT

CABINETS

STAGE TOP LEVEL

(REMOVABLE TILES)

1490 mm

GROUND

LEVEL

BASE FEET

PRINTING

ENGINE

INK

540 mm 1100 mm 400 mm

UNIT

1040 mm

PAPER ENTRY SLOT

170

200

PRESSSIDEVIEW

1 V-junction adapters

CA294-03070 rev 00 page 70 of 153

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.

1. Remove the screws securing the feed panel. Remove the panel and save it and the screws for later reinstallation.

2. Connect the four large vacuum hoses to the four blowers in electrical cabinets M1 and M2. See Figure 50.

Figure 51 Routing v

acuum hoses to PE1

PUB_6869

1 Four hoses inserted to air ducts at the vacuum box

3. Route the short ~2m hose connected to the upper blower in electrical cabinet M1 to the vacuum box in PE1 (Figure 50 and Figure 51).

Use adaptors and small hoses as shown to connect to the vacuum box.

CA294-03070 rev 00 page 71 of 153

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Figure 52 Routing vacuum hoses to PE2

PUB_6868

4. Route the short ~2m hose connected to the left blower in electrical cabinet M2 to the vacuum box in PE2 (Figure 50 and Figure 52).

Use adaptors and small hoses as shown to connect to the vacuum box.

5. Route the short ~2m hose connected to the right blower in electrical cabinet M2 to the vacuum box in PE2 (Figure 50 and Figure 52).

Use adaptors and small hoses as shown to connect to the vacuum box.

6. Reinstall the underside covers to each printing engine.

7. Route the long 3 – 4 m vacuum hose to the ILP. Refer to the section Installing the ILP on page 8

1 for details of the connection to the ILP.

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.

When installing the floor near the press, the installation should either be started at the corners of the press or at the wall, depending on the convenience of the installation engineer.

Installing the chiller and cooling water hoses

The press uses cold water to control its environment temperature as well as the temperatures of other systems such as ink tanks and imaging oil. The chiller supplies the cold water to the press.

The chiller is connected to an accumulation tank with two water pipes (inlet and outlet) and a control cable. The accumulation tank supplies each printing engine with cooling water via a pump.

Cooling water supplied to the press must meet the following conditions:

• Flow rate of 56 ±5 liters/minute

• Temperature (measured at the press inlet) of 6°C

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Installation Manual

WARNING: All electrical power connections to the chiller must

be performed only by a local authorized and licensed electrician.

1. Install the chiller. Refer to the UltraFilter ultracool 0400 installation guide.

Make sure that the external filter supplied by the chiller supplier is installed. The filter should

be installed at the chiller return pipe.

NOTE: Do not open any main water valves until the water hose

connections between the chiller, printing engines, and ink cabinets are verified as correct.

Figure 53 Chiller pipe routing (Europe)

ChillerExternal Drainage Tank

2" one-way valve suitable f or 100 liter/minute flow rate with minimum pressure drop. Present when chiller water exit is below press level.

2" ball valve. Closed during normal press operation. Open for chiller maintenance and inspect ion.

2" pipe

Engine No. 2

External wall

160 cm

(63 inches)

1" pipe

Engine No. 1

Flow-rate gauge

Temperature gauge

1" ball valve

Barb fitting, 1" insi de diameter

1" flexible tube inst alled by HP

2" main ball valve

Blower

CA294-03070 rev 00 page 73 of 153

Installation Manual

Figure 54 Chiller pipe routing (Japan)

Chiller

2" one-way valve suitable for 100 liter/minute flow rate with minimum pressure drop. Pres ent when chiller water exit is below press level.

External wall

2" pipe

Flow-rate gauge

Temperature gauge

2" main ball valve

2" ball valve. Closed during normal press operation. Open for chiller maintenance and inspection.

Engine No. 2

Blower

160 cm

(63 inches)

1" pipe

Engine No. 1

Blower

1" ball valve

Barb fitting, 1" inside diameter

1" flexible tube installed by HP

2. To connect the cooling water hoses to the press use the following adapters and tools:

a. Two hose 1.5" pipe fasteners BSP and four pipe clamps for inlet and outlet water

connections.

b. A single hose 0.5" pipe fasteners and two pipe clamps

c. Teflon tape

d. Two 90° elbow connections

3. Perform all connections of the cooling water hoses to the press and make sure that the routing pipes to the chiller are as shown in Figure 53 and Figure 54, depending on the country of installation.

