HP Indigo Division Series Technical manual

HP Indigo Division Installation Instructions
filename: CA294-03070-00.doc page 1 of 153
Installation Manual
Purpose
To provide information and instructions for performing the installation of the HP Indigo press w3250.
Installation instruction details
Item Details
Objective Modification available - performance/ Modification available -
reliability
Scope HP Indigo press w3250
Document number CA294-03070
Kit number As per press
Date 13 Feb 07
Related ECO N/A
Security level 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

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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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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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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

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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

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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

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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.

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Quick reference checklist
The following procedure is a quick reference guide of the installation procedure intended for two
integrators and extended over five days.
Heading Step Reference Procedure Notes and
check
1st Day
Pre-installation
Site
preparation
1. Verifying site
preparation on page
23
Verify site preparation as per Site
Preparation Guide
Site Preparation
check list
Measuring
and marking
2. Marking the
pressroom floor on
page 23
Use marker pen to mark profile of press,
cabinets, unwinder, ILP and Finisher on
floor
Marker pen
Cable meter
Unpacking 3. Unpacking the boxes
on page 23
Unpack the boxes and verify their contents
either with the BOM or Packing list on page
17.
Packing list
Installation
Electric
cabinets
(20 mins)
4. Installing the
electrical cabinets on
page 24
Install electrical cabinet M1 and M2 in their
marked position.
5. Position the u-bases
on page 24
Position the u-bases on the floor. Adjust
distance between u-bases to 693.0 mm at
a height of 200 mm. from the floor.
6. Position the foresight
stand on page 28
Use surveying tool to align u-bases
accurately. Raise the tripod and surveying
tool to 1550.0 mm.
U-bases
(40 mins)
7. Install the junction
bars on page 32
Install the junction bars between the two u-
bases.
8. Mount the PE2 on
page 33
Mount the PE2 on the u-base. Use the
lifting and positioning assembly.
9. install the platform on
page 43
Install the platform between the printing
engines.
10. Mounting the turnbar
on page 44
Mount the turnbar assembly to PE1.
11. Mounting the PE1 on
page 45
Mount the PE1 on the u-base. Use the
lifting and positioning assembly.
12. level each printing
engine on page 46
Level each printing engine to an accuracy
of 0.0 ± 0.1 mm
13. align the printing
engines on page 49
Accurately align the printing engines
horizontally using the surveying tool.
14. Securing the turnbar
on page 54
Mount the front and rear connection
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.
Packed with PE2
Printing
engines
(160 mins)
15. connect the printing
engines on page 56
Install front link brackets to attach two PEs.
Recheck alignment using surveying tool.
Check parallelism between PEs using the
parallel jig. Measure to an accuracy of
0.00 ± 0.01 mm

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Heading Step Reference Procedure Notes and
check
16. Install the electrical
cabinet-to-cabinet
cables on page 61
Install electrical cabinet M2 to cabinet M1
cabling.
Install electrical cabinet M1 to cabinet M2
cabling.
17. Install the electrical
cabinet M1 cables to
PE1, PE2 on page 62
Install electrical cabinet M1 to PE1 and
PE2.
18. Install the electrical
cabinet M2 to PE1,
PE2 on page 62
Install electrical cabinet M2 to PE1 and
PE2.
19. Install the electrical
cabinet M1-to-master
console cables on
page 63
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.
20. Install all Unidrive
cables on page 66
Install all PE1 and PE2 Unidrive cables in
electrical cabinets M1 and M2.
21. Install the PE1-to-
PE2 cables on page
67
Install the PE1-to-PE2 cables.
22. Install the PROFIBUS
cables as on page 67
Install ProfiBus communication cable
between electrical cabinets M1 and M2 and
PLC in cabinet M1.
23. Install the CTNET
cables on page 68
Install CTNet cables between all Unidrives
at electrical cabinets M1 and M2.
24. Route the MPI
(MODBUS) cables on
page 69
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.
Wait for floor and
ILP to connect.
Electrical
wiring
(180 mins)
25. Connect the ProfiBus
and CTNet cable
connections on page
69
Connect the following ProfiBus and CTNet
cable connections at electrical cabinets M1
and M2
Vacuum
hoses
(40 mins)
26. Installing the vacuum
hoses on page 70
Remove under-panel
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
2nd Day
Floor platform 27. Install the floor
platform on page 72
Install floor platform according to
specifications in Site Preparation Guide.
Start at unwinder and ILP area. For press,
start at corners of press or wall.

