HP Indigo Press WS4000 User manual

filename: CA293-00600.doc page 1 of 221
hp indigo field change order kit p/n:CA292-00550
HP Indigo press ws4000 Cluster 1
procedures doc p/n: CA293-00600
This document applies to the following products/serial numbers:
HP Indigo press ws4000 serial nos. 2210002-22100122 & 110001
This document applies to the following parts/assemblies:
Cluster 1 assemblies
Software affected: ⌧yes no
Type of change: mandatory ⌧partial conditional
Supporting ECO:
configuration control
Revision Description Release date Reviewer
00 Initial release 15 Jan 04 Yossi Bahar
01 Press software installation only
option
15 Mar 04 Yossi Bahar
Responsible reviewer: Meir Kormian
NameHaim signature date
R&D reviewer: Haim Belinkov
Name signature date
Engineering reviewer: Ron Levkovits
Name signature date
Group manager: Aaron Lubelski
Name signature date
Documentation manager: Ronit Shugal
Name signature date
Written by: Asher Reichert
Name signature date
Configuration control: Charles Margy
Name signature date
Hewlett-Packard Company, Indigo Division, P.O. Box 150
Kiryat Weizmann, P.O. Box 150, Rehovot 76101, Israel
©Copyright Hewlett-Packard Company, 2003. All rights reserved.
CONFIDENTIALITY NOTICE
This document contains valuable trade secrets and confidential information of Hewlett-Packard Company. Nothing herein
may be copied, reproduced or distributed in any form or medium, or disclosed to any third party in any manner, without prior
written authorization of Hewlett-Packard Company. The copyright notice, which appears in this document, is purely
precautionary and shall not be deemed to constitute publication or intent to publish, in whole or in part.

HP Indigo press ws4000 Cluster 1 procedures
proprietary and confidential CA293-00600, Rev 00 page 2 of 221
Contents
1. Purpose ...............................................................................................................10
Components ......................................................................................................................10
2. Implementation ....................................................................................................11
Estimated installation time.................................................................................................11
Required special training...................................................................................................12
Special jigs and tools.........................................................................................................12
3. Prerequisites........................................................................................................12
4. Procedure ............................................................................................................13
Preliminary steps ...............................................................................................................13
Installing the ILD Firmware update....................................................................................15
ILD Troubleshooting ..........................................................................................................22
Replacing the PLC memory cartridge ...............................................................................23
Programming the PLC .......................................................................................................24
Downloading software to the Unidrives using WinFlasher 3 .............................................25
Programming the touch screen .........................................................................................28
UniDrive – User defined error messages (trips) ................................................................31
HP Indigo press software version 6.2.1 installation ..........................................................32
Reinstalling the ink file.......................................................................................................36
Hardware configuration (software only).............................................................................36
Software testing procedures..............................................................................................37
Automatic machine LUT ....................................................................................................39
Scaling...............................................................................................................................39
Printing the CATP job........................................................................................................53
End of the Software upgrade section of the FCO .............................................................53
Performing the Hardware configuration for Cluster 1 components ...................................53
Total Shutdown procedure ................................................................................................54
Preliminary steps for changing the Cluster 1 hardware components on the press...........54
Removing the Unwinder vacuum box................................................................................56
Installing the inverters in the electric cabinet ....................................................................67
Installing the Unwinder Vacuum box .................................................................................88
Installing the Unwinder Nip roller Drive motor...................................................................90
Installing the Unwinder bottom roller .................................................................................90
Installing the Tension in Web label on the Unwinder ........................................................95
Removing the printing engine FP (Substrate transport) motor..........................................97
Removing the Input assembly .........................................................................................100
Removing the printing engine vacuum box .....................................................................104
Remaining steps in removal of the printing engine vacuum box.....................................105
Removing the Output assembly ......................................................................................105
Replacing the Output rollers and web break sensor .......................................................110
Replacing the web break sensor .....................................................................................113
BID knobs bracket ...........................................................................................................116
Installing the ILD cooling system.....................................................................................122