IMPORTANT: Make sure not to turn the water supply on at this

stage. The water should be turned on only after the unwinder and ink cabinets are connected to the printing engines.

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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

1 COM (SNMP) RS232 connection

2 Output breaker button

3 Output to printing engine

4 Breaker button

5 Input from PC

6 Input breaker

7 Mains power supply

CA294-03070 rev 00 page 75 of 153

Installation Manual

Figure 56 Connecting the UPS to the PDU

PDU_CONN1

1 Neutral

2 Three phases

3 Main

4 Breaker button

5 Input from PC

1. Install and connect the UPS cables as follows:

Cable

CC73A UPS No. 1 from slave 1 PC RS232 COM (SNMP) port at the 1st UPS

CC74A UPS No. 2 from slave 2 PC RS232 COM (SNMP) port at the 2nd UPS

CC77A UPS cable from master PC RS232 COM (SNMP) port at the 3rd UPS

CC233 Output cable from slave 1 PC Input connection at the 1st UPS

CC234 Output cable from slave 2 PC Input connection at the 2nd UPS

CC235 Output cable from master PC Input connection at the 3rd UPS

From end point To end point

2. Make sure that the cables are connected between the UPSs, the PEs, and the electrical cabinets.

Install the writing head

1. Carefully remove the writing head (P/N CA270-00101) from Box No. 8.

2. Remove the parameters diskette from the top of the writing head and save the diskette for later use.

3. Remove the four screws securing the plate secured to the heater window at the underside of the writing head.

Remove the plate. Save the plate in case of writing head replacement.

4. Install the writing head above the scorotron bridge. Refer to the service documentation Writing Head for further details.

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Installation Manual

Install the HVPS (High Voltage Power Supply)

Figure 57 HVPS installation

1 HVPS top cover

2 HVPS rear cover

3 Electrical cabinet side door

4 Baseplate

5 Electrical cabinet

6 HVPS front cover

Figure 58 The HVPS cage assembly

ex1

1 Top cover

2 Front cover

3 Baseplate

4 Rear cover

CA294-03070 rev 00 page 77 of 153

Installation Manual

Figure 59 Installing the HVPS on the baseplate

1 Screws securing HPVS to baseplate

2 Baseplate

3 HVPS unit (upside down)

1. 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

1 Baseplate

2 Screws securing baseplate to press (2 each side)

2. Use four M5 × 20 Allen screws with washers and spring washers to install the baseplate and HVPS on the press (Figure 57 and Figure 60).

Place the sponge filter on top of the HVPS.

CA294-03070 rev 00 page 78 of 153

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Figure 61 Attaching the top cover to the baseplate

1 Baseplate

2 Screws securing top cover to baseplate (4 places)

4. 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

OPT#2 SCR#3

GND

24VDC

OPT#1 BID#7 BID#6 BID#5 BID#4 BID#3 BID#2 BID#1 SCR#2 SCR#1

WARNING

HVPS

I/F

ITM

DANGER

HIGH VOLTAGE

HVPSFANS.CDR

1 Fans

2 J2 connector

3 Cage

6. Connect the cables to the HVPS (Figure 62).

Install the HVPS rear cover.

Install the roof covers

Install the two roof covers above and opposite the writing head.

CA294-03070 rev 00 page 79 of 153

Installation Manual

Install system components

1. For each printing engine, unpack the section and perform the following:

a. Install the PTE/air knife.

b. Install the scorotron units.

c. Install the cleaning station and wiper blade.

d. Install the ITM cover.

e. Thoroughly clean the BID units with imaging oil and a lint-free cloth.

f. Install the BID units.

Make sure that the BID units are thoroughly clean before installing them. If necessary

re-clean the BID units.

g. Install the Ametek filters.