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Heading Step Reference Procedure Notes and
check
Chiller and
chiller pipes
(60 mins)
28. Installing the chiller
on page 72
Install chiller pipes adapters and
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
inlet) of 6°C
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
(depending on country of installation).
Hoses from chiller
should be prepared
UPS
(10 mins)
29. Install the UPS on
page 75
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.
Writing head
(30 mins)
30. Install the writing
head on page 76
Remove writing head from box 8.
Remove under-plate at heater window.
Install and align writing head.
HVPS
(40 mins)
31. Install the HVPS on
page 77
Install HVPS units and covers.
Roof
(15 mins)
32. Install the HVPS on
page 77
Install roof covers.
Utility cabinet
top cover
(15 mins)
33. install on page 117 Install utility cabinet top cover.
Various
components
(45 mins)
34. Install system
components on page
80
Install the following in each engine:
PTE/air knife.
Scorotron units.
Cleaning station and wiper blade.
ITM cover.
BID units.
Thoroughly clean the BID units.
Ametek filters.
3rd Day
Lift ILP,
unwinder,
utility
cabinets, ink
cabinets
(20 mins)
35. Lift and move the ILP,
unwinder, utility
cabinets, and ink
cabinets on page 80
Lift the ILP, unwinder, utility cabinets, and
ink cabinets to the raised platform floor.
36. Installing the ILP on
page 81
Position ILP near PE1. Position ILP feed
and exit stepping plate assemblies near
ILP.
ILP
(120 mins)

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Heading Step Reference Procedure Notes and
check
37. install the ILP exit
stepping plate on
page 83
Install the ILP exit stepping plate assembly
to the ILP.
38. align the ILP and
stepping plate
assembly on page 86
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.
39. Measure on page 87 Measure distance between stepping plate
front edge and PE1 front wall. Distance
should measure 30 mm.
40. Release on page 88 Release (do not remove) six ILP alignment
plate locking screws.
41. Lower on page 88 Lower four ILP feet until castors
approximately 5 mm above floor platform
and feet touch floor.
42. level and align the
ILP on page 89
Level the the ILP
43. align the ILP on page
93
Align the ILP using the parallel jig.
44. level and align the
ILP exit stepping
plate rollers on page
94
Level and align the ILP exit stepping plate
rollers.
45. Install the ILP feed
stepping plate on
page 96
Install the ILP feed stepping plate. Align
and level the stepping plate to the ILP.
46. install the priming
rollers on page 99
Install the ILP priming rollers
47. Installing the
unwinder on page
100
Position, install, level and align the
unwinder.
48. align the unwinder on
page 103
Align the unwinder with the ILP feed
stepping plate.
Unwinder
(60 mins)
49. Unwinder electrical
connections on page
104
Install and connect all appropriate wiring
and air hoses.
50. ILP electrical
connections on page
105
Install cables between the ILP connections
panel and cabinet M1.
51. Install on page 105 Install cables between cabinet M1and the
ILP connections panel
52. Connect on page 105 Connect air hoses and cables to the ILP
connections panel
53. Install on page 106 Install the cable securing clamps on the
clamp rail.
ILP wiring and
air hose
connections
(160 mins)

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Heading Step Reference Procedure Notes and
check
54. Connect on page 108 Connect the following air hoses at the ILP
front:
Input hose from mains air supply to
Inlet connection.
Long outlet hose from Outlet to PE
connection to PE1.
Long outlet hose from Outlet to UW
connection to unwinder.
55. Install the ILP rear
panel safety cover on
page 111
Install safety cover at the ILP front.
56. Install the ILP
vacuum hoses on
page 112
Connect the vacuum hose to the ILP.
57. Installing the ink
cabinets on page 113
Install each ink cabinet according to color
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 installed,
make sure that relevant calibration kit is
ordered for extra colors.
Ink cabinets
(90 mins)
58. Place on page 116 Mount and install the corian working
surface.
Mount the monitor, keyboard and mouse
on working surface.
Web guide
(10 mins)
59. Adjusting the web
guide on page 116
Remove the two securing screws and
adjust the web guide.
Customer to save screws.
To troubleshoot, refer to w3200 service
manual Calibrations.
Utility
cabinets
(20 mins)
60. Install the utility
cabinet on page 117
Install the utility cabinets and connect
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.
61. Connect the
computers on page
121
Check the network diagrams in Figure 102,
Figure 103, and Figure 104 on page 121 -
122.
Install Slaves 1 and 2 computers in
electrical cabinet M2.
62. Install the computer
cables on page 126
Install the computer cables to both slave
computers.
Computers
installation
(40 mins)
63. Install the master
console on page 127
Install master console, and connections to
master computer.

