On-press Fast Ink Replacement

for HP Indigo press ws4050 Value Pack, HP Indigo press ws4500,

HP Indigo press 5000 and upgraded HP Indigo press 5000

User guide
On-Press Fast Ink Replacement for
HP Indigo press 5500
Upgraded HP Indigo press 5000
HP Indigo ws4050 value pack and
HP Indigo ws4500

User guide
 © 2006, 2007 Copyright directions provided by HP
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CA293-03240
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February 2007
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Printed in Israel.
 Contents
1 On-Press Fast 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

2 Changing color on web-based presses

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Run the Special Ink Replacement Wizard Manager . . . . . . . . . . . . . . . . . . . . . . 11
Run the Automatic Internal BID Flushing wizard . . . . . . . . . . . . . . . . . . . . . 11
Run the Automatic Special Ink Replacement wizard . . . . . . . . . . . . . . . . . . 15

3 Changing color on sheet-fed presses

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Run the Special Ink Replacement Wizard Manager . . . . . . . . . . . . . . . . . . . . . . 23
Run the Automatic Internal BID Flushing wizard . . . . . . . . . . . . . . . . . . . . . 23
Run the Automatic Special Ink Replacement wizard . . . . . . . . . . . . . . . . . . 27
Run Substrates and Screening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Appendix A Kit contents and setting the imaging oil level

On-Press Fast Ink Replacement kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Marking the imaging oil level on the flushing tank . . . . . . . . . . . . . . . . . . . . . . . 34

Appendix B Service and support

ENWW 3
4 Contents ENWW
 1 On-Press Fast 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

ENWW 5
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.
On-press fast ink replacement (OFIR) enables the customer to swap colors while the
press is printing with the minimum of down-time. OFIR removes the need for an off-line
BID washing station as BID cleaning is done on the press.

System requirements

HP Indigo press 50x0 with press software version 7.4 or higher.

HP Indigo press 4xx0 with press software version 6.6.2 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.
A press software upgrade may require a restart of the press software when the first wizard
is run after the upgrade. This is necessary to update the TIC board version

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.

6 Chapter 1 On-Press Fast Ink Replacement ENWW

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 special color 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

ENWW Setting the imaging oil level markers 7

 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 5000

6 Under Number of inks (Figure 1-3) select the checkbox for each tank which you
intend to use.
7 Click OK.

8 Chapter 1 On-Press Fast Ink Replacement ENWW

 2 Changing color on
web-based presses

This chapter contains the following sections:

z Overview
z Run the Special Ink Replacement Wizard Manager

ENWW 9
Overview

The OFIR system for changing colors consists of the following wizards run from the
Special Ink Replacement Wizard Manager:
z Automatic Internal BID Flushing—cleans the pipes and the BID using the flushing
tank
z Automatic Special Ink Replacement—installs the new ink on the press
Perform each wizard in turn to complete the changing color process.
There are the following options for the source of the new ink:
z First can—a calibration can used to create an exact density solution. The can is either
supplied with each special color box or created in the on-site ink mixing system (if
available).
z Prepared ink solution—a previously used ink solution, which is now to be reused.
Before you start this procedure, make sure that you have the following items (see
Appendix A for part numbers):
z Auxilliary ink 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 Flushing tank (with filter)

Note The filter is good for 3 cleaning cycles, after which it should be replaced. Mark the filter each
time after using the flushing cycle.

Filter

Figure 2-1. Flushing tank

10 Chapter 2 Changing color on web-based presses ENWW

Run the Special Ink Replacement Wizard Manager

From the control panel, click Consumables, and Special Ink Replacement to open the
Special Ink Replacement Wizard Manager.

Figure 2-2. Ink Installation Wizard Manager

Run the Automatic Internal BID Flushing wizard

1 Click Automatic Internal BID Flushing Wizard. The wizard window opens.

Figure 2-3. Select Ink Tank

2 Select the BID to be flushed.

ENWW Run the Special Ink Replacement Wizard Manager 11

 3 Click Next. The Flush Tube step opens.

Figure 2-4. Flush Tube

4 Fill the auxilliary ink can with clean imaging oil, and place it into the desired ink can
holder.
5 Select Insert the flushing can with imaging oil into the can holder.
6 Click Flush Tube.

Figure 2-5. Flush Tube – in progress

12 Chapter 2 Changing color on web-based presses ENWW

 7 Click Next when the flushing cycle is finished. The Dry BID step opens.

Figure 2-6. Dry BID

8 Click Dry BID.

9 Click Next when the BID drying cycle is finished. The Replace Tank step opens.

Figure 2-7. Replace Tank

10 Drain the ink from the ink tank.

11 If the drained ink is to be reused, mark the container of the drained ink with the
density value displayed on the Replace Tank screen.
12 Remove the drained ink tank.
13 Install the flushing tank supplied with the kit.
14 Fill the flushing tank with 4 liters of imaging oil.

ENWW Run the Special Ink Replacement Wizard Manager 13

 15 Select Replace the selected tank with a flushing tank.
16 Click Next. The Flushing step opens.

Figure 2-8. Flushing

17 Click Flush BID. The Flushing cycle takes about 20 minutes.

At the end of the Flushing cycle, the imaging oil in the flushing tank should be clear of
ink. (A slight tint does not indicate that the flushing process was incomplete.)

Note Cleaning the drained ink tank and its ink pump during the Flushing cycle saves valuable time.
Any residue left in the tank or pump can effect the resultant color of a new ink.

18 Click Next when the Flushing cycle finishes.

Figure 2-9. Finish

14 Chapter 2 Changing color on web-based presses ENWW

 19 Remove the flushing tank.
20 Click Finish.

Run the Automatic Special Ink Replacement wizard

1 Click Automatic Special Ink Replacement Wizard on the Special Ink Replacement
Wizard Manager screen. The wizard window opens.

Figure 2-10. Select Ink Tank

2 Select the ink you want to replace.

3 Click Next. The Ink File Selection step opens.

Figure 2-11. Ink File Selection

4 Select the required ink file from the list.

ENWW Run the Special Ink Replacement Wizard Manager 15

 5 Click Replace.
6 Click Next. The Ink Sourcing step opens.

Figure 2-12. Ink Sourcing

7 Select one of the ink source options:

• First can—a calibration can, used to create an exact density solution. The can is
either supplied with each special color box or created in the on-site ink mixing
system (if available). Continue the procedure with ‘First can’ on page 16.
• Prepared ink solution—a previously used ink solution, which is now to be reused.
Continue the procedure with ‘Prepared ink solution’ on page 17.

First can
1 Click Next. The Ink Building step opens.

Figure 2-13. Ink Building—First can

16 Chapter 2 Changing color on web-based presses ENWW

 2 Install the First can into the relevant pump and select Insert first can.
3 Fill the ink tank with clean imaging oil until the middle line (between the maximum and
minimum lines).
4 Install the ink tank in the press.
5 Select Install an ink tank that contains the precise quantity of imaging oil.
6 Click Build Ink.
The ink in the First can is emptied into the ink tank and the press recalibrates the
density sensor to a value between 1.65 and 1.75.

7 Click Next. The CA (Color Adjust) Selection step opens.

Prepared ink solution

1 Click Next. The Ink Building step opens.

Figure 2-14. Ink Building—prepared ink solution

2 Shake the prepared ink solution.

3 Pour the solution into the ink tank and install the ink tank in the press.
4 Type the density value kept with the stored ink solution into the value field.
5 Click Build Ink.
The press recalibrates the density sensor. Once this step is finished, the recalibrated
density value appears in the Value field.

ENWW Run the Special Ink Replacement Wizard Manager 17

 6 Click Next. The CA (Color Adjust) Selection step opens.

Figure 2-15. Color adjust

7 Select one of the color adjust options:

• Perform Color Adjust automatically—the color adjust process for the new color is
performed during the regular color adjust process.
• Perform full custom Color Adjust—the color adjust process for the new color is
performed at the end of the current job using the custom color adjust process.
• Perform Color Adjust after current job—the color adjust process for the new color is
performed at the end of the current job using the regular color adjust process.
8 Select the screening types that will be used for the Color Adjust.
9 Click Next. The Finish step opens.