Unpacking the ILP, unwinder, utility cabinets, and ink cabinets

1. Unpack the ILP, unwinder, two utility cabinets and two ink cabinets.

2. Lift and move the ILP, unwinder, utility cabinets, and ink cabinets to the raised floor platform.

If necessary, use a pallet jack to raise the units to the raised platform.

CA294-03070 rev 00 page 80 of 153

Installation Manual

Installing the ILP

Figure 63 ILP rollers

1 Inner station duplex primer No. 5 (DP5) 17 Lower drive roller

2 Idler No. 5 18 Lower nip roller

3 Outer station simplex primer No. 5 (SP5) 19 Lower buffer roller

4 Outer station simplex primer No. 4 (SP4) 20 Inner station duplex primer No. 1 (DP1)

5 Outer station simplex primer No. 3 (SP3) 21 Idler No. 10

6 Outer station simplex primer No. 2 (SP2) 22 Upper buffer rollers

7 Outer station simplex primer No. 1 (SP1) 23 Idler No. 9

8 Idler No. 3 24 Inner station duplex primer No. 2 (DP2)

9 Idler No. 4 25 Idler No. 8

10 Idler No. 13 26 Upper driver roller

11 Idler No. 2 27 Upper nip roller

12 Idler No. 1 28 Idler No. 7

CA294-03070 rev 00 page 81 of 153

Installation Manual

13 Idler No. 14 29 Inner station duplex primer No. 3 (DP3)

14 Idler No. 15 30 Inner station duplex primer No. 4 (DP4)

15 Idler No. 12 31 Idler No. 6

16 Idler No. 11

The following ILP installation procedure is performed (Figure 63):

Install the exit stepping plate.

2. Set the ILP close to its final position.

3. Raise the ILP 5 mm above the ground.

4. Adjust the ILP to its final position (level and parallelism).

5. Install the feed stepping plate

6. Adjust the feed and exit stepping plates.

7. Install the unwinder.

8. Install all cables to/from the Electrical cabinet M1, ILP and unwinder.

Positioning the ILP

1. Move the ILP on the floor platform to the input side of PE1.

The ILP should be supported by its castors enabling it to be rolled into position.

Figure 64 Distinguishing the ILP feed and exit stepping plate assemblies

1 ILP feed stepping plate assembly 6 Front section connected to PE1 feed

2 Connecting studs 7 Holes for ILP exit cover securing pins

3 Front section connected to ILP feed 8 Gas spring arm

4 Gas spring arm 9 ILP exit stepping plate assembly

5 Holes for ILP exit cover securing pins

CA294-03070 rev 00 page 82 of 153

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 inputside stepping plate assembly does not have these holes. See Figure 64.

When installing the securing screws for the stepping plate assemblies, it is recommended to use magnetized balled-end Allen keys.

1. Release the two ILP feed and exit stepping plate assemblies from the ILP stepping plate pallet (P/N CA245-01234) by releasing the stepping plates securing bracket.

Use an 6 mm wrench to remove the nuts securing the four screws.

2. To install the ILP exit stepping plate assembly (Figure 64):

Set the ILP close to its final position.

Figure 65 Mounting the ILP stepping plate assemblies on the ILP

1 Mounting interface

b. Mount the exit stepping plate assembly next to the ILP exit.

Make sure that the connecting studs (Figure 64) fully insert to the ILP exit wall holes.

Open the assembly cover.

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Figure 66 Installing the stepping plates to the ILP

EXIT STEPPING

ILP EXIT

PLATE ASSEMBLY

W3250_STEP_PL

TE_4084

1 Lower bracket 5 ILP

2 Upper securing screw 6 Lower securing screws

3 Upper frame 7 Stepping plate assembly

4 Upper securing screw

c. Install the exit stepping plate assembly to the ILP using four Allen M5 screws,

washers, and spring washers (Figure 66).

screws are inserted at the upper frame and two within the lower bracket slots.

Two

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Figure 67 Installing the ILP exit cover on the exit-side stepping plate assembly

1 Exit cover

2 Exit-side stepping plate assembly

d. 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.

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Figure 68 Positioning the ILP next to PE1

4 - 5 mm

At the PE1 feed

3. 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.