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Heading Step Reference Procedure Notes and
check
Production
flow
64. Production flow on
page 130
Organize and install network cabling, RIP
systems, HPPF units to aid production
flow.
4th Day
Rewinder jig
and finishing
components
65. Install the finishing
components on page
130
Install the rewinder jig to test the press.
After testing, install finishing components
according to customers design and Site
Preparation Guide.
Turnbar
stepping plate
66. Installing the turnbar
stepping plate on
page 130
Install turnbar stepping plate.
Transformer
67. Install the main power
connection and
transformer on page
130
A local qualified electrician should install
and connect the transformer and electrical
mains power connections.
Initial
power-up
68. Initial power-up on
page 131
Perform initial power up as detailed on
page 131.
Local electrician to be present at startup to
check mains power connections.
Thread web 69. Threading the web on
page 138
Mount a roll at unwinder and thread to
finisher according to
Configure
press
70. Configure the press
software on page 139
Install latest version of press software with
authorization codes.
PIP and
blankets
71. Install PIP and
blankets on page 139
Mount and install PIP and blankets on
relevant drums.
5th Day
72. Testing and
calibrating the press
on page 139
Test and calibrate press:
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.
In the Diagnostics>Elements Ink Flow
tab perform tests
Testing printing engine voltages on page
142.
ATP
Performing integration and testing on page
143:
1. Build the inks.
2. Verify that the ink flows.
3. Verify that the second transfer
pressure is correct.
4. Install a new blanket and PIP foil.
5. Adjust the BID pressure.
6. Perform the first transfer pressure
calibration.
7. Verify the writing head skew.
Changing the skew may affect focus.

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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.

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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.

Installation Manual
CA294-03070 rev 00 page 16 of 153
Heading Step Reference Procedure Notes and
check
aa. Click Setup.
The Setup OD of 100% Spec
Values window opens.
bb. Enter the optical density values
noted in step l above in the
appropriate color fields.
cc. Click OK.
A warning may appear. 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.
Testing during normal operation on page
145.
73. CATP on page 145 Perform CATP test procedure:
Printing CATP test on page 147.
Check CATP against CATP specification
checklist on page 147.
COI 74. Complete the
installation on page
150
Complete installation as detailed on page
150.

Installation Manual
CA294-03070 rev 00 page 17 of 153
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. Part number Contents Qty Name and weight (kg)
1
CA254-01592
CA294-03070
WHS electrical cabinet M1b
Keys
Installation Manual
1
3
1
Electric Cabinet
2
CA254-00322
CA271-00263
EBC-3005-01
WHS electrical cabinet M2b
Keys
Computer Slave #1 and #2
Network Ethernet SW1
1
4
2
2
Electric Cabinet
3 MPQ-0620-51 U-base assembly 2 U-base
4
CA290-05140
MPQ-0024-33
MSQ-0017-02
MJX-2427-51
MZH-0328-02
Printing engine 2 (PE2)
Working surface
Leveler 75x150-55 Airloc
Fixing bracket assembly
Pipe Insulation 1-1/8”
1
1
4
2
1
PE2 engine
5
CA290-05130
MPQ-0024-33
MSQ-0017-02
MZH-0328-02
Printing engine 1 (PE1)
Working surface
Leveler 75x150-55 Airloc
Exit inverter roller
Pipe Insulation 1-1/8”
1
1
4
1
1
PE1 engine
6 CA290-0523X Vacuum hose pipes kit for
w3250
1 Vacuum pipes kit for w3250
7
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
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
1
2
1
1
2
1
2
1
Miscellaneous PE2

Installation Manual
CA294-03070 rev 00 page 18 of 153
Box no. Part number Contents Qty Name and weight (kg)
8
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
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
1
2
6
8
2
2
1
1
1
1
2
1
1
2
1
1
2
Miscellaneous PE1
9 CA244-05941
CA245-08182
CA245-08352
Screws M8x40, flat
Washers, Spring Washers
Cover for left ramp
Left ramp assembly – ILP
Right ramp assembly -ILP
8 of
each
1
1
1
Ramp
10
CA245-01234
CA240-47210
CA245-16791
CA245-04963
ILP
Air pipe black dia.=12
Upper rubber roller assy
ILP, lower roller assy
1
2
2
2
ILP
11
5188-1250
CA240-60860
5188-4872
UW6 - Unwinder for w3250
Pipe air 8mm
Panel front
Perspex covers for uw6
Feed roller
Unwinder book
1
1
1
1
1
1
Unwinder
12
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
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
1
1
1
1
1
1
1
1
3
1
1
1
3
1
Master Console

Installation Manual
CA294-03070 rev 00 page 19 of 153
Box no. Part number Contents Qty Name and weight (kg)
13 Q5391-00680 Kit cons. Instl. W3250 1 Consumables kit
14 MPR-1309-11 Pap. Roll condat 115 1 Paper roll condat 115
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

Installation Manual
CA294-03070 rev 00 page 20 of 153
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
6
9
5
4
2
3
1
87
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