Black rod replacement.....................................................................................................130
Installing the Output assembly ........................................................................................134
Installing the printing engine vacuum box .......................................................................143
Installing the Input assembly ...........................................................................................150
Replacing the FP motor belt............................................................................................152
Installing the anti-drip kit assembly .................................................................................160

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Installing the printing engine antistatic brushes ..............................................................173
Leveling the press ...........................................................................................................176
Aligning the Unwinder to the press..................................................................................179
Rewinder Antistatic bars..................................................................................................181
Installing the ILD cooling assembly on the ILD support bar ............................................183
Powering up the press.....................................................................................................185
Setting Inverter parameters for the press........................................................................185
Setting position of the vacuum box .................................................................................187
Post installation procedures ........................................................................................187
Corner job calibration ......................................................................................................188
Troubleshooting...............................................................................................................192
Calibrating the vacuum box and web break sensors ......................................................192
Vacuum box Sensor troubleshooting ..............................................................................197
Downloading parameters to the Unidrive using Unisoft ..................................................201
Downloading system files to the Unidrive........................................................................203
5. Test procedures.................................................................................................205
BID knobs bracket for ws4000 ........................................................................................205
ILD cooling system ..........................................................................................................205
Anti-drip kit assembly ......................................................................................................205
Rewinder Antistatic bars..................................................................................................205
Printing CATP job ............................................................................................................206
6. Parts list .............................................................................................................206
ILD cooling system ..........................................................................................................206
BID knobs bracket for ws4000 ........................................................................................206
Anti-drip kit assembly ......................................................................................................206
FCO parts ........................................................................................................................206
Spare parts ......................................................................................................................206
7. Materials disposition ..........................................................................................206
BID knobs bracket for ws4000 ........................................................................................206
Scorotron black rod replacement ....................................................................................207
ILD cooling system ..........................................................................................................207
Anti-drip kit assembly ......................................................................................................207
8. Appendix............................................................................................................207
Replacing the second transfer knob................................................................................215
9. Attached documents ..........................................................................................220
List of figures
Figure 1 ILD bracket.....................................................................................................13
Figure 2 Font Manager window....................................................................................13
Figure 3 Export window................................................................................................14
Figure 4 Press Configuration window, Configuration Management tab .......................14
Figure 5 Removing the upper nip cover .......................................................................15
Figure 6 ILD hand knobs..............................................................................................16
Figure 7 Removing the ILD connector..........................................................................17
Figure 8 Cable..............................................................................................................17
Figure 9 Connecting the cable to the ILD.....................................................................18
Figure 10 Flash Memory Loader – Main Menu ............................................................19

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Figure 11 File Select option..........................................................................................19
Figure 12 Downloading file...........................................................................................20
Figure 13 Download complete......................................................................................20
Figure 14 Flash Memory Loader – Main Menu ............................................................21
Figure 15 Fastening software version label to ILD.......................................................21