4. To align the ILP and stepping plate assembly with the press (Figure 68):

Move the ILP closer to the PE1 feed.

b. Align the ILP exit cover side with the PE1 web entrance cover side.

c. Make sure that the gap between the ILP exit cover and the web entrance cover at

PE1 is approximately 4-5 mm.

If not, adjust the position of the ILP until the gap between the covers is 4-5 mm.

d. Remove all the packing material from the ILP and stepping plate assemblies.

Close the stepping plate assembly covers to prevent damage to the rollers inside.

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Figure 69 Aligning the stepping plate to the PE1 front wall

1 Exit-side stepping plate

2 PE1 chassis

3 30 mm from straight edge to PE1 chassis

d. Remove the cover. Place aside temporarily.

e. Align the center of the stepping plate rollers with the PE1 input rollers.

f. Remount the ILP exit cover.

g. Place a meter ruler or straight bar along the stepping plate front edge, and extend it

to touch PE1 (Figure 69).

Measure the distance between the stepping plate front edge and the PE1 front wall.

The distance should measure 30 mm.

If not, adjust the position of the ILP as necessary.

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At the ILP exit stepping plate assembly

5. Adjust the stepping plate gas spring arm so that the plate lifts without touching the ILP exit side (Figure 64).

Figure 70 Unlocking th

e ILP alignment plates

1 Alignment plate locking screws (x6)

6. Open the front and rear ILP doors.

7. Release (do not remove) the six ILP alignment plate locking screws (Figure 70).

Lower the four ILP feet until the castors are approximately 5 mm above the floor platform and the feet touch the floor.

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Figure 71 Leveling and aligning the ILP

W3250_ILD_ALIGNMENT_2971

1 ILP external frame 9 Securing nut

2 Feed pull screw (similar at exit) 10 ILP internal frame

3 Feed push screw (similar at exit) 11 ILP frame securing screw

4 ILP internal frame 12 ILP external frame

5 ILP rear foot 13 Position of ILP front frame securing screws

6 ILP feed stepping plate assembly 14 Position of ILP rear frame securing screws

7 ILP front foot 15 ILP exit stepping plate assembly

8 Height adjustment nut

NOTE: There are two sets of push/pull screws (Figure 71). The

outside screws of each set are the push screws. The inside screws are the pull screws. The ILP moves forward/backward 1 mm for each turn of a screw.

9. To level and align the ILP (Figure 71):

At the lower ILP frame

a. Using an Allen M6 key, loosen the six frame securing screws shown in Figure 71.

This allows adjustments to the ILP internal and external frames.

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Figure 72 Adjust the ILP feet height

1 ILP feet

2 Stepping plate assembly feet (shown raised; 2 each assy)

b. 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.

NOTE: Two persons will be necessary for the next procedure.

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Figure 73 Leveling the ILP

1 ILP feed frame

2 Leveler

d. 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.

e. Repeat step d above at the exit ILP.

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Figure 74 Leveling the ILP at the rollers

1 ILP idler No.3

2 Leveler

3 Roller securing jig

At the ILP feed

f. Mount the roller securing jig on the idler No.3.

Make sure that the roller is secure. Place the level on the roller.

g. While one person measures the level at idler No. 3 (Figure 63), another person

sho

uld raise/lower the two feet 20 mm height adjustment nuts until the feet rest on the

floor and the ILP is level.

Measure the level to an accuracy of 0.0±0.1 mm.

If necessary, use a jack to raise the frame and place 20 x 20 cm x 2cm spacer plates under each foot of at the ILP feed.

At the ILP exit

h. Repeat step g above placing a leveler on idler No. 10 (Figure 63).

If necessa

ry, use a jack to raise the frame and place 20 x 20 cm x 2cm spacer plates

under each foot of at the ILP feed.

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At the ILP feed

i. 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/pu

sh screws at the feed and exit of

the rear lower frame: i. Turn the push screw counterclockwise to release the internal frame.

ii. Turn the pull screw to adjust the skew of the ILP frame until leveled. iii. Tighten the push screw to accurately align the ILP.

Repeat until the ILP are sitting firmly on the floor and the ILP is level.

