Ink Replacement Kit

HP Indigo press series 3000, series 4000 and UltraStream 2000

User guide

English version

illustration
Ink Replacement Kit

User guide
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September 2005
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Printed in Israel.
 Contents
1 Ink Replacement
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
System requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Important system information and limitations . . . . . . . . . . . . . . . . . . . . . . . . . 6
Preventing eye irritation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Setting the imaging oil level markers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Changing the press configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Loading the ink definition file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Changing color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Overview of changing color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cleaning the ink system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cleaning the BID and flushing the system . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Ink Installation Wizard Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Changing the optical density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Performing a color adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Appendix A Supplies and jigs

Ink Replacement kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Appendix B Service and support

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4 Contents ENWW
 1 Ink Replacement

This chapter contains the following sections:

z Overview
z System requirements
z Preventing eye irritation
z Setting the imaging oil level markers
z Changing the press configuration
z Loading the ink definition file
z Changing color
z Changing the optical density
z Performing a color adjustment

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Overview

It is often desirable to print with spot color inks in addition to the Cyan, Magenta, Yellow,
and Black (CMYK) process colors. The HP Indigo presses enable you to use such special
inks. The HP IndiChrome ink mixing system (IMS) gives you the capability to prepare the
special ink you require by mixing inks from a set of basic inks. Because the inks are
specially tailored to customer requirements, the inks are referred to as custom inks.
This user guide is suitable for the following HP Indigo presses:
z HP Indigo press 3000
z HP Indigo press 3050
z HP Indigo press ws4000
z HP Indigo press ws4050
z HP Indigo press w3200
z UltraStream 2000

System requirements

HP Indigo press software version 6.0 or higher.

Important system information and limitations

Cleaning and preparing the ink tank may take between 40 and 60 minutes. You can save
20 minutes if you use a replacement BID, ink pump, and ink tank.

Preventing eye irritation

Inks and imaging oil may irritate the skin and eyes. In extreme cases of exposure, these
substances may cause blindness.
As a precaution:
z Wear protective eye covering.
z Install eye wash stations within 7.6 m (25 ft) of areas where the ink and imaging oil
are handled, dispensed, or stored.
Provide eye wash liquid at the eye wash stations (available from most safety supply
companies) to comply with ANSI standard Z358.1-1990.

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Setting the imaging oil level markers

1 Fill the empty ink tank with 3775 ± 25 ml (127.6 ± 0.9 fluid ounces) of clean imaging
oil. The equivalent weight of this volume of imaging oil is 2900 ± 20 g (102.3 ±
0.7 ounces).

You can use the imaging oil bottle to determine the amount
of imaging oil to add. The correct level is between the two
10 mm (0.39 inch)

5 mm (0.19 inch)
level lines marked on the bottle.
If the lines are missing on the bottle, then follow the steps
below to mark the bottle:
• To mark the lower line, measure 5 mm (0.19 inch) from the
curved line on the bottle.
• To mark the upper line, measure 10 mm (0.39 inch) from
the curved line on the bottle.

Figure 1-1. Marks on imaging oil bottle

2 Attach the imaging oil level label supplied with the kit to the tank—the vertical
midpoint of the label should be placed at the imaging oil level in the tank. If labels are
not available, use a marker to mark the ink tank.

MAX

MIN

MAX

MIN

Figure 1-2. Imaging oil label

Changing the press configuration

Change the press configuration to the required number of inks as follows:

1 Go to the System menu and select User level
2 Select Technician and type in the password.
3 Click OK and the press changes to Technician mode.
4 Go to the Options menu and select Press Configuration

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 5 Click Inks and Bids from the tree on the left of the window.

Figure 1-3. Inks and BIDs in the HP Indigo press

6 Under BIDs configuration, select the required extra BIDs that you plan to install and
select the color(s) to be installed in them.
7 Click Apply, and you will be asked to restart the press. Do so before continuing.

Loading the ink definition file

1 From the Options menu, click Ink List.

The Ink List window is displayed.

Figure 1-4. Ink List

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 2 Click Import.
The Import ink definition window is displayed.

Figure 1-5. Import ink definition

3 Select the network folder in which you saved the ink definition file on the IMS
computer.
If you have the ink definition file on a disk, insert the disk into the press computer, and
select the 3½ inch floppy drive (A:).

4 Select the ink definition file. The file must have a .osm extension.

Note To see only ink definition files, select On-Site Mixing (*.osm) in the Files of type field.

5 Click Open.
6 Click Close.

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Changing color

Before you start this procedure, make sure that you have the following items (see
Appendix B for part numbers):
z Ink cleaning can (an empty can with a hole on top for adding imaging oil)
z Ink calibration can (contains a predetermined amount of ink for calibrating the ink
density sensor—for spot colors)
z Pipe cleaning system (includes a filter and a BID simulator)

Note The filter is good for 40 cleaning cycles, after which it should be replaced.