Figure 16 Connection error message...........................................................................22
Figure 17 SysTab Window showing angleToStartMeasure parameter ........................23
Figure 18 PLC panel ....................................................................................................23
Figure 19 UniDrive port ................................................................................................25
Figure 20 Touch screen control panel..........................................................................29
Figure 21 Press Setup, Setup Data Folders window....................................................33
Figure 22 sysTabInit.pl message .................................................................................33
Figure 23 Launch failure warning.................................................................................34
Figure 24 Alert message ..............................................................................................35
Figure 25 HP Indigo RIP window .................................................................................35
Figure 26 RIP Administration window, RIP Configurations tab ....................................36
Figure 27 System table editor WHS_R_Configuration parameter................................37
Figure 28 System table editor WHS_R_Sw_Ver parameter ........................................38
Figure 29 Opening the Substrate Scaling Correction wizard .......................................40
Figure 30 Warning to verify motion profile....................................................................40
Figure 31 Opening the Press Configuration parameters..............................................41
Figure 32 Motion Profile field on Press Configuration screen ......................................42
Figure 33 Substrate Scaling Correction wizard Print step............................................43
Figure 34 Notification to go to Ready mode.................................................................43
Figure 35 RL Conflict notification message..................................................................44
Figure 36 MMI screen to recalibrate press...................................................................45
Figure 37 Periphery edge lines ....................................................................................46
Figure 38 Measuring the values on the Scaling job printout ........................................46
Figure 39 Directions for measuring Scaling job as found on job sheet ........................47
Figure 40 Substrate Scaling Correction screen Enter Values step ..............................48
Figure 41 Enter Values step with new values entered .................................................48
Figure 42 Values within tolerance appear in green......................................................49
Figure 43 Substrate Scaling Correction wizard Analysis step......................................50
Figure 44 Substrate Scaling Correction wizard Fix step ..............................................51
Figure 45 Finish button.................................................................................................52
Figure 46 Web Handling field Default Web Scaling Correction parameter ..................53
Figure 47 Removing junction box.................................................................................55
Figure 48 Unscrewing the bottom cover.......................................................................56
Figure 49 Pull out the bottom of the front Unwinder cover ...........................................57
Figure 50 Disconnecting Unwinder rear panel .............................................................58
Figure 51 Removing the Unwinder rear panel..............................................................59

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Figure 52 Lifting off Unwinder front door ......................................................................59
Figure 53 Take out Unwinder deflector roller to remove vacuum box..........................60
Figure 54 Removing Unwinder lower roller screw on front wall ...................................61
Figure 55 Removing Unwinder lower roller screw on rear wall ....................................62
Figure 56 Unwinder side understep roller to be replaced.............................................63
Figure 57 Input press side Understep roller to be replaced .........................................64
Figure 58 Removing the Unwinder Nip roller drive motor ............................................65
Figure 59 Unplugged vacuum box sensor....................................................................65
Figure 60 Removing vacuum box bracket screws........................................................66
Figure 61 Rear vacuum box bracket spacer ................................................................66
Figure 62 VBFU and VB1 Inverters..............................................................................67
Figure 63 Electric cabinet before inverter installation...................................................68
Figure 64 22Q3 and 22Q5 switches.............................................................................69
Figure 65 71K1, 71K2 and 71K4 circuit protectors.......................................................70
Figure 66 X15, X16 AC block connection.....................................................................71
Figure 67 Blower connector boxes...............................................................................72
Figure 68 Blower wiring................................................................................................73
Figure 69 60A0 power supply.......................................................................................74
Figure 70 60A5 electronic block ...................................................................................75
Figure 71 Wrapping two exposed red wires.................................................................75
Figure 72 new 22Q3 and 22Q5 circuit breakers...........................................................76
Figure 73 Inverters installed on electric cabinet...........................................................77
Figure 74 Blower connector box connections .............................................................78
Figure 75 3 brown wires to the 22Q3 breaker ..............................................................79
Figure 76 Connecting the 60A0 power supply .............................................................80
Figure 77 Unidrive........................................................................................................81
Figure 78 Unwinder junction box..................................................................................82