Figure 2-16. Finish

18 Chapter 2 Changing color on web-based presses ENWW

 10 Click Finish. The press performs the color adjustment according to the selections.

ENWW Run the Special Ink Replacement Wizard Manager 19

20 Chapter 2 Changing color on web-based presses ENWW
 3 Changing color on sheet-fed
presses

This chapter contains the following sections:

z Overview
z Run the Special Ink Replacement Wizard Manager

ENWW 21
Overview

The OFIR system for changing colors consists of the following wizards run from the
Special Ink Replacement Wizard Manager:
z Automatic Internal BID Flushing—cleans the pipes and the BID using the flushing
tank
z Automatic Special Ink Replacement—installs the new ink on the press
z Substrates and Screening—selects the substrate and the screening types for the
color adjust
Perform each wizard in turn to complete the changing color process.
The following options are available for the source of the new ink:
z First can—a calibration can used to create an exact density solution. The can is either
supplied with each special color box or created in the on-site ink mixing system (if
available).
z Prepared ink solution—a previously used ink solution, which is now to be reused.
Before you start this procedure, make sure that you have the following items (see
Appendix A for part numbers):
z Auxillary ink can (an empty can with a hole in the 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 Flushing tank (with filter)

Note The filter is good for 3 cleaning cycles, after which it should be replaced. Mark the filter each
time after using the flushing cycle.

Filter

Figure 3-1. Flushing tank

22 Chapter 3 Changing color on sheet-fed presses ENWW

Run the Special Ink Replacement Wizard Manager

From the control panel, click Consumables, and Special Ink Replacement to open the
Special Ink Replacement Wizard Manager.

Figure 3-2. Ink Installation Wizard Manager

Run the Automatic Internal BID Flushing wizard

1 Click Automatic Internal BID Flushing Wizard. The wizard window opens.

Figure 3-3. Select Ink Tank

2 Select the BID to be flushed.

ENWW Run the Special Ink Replacement Wizard Manager 23

 3 Click Next. The Flush Tube step opens.

Figure 3-4. Flush Tube

4 Fill the auxilliary ink can with clean imaging oil, and place it into the desired ink can
holder.
5 Select Insert the flushing can with imaging oil into the can holder.
6 Click Flush Tube.

Figure 3-5. Flush Tube – in progress

24 Chapter 3 Changing color on sheet-fed presses ENWW

 7 Click Next when the flushing cycle is finished. The Dry BID step opens.

Figure 3-6. Dry BID

8 Click Dry BID.

9 Click Next when the BID drying cycle is finished. The Replace Tank step opens.

Figure 3-7. Replace Tank

10 Drain the ink from the ink tank.

11 If the drained ink is to be reused, mark the container of the drained ink with the
density value displayed on the Replace Tank screen.
12 Remove the drained ink tank.
13 Install the flushing tank supplied with the kit.
14 Fill the flushing tank with 4 liters of imaging oil.

ENWW Run the Special Ink Replacement Wizard Manager 25

 15 Select Replace the selected tank with a flushing tank.
16 Click Next. The Flushing step opens.

Figure 3-8. Flushing

17 Click Flush BID. The Flushing cycle takes about 20 minutes.

At the end of the Flushing cycle, the imaging oil in the flushing tank should be clear of
ink. (A slight tint does not indicate that the flushing process was incomplete.)

Note Cleaning the drained ink tank and its ink pump during the Flushing cycle saves valuable time.
Any residue left in the tank or pump can effect the resultant color of a new ink.

18 Click Next when the Flushing cycle finishes.

Figure 3-9. Finish

26 Chapter 3 Changing color on sheet-fed presses ENWW

 19 Either leave the flushing tank in the press or remove it and install a clean ink tank.
20 Click Finish.

Run the Automatic Special Ink Replacement wizard

1 Click Automatic Special Ink Replacement Wizard on the Special Ink Replacement
Wizard Manager screen. The wizard window opens.