Figure 1-6. Pipe cleaning system

Overview of changing color

The details for performing each step are outlined below.
z Clean the ink system
z Clean the BID and flush the system
z Run the Ink Replacement wizard
z Run the Density Calibration wizard

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 Cleaning the ink system
1 Fill the HP cleaning canister with clean imaging oil, and place it into the desired ink
can holder.
2 Click Diagnostics, Ink, and in the Ink Properties window that opens, select the
relevant spot color tab.
3 Click the Density Add Control green button to drain the imaging oil in the HP cleaning
canister through the ink pump tubes.

Figure 1-7. Ink Properties—Density Add Control button

Cleaning the BID and flushing the system

In order to flush the system of residual ink, and to clean the ink tank, do the following:
1 Dry the BID. From the control panel, click Consumables, BID units, and select the
Dry BID Units tab. Select the check box for the desired color, and click the Dry green
button.
2 Remove the BID.

Note Never wipe the developer roller with a dry wipe, as you will scratch it.

3 Use a lint-free wipe dampened with imaging oil to wipe the surface of the developer
roller. Keep rotating the developer until its surface is clean.
4 If a BID washer is available, use it to clean the BID using the "Long" wash cycle (refer
to the BID Washer User guide under the section "Cleaning the BID unit").
5 Store the BID in its original styrofoam container. The BID can be reused in the cyan,
magenta, or black positions.
6 Drain the ink from the ink tank.
7 Remove the ink pump and the ink tank. Clean the ink pump and the ink tank only after
this procedure is completed to save valuable time.
8 Install the clean ink pump and ink tank supplied with the kit.

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Note Skip steps 9, 10, and 12 below if you have a BID washer.

9 Remove the clean BID fitting from the BID simulator.

10 Connect the used BID fitting to the BID simulator.
11 Latch the BID simulator into place in the press.

BID simulator

Front door

Filter

Figure 1-8. Pipe cleaning system installed in the press

12 Connect the hose fitting to the BID fitting (Figure 1-8).

13 Hang the filter in the position shown in Figure 1-8.
14 Close the front door (Figure 1-8).
15 Run the ink replacement wizard (see below).

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 Ink Installation Wizard Manager
The Ink Installation Wizard Manager consists of four stages. Follow the steps shown on
the Ink Installation Wizard Manager window in order to install the spot color.
From the control panel, click Consumables, and Install Ink to open the Ink Installation
Wizard Manager.

Four steps

Figure 1-9. Ink Installation Wizard Manager

Step 1: Ink Replacement

1 Put the press in Standby.
2 From the Ink Installation Wizard Manager, click Ink Replacement.
3 Follow the wizard instructions.
4 Load the appropriate ink file located on the supplied CD/floppy.
5 Click Options, Ink List, and Import. From the list in the Import ink definition window,
select the CD/floppy location, highlight the desired ink file, and click Open.
6 Click Ink Replacement to open the Ink Replacement window.

Figure 1-10. Ink Replacement—Select Ink Tank window

7 Select the ink you want to change (Figure 1-10).

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 8 Click Next.

Figure 1-11. Ink Replacement—Clean Tube window

9 Follow the steps in Figure 1-11.

10 When the cleaning cycle is complete, click Next.
11 Follow the instructions on the window below.

Figure 1-12. Ink Replacement—Cleaning Cycle window

12 The cleaning cycle operates for twenty minutes.

13 If the imaging oil in the ink tank is not sufficiently clean, then you need to repeat the
Start Cleaning cycle.
14 Remove the BID simulator after cleaning out the tank.
15 Install a new BID in the press.
16 Install the ink calibration can for a new spot color.

Note You can obtain the ink calibration can from the ink mixing process, or by purchasing it from HP
Indigo.

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 17 Click Next in Figure 1-12. The Ink Replacement—Select Ink window opens.

Figure 1-13. Ink Replacement—Select Ink window

18 Choose the desired ink file, and click Replace.

19 Click Finish.
20 Add imaging oil, if needed, to the ink tank until its level reaches the vertical midpoint
of the imaging oil label.

Step 2: Density Calibration

1 Insert the calibration ink can into the press ink can holder.
2 Click Density Calibration. The Density Calibration window opens.

Figure 1-14. Density Calibration—Select Ink Tank window

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 3 Select the desired spot color to be replaced, and click Next.

Figure 1-15. Density Calibration—Ink Preparation window

4 Click the Ink Preparation start button (Figure 1-15).

5 Click Next.

Figure 1-16. Density Calibration—Enter Values window

6 Click the green Add Ink button for two minutes to push the first can contents into the
ink tank.
7 If using an ink calibration can, enter 1.75 for ink density (Figure 1-16). If not, enter the
reading from an external density meter (for readings between 1.65 and 1.75).

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 8 Click Next, and wait for the results.