Figure 79 Side view of the connector terminal .............................................................83
Figure 80 Unwinder junction box connections closeup ...............................................83
Figure 81 Press junction box........................................................................................84
Figure 82 Press junction box connections closeup ......................................................85
Figure 83 Running the vacuum box sensor cable to the vacuum box..........................86
Figure 84 Input side vacuum box brackets...................................................................88
Figure 85 Vacuum box hoses with clamps alternated..................................................89
Figure 86 Unwinder vacuum box ground cables ..........................................................89
Figure 87 Installing the Unwinder Nip roller drive motor ..............................................90
Figure 88 Unwinder lower roller ...................................................................................91
Figure 89 Installing Unwinder roller screws..................................................................91
Figure 90 Installing the stepping plate deflector roller..................................................92
Figure 91 Long brush assembly for the Unwinder bottom roller...................................92
Figure 92 Clamps on the right and left sides of the roller axle .....................................93

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Figure 93 Long antistatic brush installed on the Unwinder bottom roller axle ..............93
Figure 94 Longer and shorter axles on understep roller Input press side....................94
Figure 95 Longer and shorter axles on understep roller Unwinder side.......................95
Figure 96 Placement of Tension in web label ..............................................................96
Figure 97 Disconecting ground cable...........................................................................97
Figure 98 Disconnecting the encoder and power supply .............................................98
Figure 99 Four screws that secure the motor to the wall .............................................99
Figure 100 Loosen long belt on motor drive shaft........................................................99
Figure 101 Motor plate and Input section drive belt ...................................................100
Figure 102 Impression encoder connector.................................................................101
Figure 103 Input side ground cables.........................................................................102
Figure 104 Removing Input side vacuum box bracket ...............................................103
Figure 105 Output side vacuum box brackets............................................................103
Figure 106 Vacuum box sensor cable Molex and vacuum hoses..............................104
Figure 107 Removing the interlock.............................................................................105
Figure 108 Removing the interlock cable bracket ......................................................106
Figure 109 Pneumatic manifold..................................................................................107
Figure 110 Top and bottom ground cables on rear Output wall.................................108
Figure 111 Removing Output guard interlock cables .................................................108
Figure 112 Pushing Molex out of bracket...................................................................109
Figure 113 Removing Output and Exit Nip guard interlock cables.............................109
Figure 114 Homing sensor.........................................................................................110
Figure 115 Replacing Output rollers and the web break sensor ................................111
Figure 116 New rollers from kit ..................................................................................112
Figure 117 Sensor kit parts ........................................................................................113
Figure 118 Extra sensor bracket ................................................................................113
Figure 119 Position of the reflector the reflector plate and the bar ............................114
Figure 120 Screwing reflector on support bar ............................................................114
Figure 121 Web break Sensor assembly as seen from inside press ........................115
Figure 122 Screw sensor on the bottom of the sensor plate......................................115
Figure 123 Output side–printing engine .....................................................................116
Figure 124 Press Output with Output assembly cover removed ................................116
Figure 125 Marking knobs..........................................................................................117
Figure 126 BID engage knob removal........................................................................118
Figure 127 BID engage assembly..............................................................................118
Figure 128 Routing BID 1 cable .................................................................................119
Figure 129 BID 7 cable location ................................................................................119
Figure 130 New BID 7 assembly................................................................................120
Figure 131 New BID 7 assembly in place ..................................................................120
Figure 132 Mark BID knobs........................................................................................121
Figure 133 Output view–fully assembled ...................................................................121

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Figure 134 ESB board with old connector on J38 ......................................................122
Figure 135 Ceiling cover gasket.................................................................................123
Figure 136 Removing the right Molex from the GDB panel........................................123
Figure 137 CC108C cables pulled from ESB board on back of press .......................124
Figure 138 Output assembly front cover ....................................................................125
Figure 139 Laser shroud tube assembly seen from Output of press .........................125
Figure 140 Roof top panel and left channel cover removed.......................................126
Figure 141 Running the CC108C cable from the ESB board to the left channel .......127
Figure 142 MPT-4099-51 Light guard assembly ........................................................128