Measure the level to an accuracy of 0.0±0.1 mm.

j. Tighten the six leveling screws until just tight.

Then turn the adjustment nuts one further complete turn and tighten the locking nuts.

At the ILP exit

k. Repeat step g above, placing a leveler on the idler No. 10 (Figure 63), and adjust the

two feet 20 m

m height adjustment nuts until accurately leveled.

Measure the level to an accuracy of 0.0±0.1 mm.

l. Tighten the six leveling screws until just tight and

Then turn the adjustment nuts one further complete turn and tighten the locking nuts.

10. Configure the parallel jig for the long configuration. Refer to the section General information on pag

Figure 75 Al

e 17.

igning the PE1 and ILP using the Parallel jig

1 ILP 4 PE1 driver roller

2 Parallel jig 4 PE1

3 ILP idler No. 10

At the ILP exit and PE1 feed

11. To align the ILP using the parallel jig:

a. Remove the two screws securing the IR sensor bracket.

Save the screws for later reinstallation.

Carefully place the bracket and sensor aside. Do not disconnect its cable.

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b. 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.

Figure 76 Aligning the ILP feed stepping plate rollers

1 Allen M5 rear adjustment screw 6 Allen M5 front adjustment bracket locking

screw

2 Allen M5 rear adjustment bracket locking screw 7 Parallel jig

3 Stepping plate roller (to be aligned) 8 ILP exit stepping plate rollers

4 Gauge bracket 9 PE1

5 Allen M5 front adjustment screw 10 PE1 input idler No. 2

12. To level and align the ILP exit stepping plate rollers (Figure 76):

For each roll

a. Place a leveler on the roller and verify that the roller is level at the front and rear.

b. Reconfigure the parallel jig for the intermediate configuration. Refer to the section

General information on page 17.

Place the Parallel jig between the PE1 input idler No. 2 and the roller shown in Figure 76.

Make sure that the gauge bracket is orientated as shown in Figure 76.

Loosen the Allen M5 front and rear adjustment bracket locking screws.

e. Adjust the Allen M5 front and rear adjustment screws and move the Parallel jig from

front to back to accurately align the roller.

Make sure that the rollers are aligned to an accuracy of 0.00 ± 0.01 mm.

If the difference between the readings is more than 0.00 ± 0.01 mm, turn the adjustment screw on the front mount of the roller to correct the alignment.

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e. Tighten the front and rear adjustment bracket locking screws.

Figure 77 Aligning the ILP feed stepping plate rollers - between stepping plate rollers

1 Stepping plate roller (previously aligned and

leveled)

2 Parallel jig (shortened) 6 Allen M5 rear adjustment bracket locking

3 Allen M5 front adjustment screw 7 Allen M5 rear adjustment screw

4 Allen M5 front adjustment bracket locking

screw

5 Stepping plate roller (to be aligned and

leveled)

screw

NOTE: The adjustment screws on the rear mounts of the stepping

plate assembly rollers move the rollers in the up/down direction. The screws on the front mounts move the rollers in the web feed direction (Figure 77).

The adjustment screws are locked with setscrews.

f. Reconfigure the parallel jig for the short configuration. Refer to the General

information on page 17.

Use the Paral

lel jig in order to measure the variation in distance between the two

stepping plate rollers as shown in Figure 77.

Mount the Parallel jig between the two rollers.

g. Loosen the Allen M5 front and rear adjustment bracket locking screws (Figure 77).

Adjust the Allen M5 front and rear adjustment screws and move the Parallel jig from front to back to accurately align the roller (Figure 77).

Make sure that the rollers are aligned to an accuracy of 0.00 ± 0.01 mm.

If the difference between the readings is more than 0.00 ± 0.01 mm, turn the adjustment screw on the front mount of the roller to correct the alignment.

i. Place a leveler on the roller and verify that the roller is level at the front and rear.

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j. Tighten the front and rear adjustment bracket locking screws (Figure 77).

13.

14. Rep

15. Rep

Install the ILP feed stepping plate between the Unwinder position and the ILP as described in step 2 on page 83.