Figure 3-10. Select Ink Tank

2 Select the ink you want to replace.

3 Click Next. The Ink File Selection step opens.

Figure 3-11. Ink File Selection

4 Select the required ink file from the list.

ENWW Run the Special Ink Replacement Wizard Manager 27

 5 Click Replace.
6 Click Next. The Ink Sourcing step opens.

Figure 3-12. Ink Sourcing

7 Select one of the ink source options:

• First can—a calibration can, used to create an exact density solution. The can is
either supplied with each special color box or created in the on-site ink mixing
system (if available). Continue the procedure with ‘Using a First can’ on page 28.
• Prepared ink solution—a previously used ink solution, which is now to be reused.
Continue the procedure with ‘Using a prepared ink solution’ on page 30.

Using a First can

1 Click Next. The Ink Building step opens.

Figure 3-13. Ink Building—first can

28 Chapter 3 Changing color on sheet-fed presses ENWW

 2 Install the first can into the relevant pump and select Insert first can.
3 Fill the ink tank with clean imaging oil until the middle line (between the maximum and
minimum lines).
4 Install the ink tank in the press.
5 Select Install an ink tank that contains the precise quantity of imaging oil.
6 Click Build Ink.
The ink in the First can is emptied into the ink tank and the press recalibrates the
density sensor to a value between 1.65 and 1.75.

7 Click Next. The Finish step opens.

Figure 3-14. Finish

8 Click Finish.
9 Continue with "Run Substrates and Screening" on page 31 .

ENWW Run the Special Ink Replacement Wizard Manager 29

 Using a prepared ink solution
1 Click Next. The Ink Building step opens.

Figure 3-15. Ink Building—prepared ink solution

2 Shake the prepared ink solution.

3 Pour the solution into the ink tank and install the ink tank in the press.
4 Type the density value kept with the stored ink solution into the value field.
5 Click Build Ink.
The press recalibrates the density sensor. Once this step is finished, the recalibrated
density value appears in the Value field.

6 Click Next. The Finish step opens.

Figure 3-16. Finish

30 Chapter 3 Changing color on sheet-fed presses ENWW

 7 Click Finish.

Run Substrates and Screening

1 Click Substrates and Screenings on the Special Ink Replacement Wizard Manager
screen. The wizard window opens.

Figure 3-17. Substrate

2 Select the substrate for the color adjust.

3 Click Next. The Screenings step opens.

Figure 3-18. Screenings

4 Select the screening types that will be used for the Color Adjust.
5 Click Finish. An automatic color adjust is performed after the current job is finished.

ENWW Run the Special Ink Replacement Wizard Manager 31

32 Chapter 3 Changing color on sheet-fed presses ENWW
 A Kit contents and setting the
imaging oil level

This appendix contains the following sections:

z On-Press Fast Ink Replacement kit contents

z Marking the imaging oil level on the flushing tank

EN 33
On-Press Fast Ink Replacement kit

Description Part number

Auxilliary can MJX-0605-41

Ink flushing tank CA245-18850

Imaging oil level label MLB-0175-01

Spin-on filter MFL-1901-01

Marking the imaging oil level on the flushing tank

The flushing tank contains 4 liters of imaging oil. Use the imaging oil bottle as a
measuring container of 4 liters
1 Fill the flushing tank with a complete bottle of imaging oil.
2 Insert the pump into the flushing tank.
3 Attach the imaging oil level label, supplies with the kit, to the tank - the vertical
midpoint of the label should be placed at the imaging oil level in the tank. You may
also use a marker pen to mark it.

34 Chapter A Kit contents and setting the imaging oil level 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
165 Dascomb Road Limburglaan 5
Andover, MA 01810-5897 6221 SH Maastricht
USA The Netherlands

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

EN 35
EN 36
Copyright © 2006 Hewlett-Packard Company

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

www.hp.com/go/indigo

reorder: P/N CA293-03240