Figure 143 ILD cooling assembly P/N 245-00840......................................................129
Figure 144 ILD cooling fan and CC108C connectors.................................................129
Figure 145 Scorotrons and scorotron bridge..............................................................130
Figure 146 Removing the scorotrons .........................................................................131
Figure 147 Scorotron Bridge control handle...............................................................131
Figure 148 Removing the screw from the back of the pivot shaft ..............................132
Figure 149 Removing the C clips from the pivot shaft................................................132
Figure 150 Removing the pivot arms .........................................................................133
Figure 151 Removing screw from front side of pivot shaft .........................................133
Figure 152 Spacers between the drive motor and the plate.......................................135
Figure 153 Washer screw and anaerobic adhesive ...................................................135
Figure 154 Reconnecting encoder and power connectors.........................................136
Figure 155 Push interlock cable Molex connector through the wall ...........................137
Figure 156 Connect the interlock Molex.....................................................................137
Figure 157 Secure the interlock and pneumatic piston ..............................................138
Figure 158 Replacing the interlock cable cover .........................................................139
Figure 159 Pneumatic manifold..................................................................................139
Figure 160 Connecting the manifold connector..........................................................140
Figure 161 Connecting the main air supply to the manifold .......................................141
Figure 162 Engage NIP roller air hoses .....................................................................142
Figure 163 Attaching the ground cables.....................................................................142
Figure 164 Vacuum box supporters ...........................................................................144
Figure 165 Installed vacuum box supporters .............................................................144
Figure 166 Vacuum box ground cables......................................................................145
Figure 167 Installing Input and Output side vacuum box brackets.............................147
Figure 168 Vacuum box hoses with clamps alternated..............................................148
Figure 169 Cables from touchscreen to junction box and Profibus............................149
Figure 170 Motor plate position..................................................................................151
Figure 171 Installing motor on Output assembly wall.................................................152
Figure 172 Removing the preheater connector bracket cover ...................................153
Figure 173 Removing the preheater spindle screws..................................................153
Figure 174 Removing the reheater spindle and spring ..............................................154

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Figure 175 Loosen the inner locking screw................................................................154
Figure 176 Removing the inner gear pin....................................................................155
Figure 177 Sliding out the Input section drive belt .....................................................155
Figure 178 Replacing the preheater spidle and screw...............................................156
Figure 179 Gates Sonic meter 505C..........................................................................157
Figure 180 Measuring belt tension.............................................................................157
Figure 181 Plucking the belt to get a reading.............................................................158
Figure 182 Belt locations............................................................................................159
Figure 183 Loosening the motor bracket....................................................................160
Figure 184 Parts to be installed..................................................................................160
Figure 185 New parts in place—press feed side........................................................161
Figure 186 Press input ...............................................................................................161
Figure 187 Press front................................................................................................162
Figure 188 Remove cleaning station connector.........................................................162
Figure 189 Remove the cleaning station....................................................................163
Figure 190 IR sensor and bracket..............................................................................163
Figure 191 Remove IR sensor electrical connector ...................................................164
Figure 192 Remove IR sensor bracket.......................................................................165
Figure 193 Remove tray below PIP drum ..................................................................166
Figure 194 Remove two tray support screws in front .................................................166
Figure 195 Remove tray support screw in rear of press ............................................167
Figure 196 Remove the rear bracket..........................................................................167
Figure 197 Install new rear bracket and cable clamp.................................................168
Figure 198 Install catch tray below PIP drum.............................................................169
Figure 199 Fasten catch tray support screw in rear of press .....................................169
Figure 200 Fasten catch tray support screws in front of press...................................170
Figure 201 Install new IR sensor bracket ...................................................................170
Figure 202 Insert IR sensor cable through wall and attach IR sensor cable ..............171
Figure 203 Connect mating connectors .....................................................................171
Figure 204 Move bracket to center.............................................................................172
Figure 205 Attach gutter.............................................................................................172
Figure 206 Antistatic brush on second transfer knob housings..................................173