Place the Parallel jig between the unwinder lower roller and the stepping plate rollers.

eat step 4 on page 86 to align the ILP feed stepping plate rollers.

eat step 12 on page 94 to level the ILP feed stepping plate rollers.

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Installation Manual

Installing the ILP web rollers

Figure 78 The priming unit rollers - position in the ILP

1 Priming unit 8 Simplex station

2 ILP 9 Duplex station

3 Simplex priming roller 5, SP5 (impression roller) 10 Duplex priming roller 1, SP1 (reservoir roller)

4 Simplex priming roller 4, SP4 (upper rubber

11 Duplex priming roller 2, SP2 (lower rubber roller)

roller)

5 Simplex priming roller 3, SP3 (intermediate

12 Duplex priming roller 3, SP3 (intermediate roller)

roller)

6 Simplex priming roller 2, SP2 (lower rubber

13 Duplex priming roller 4, SP4 (upper rubber roller)

roller)

7 Simplex priming roller 1, SP1 (reservoir roller) 14 Duplex priming roller 5, SP5 (impression roller)

The priming unit consists of two priming stations. Each station consists of five rollers as shown in Figure 78. Each roller is identified by its number (No. 1 - 5) from th

e lower to top roller. A numbered

outer station roller corresponds to its parallel inner station roller.

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Figure 79 Identifying the rollers

1 SP1 or DP1 steel roller with ends recessed 4 SP4 or DP4 rubber roller with a narrow priming

surface

2 SP2 or DP2 rubber roller with a wide priming

surface

3 SP3 or DP3 steel roller

5 SP5 or DP5 steel roller

The installation for the inner and outer station rollers is similar. The order of the rollers installation is as follows (refer to Figure 78 and Figure 63):

1st

2nd Rubber rollers SP2 and DP2

Rubber roller SP4 or DP4

CAUTION: Take care not to damage the priming surface of the

rubber rollers. They are very delicate and can be damaged easily.

The rubber rollers should be supported by their

shafts either in their shipping box or in the ILP. They should not be allowed to rest on a flat surface (even for a short time) as damage will be caused to the rollers surface.

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Figure 80 Installing the priming rollers - outer and inner stations

1 Clamp 3 SP2 or DP2 rubber roller

2 Bearing 4 SP4 or DP4 rubber roller

13. To install the priming rollers (Figure 80):

Open the ILP feed door.

b. Remove the outer station priming roller mount clamps.

Place them aside on a flat clean surface.

c. Mount the SP2 rubber, and secure it with the clamps.

d. Mount the SP4 rubber roller, and secure it with the clamps.

e. Open the ILP top cover.

f. Remove the inner station priming roller mount clamps.

Place them aside on a flat clean surface.

g. Mount the DP2 rubber roller, and secure it with the clamps.

h. Mount the DP4 rubber roller, and secure it with the clamps.

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Installing the unwinder

Positioning the unwinder

1. Place the unwinder on the floor platform at the input side of the ILP.

Figure 81 Moving the unwinder into its final position

1 Unwinder v6 2 Pallet jack

2. 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.

CAUTION: When moving the unwinder, make sure to place the

pallet jack under the frame as shown in Figure 81. Otherwise, the unwinder will be damaged.

CA294-03070 rev 00 page 100 of 153

HP Indigo Division, w3250 Instruction For Use & Installation Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual

Installation instruction details

Overview

Warranty disqualifier

Quick reference checklist

General information

How to use this manual

Packing list

The alignment jig

The parallel jig

Prerequisites

Estimated installation time

Special skills

Special jigs and tools

Pre-installation procedure

Verifying site preparation

Marking the pressroom floor for press components

Unpacking the boxes

Procedure

Installing the electrical cabinets

Installing the printing engines

Mounting the turnbar

Mounting the PE1

Leveling the printing engines

Securing the turnbar

Electrical cabling

Installing the vacuum hoses

Install the floor platform

Installing the chiller and cooling water hoses

Install the UPS

Install the writing head

Install the HVPS (High Voltage Power Supply)

Install the roof covers

Install system components

Unpacking the ILP, unwinder, utility cabinets, and ink cabinets

Installing the ILP

Installing the ILP web rollers

Installing the unwinder