Figure 1-17. Density Calibration—View Results window

9 Click Calculation.
10 If results are within range, click Finish. If not, on the Density Calibration—View
Results window, click the question mark to view corrective actions (Figure 1-17).

Step 3: Conductivity Calibration

1 From the Conductivity Calibration window, select the relevant spot color and click
Next.
2 Record the Conductivity value shown in the window, and click Next.
3 Enter the recorded value in the relevant spot color text box, and click Calculate.
4 When the conductivity sensor is successfully calibrated , click Finish.

Note If the ink pump conductvity sensor was never calibrated, contact your local customer care center.

Step 4: Custom Auto Color Adjustment

1 From the Ink Installation Wizard Manager, click Custom Auto Color Adjustment.
2 Follow the wizard instructions.

Note Remember to clean the dirty ink tank and ink pump for later use.

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Changing the optical density

Some custom inks require you to change the optical density before performing color
adjustment. To do this, perform the following:
1 Go to Standby, and press an Emergency Stop button.
2 Open the ink cabinet door.
3 Drain some ink from the tank, see the following table for details. You do not need to
drain the entire tank to correct the ink density. The amount of ink that is drained is
proportional to the density decrease needed.
Drain 0.19 liter (6.4 ounces) of ink for every 0.1 percent decrease in ink density.

Reduction in Amount of Amount of

ink density drained ink drained ink
(percent) (liter) (ounces)
0.1 0.19 6.4

0.2 0.36 12.2

0.3 0.52 17.6

0.4 0.67 22.7

0.5 0.80 27.1

4 Release the Emergency Stop button.

5 On the control panel, click Consumables, and Ink Cans.
6 Select the desired ink color, and click Rebuild.

Figure 1-18. Ink cans window

7 Click Close.

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 8 On the control panel, click Diagnostics, and Ink. The Inks Properties window opens.

Click Get Ready or this icon to

calibrate fluid levels automatically

Figure 1-19. Ink Properties window

9 On the control panel, click Get Ready, or the arrow in the Ink Properties window
(Figure 1-19).
10 In the Inks Properties window, click Ink Pump for the desired color. This replaces the
drained ink with imaging oil.
11 Wait for the density to stabilize.

Note If the ink density keeps rising above 2.0, clean the pump and density sensor, and then recheck
the density. If the problem persists, call your local customer care center.

Performing a color adjustment

1 Insert an additional can into the ink can holder.

2 In the Ink Installation Manager window, click Custom Auto Color Adjust, and use
the wizard as instructed.
3 If a value in the Measured / Dot Area of 50% field in the View Results table is red,
ignore the respective red Error indicator.
4 The following error may appear after color adjustment printing:
In the View Results table, a value in the Measured / OD of 100% field may be red. In
this case, the red Error indicator appears in the Color Adjustment Status row.

This indicates the inability of the press to achieve the OD as high as required for the
colors indicated.

If these Error indicators appear for the custom color, perform the following steps:

a Record the Measured / OD of 100% value.

b Click Finish.
c Click Custom Auto Color Adjust.
d Click Setup, and change the OD spec to the Measured / OD of 100% value
multiplied by 0.9.
e Click OK, and continue with the wizard.
f Return to step 3.
g Click Close.

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20 Chapter 1 Ink Replacement ENWW
 A Supplies and jigs

This appendix contains the following sections:

z Ink Replacement kit

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Ink Replacement kit

Description Part number

Ink cleaning can (HP cleaning canister) MJX-0605-41

Pipe cleaning device MKT-0503-41

Ink tank assembly CA245-12450

Ink pump CA245-14080

Imaging oil level label MLB-0175-01

Spin-on filter MFL-1900-01

The Ink Replacement kit (Q4870A), contains all of the parts listed in the above table.

Note Orders for supplies may be handled through the HP Indigo portal:

www.hp.com\go\indigo

22 Chapter A Supplies and jigs EN

 B Service and support

To obtain service, please contact the customer care center (CCC) within your
country/region:
Europe
Germany: +49 (0) 6995307080
France: +33 (0) 149932498
UK: +44 (0) 2072950038
Italy: +39 0 238591081
Belgium: +32 (0) 26264803
Netherlands +31 (0) 43 3565900
Luxembourg: +352 (0) 2730 2067
Ireland: +353 (0) 1 605 8409
Distribution Channels (DC): +31 (0) 20 6545543
North America: 1-800-204-6344
Israel: +972 8 938 1818

North America International

Hewlett-Packard Company Hewlett-Packard Company
Indigo Division Indigo Division
550 King Street Limburglaan 5
Littleton, MA 01460 6221 SH Maastricht
USA The Netherlands

Israel
Hewlett-Packard Company
Indigo Division
Kiryat Weizmann
P.O. Box 150
Rehovot 76101, Israel

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EN 24
Copyright © 2005 Hewlett-Packard Company

This is an HP Indigo digital print. Printed in Israel.

www.hp.com/go/indigo

reorder: P/N CA293-02280