Figure 207 short antistatic brush and inspection plate...............................................173
Figure 208 Short anistatic brush installed on the inspection plate .............................174
Figure 209 Pin on Output assembly for Inspection plate............................................174
Figure 210 Inspection plate and antistatic brush installed..........................................175
Figure 211 Long brush brass rod and clamps............................................................175
Figure 212 Clamps on the right and left sides of the roller axle .................................176
Figure 213 Long antistatic brush installed on lower Exit roller axle............................176
Figure 214 Leveling the press....................................................................................177
Figure 215 Leveling the press....................................................................................177

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Figure 216 Leveling pad height adjustment bolt.........................................................178
Figure 217 Leveling the vacuum box .........................................................................179
Figure 218 Distance jig...............................................................................................180
Figure 219 Using the distance jig...............................................................................180
Figure 220 Antistatic bars and brackets.....................................................................181
Figure 221 Final placement of Rewinder Antistatic bars ............................................181
Figure 222 Removing the screws...............................................................................182
Figure 223 Bracket and slot .......................................................................................182
Figure 224 Brackets facing center of table.................................................................183
Figure 225 ILD cooling unit on its bracket..................................................................184
Figure 226 Aligning the ILD sight blade on the ILD bar..............................................184
Figure 227 Inverter panel ...........................................................................................185
Figure 228 Damaged impression roller ......................................................................188
Figure 229 Printing the rectangle (corner) on the drum .............................................190
Figure 230 Measuring from the left side of the drum (old and new drums)................191
Figure 231 Using the corner jig ..................................................................................192
Figure 232 Tape down the sponge on the sensor strip..............................................193
Figure 233 Ensure the Sensor mode is set to D ........................................................193
Figure 234 Lit LEDs seen from the end of the sensor strip on Vacuum box ..............194
Figure 235 Checking the sensor on the vacuum box.................................................195
Figure 236 Vacuum box TSP Screen showing only the middle sensor is covered ....196
Figure 237 Ensure the Sensor mode is set to D ........................................................196
Figure 238 Diagnostic screen.....................................................................................198
Figure 239 Remove the sensor..................................................................................199
Figure 240 Removing clip from the sensor.................................................................200
Figure 241 Pull sensor off its base.............................................................................200
Figure 242 Fitting sensor into sensor base ................................................................200
Figure 243 Clip fits into the sensor.............................................................................201
Figure 244 UniDrive keypad.......................................................................................201
Figure 245 Knobs and housings on Input assembly wall ...........................................215
Figure 246 Unscrew the screw that secures the adjustment knob.............................215
Figure 247 Lifting off the knob cover..........................................................................216
Figure 248 Set screw .................................................................................................216
Figure 249 Removing C clip.......................................................................................217
Figure 250 Installing housing on Input assembly wall................................................217
Figure 251 Closeup of outside of wall ........................................................................218
Figure 252 Second transfer cable in housing.............................................................218
Figure 253 Second transfer cable clip........................................................................219

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1. Purpose
To include a group of component features in a kit for HP Indigo press ws4000.
Combining these features into one kit saves press down time during the upgrade.
This cluster of features is generally inter-related and may have prerequisites of other
features in the group.
This document describes how to perform the upgrades in two steps:
•Software only
•Non software procedures
If you install only the software portion of the document, it is independent of the
hardware portion of the document, and you will not need to perform the hardware
portion of the document.
The new features enable printing on transparent substrates and improve the
performance of and ease of access to various press components including the
following functions.
Software version 6.2.1
Improves reliability and servicing of: scaling job, vacuum level control, input roll
diameter, small repeat length correction and corner wizard procedures.
WHS Software 1.0.9
Software upgrade for WHS
ILD firmware
Supports auto machine LUT processes.
Black rod replacement
Reduces LE to TE OD varience
BID knobs bracket for ws4000
Improves usability of BID knobs
New Input assembly unit (Feed III)
Enables simpler changing of Input section (long) drive belt
ILD Cooling Assembly
Prevents overheating and reading errors
Anti-drip kit assembly
Minimizes imaging oil splatter from the gears around the ITM and from the Cleaning
station condensation onto the substrate
Rewinder Antistatic bars
Reduces static charge on substrate as it passed over the Rewinder plate.
Components
The changes to the press include the following assemblies and features: