HP Indigo Press 5000 maintenance and repair for new service engineers

Course overview

The new hire training is a beginning class for newly hired field technicians who have no previous training on Indigo digital printing presses. The course focuses on the operation, maintenance, and servicing of the mechanical, electronic, fluid and substrate transport systems on the HP Indigo press. Participants will be taught how to apply maintenance skills to resolve problems.

Prerequisites

The following is the typical profile of the person who meets the prerequisites:

1. Education:
   • Associates Degree in Engineering or equivalent educational background in mechanics, electricity or electronics
2. Skills:
   • A good electronic and mechanical aptitude and demonstrated excellent troubleshooting skills
   • An ability to analyze problems in non-functional electronic and mechanical equipment
   • A working knowledge of primary and subtractive color theory and xerography (Preferred)
   • English comprehension at a technical, appropriate for comprehending the course materials (Must)
3. Field experience:
   • Minimum 2 years of field service experience (Preferred)
   • Experience in Print industry, electronics and mechanical system troubleshooting (Preferred)

Audience

• HP Indigo digital press customer engineers and engineers from hp indigo distributors

Ways to save

Course outline

• Company overview
• Training center

• Digital Printing
• HP indigo 5000 overview

• Mechanical systems
• Electrical systems
• Fluid systems

• Press safety
• Electrical safety
• Safety Instructions
• Emergency procedures

Press Demonstration

• Major components and assemblies
• Major electrical systems
• Demonstrate removal
• Perform assembly removal
• Present UltraStream differences
• Safety components inside and outside of press

Electrophotography

• Overview
• Discussion at press
• Stage 1 – Image creation
• Stage 2 – Image development
• Stage 3 – First transfer
• Stage 4 – Second transfer
• Support systems

Machine Software Overview

• Control Panel features
• Job Manager features
• Job Editor features
• Printing
• Maintaining consumables

Daily Routines

• Review software directions and documentation
• Start of day
• End of day
• Weekly maintenance
• Monthly maintenance
• 2 Million impression maintenance
• Lubrication

Electrical System

• Major boards
• Basic components
• Function & control
• Board placement
• DVM basics
• Introduction to wiring diagrams
• Power Distribution Unit (PDU)
• High voltage power supplies
• Low voltage power supplies
• Interlock system
• Interlock safety
• Servo drive motor
• Electrical diagnostics
• Differences between the hp indigo 3000 and US 2000
• Verifying input and output voltages

PC System

• PC specifications
• Pentium III and IV key features
• Boards, components, and layout
• Connections
• Functions
• PC troubleshooting
• V-corn features & diagnostics
• Operating System, Press software, IndigoServe, Config save, Ghost Back-up

Paper Transport System

• Paper qualities
• Paper feed specifications
• Paper storage
• Feed unit main components
• Double paper feed tray set up
• Installing / attaching the paper feed unit to the press
• Simplex operation
• Duplex operation
• Motorized feed roller
• ITM feed cam adjustment
• Duplex conveyor
• Perfector
• Paper feed unit adjustments
• Software adjustments and paper path wizards
• Paper path sensors
• Exit unit
• Rotor timing to machine timing synchronization
• Vacuum system
• Troubleshooting paper feed

Imaging Products

• Ink cans and rebuilding ink
• Imaging agent
• Blanket
• First transfer pressure adjustment
• PIP
• Impression Film – New and old
• Imaging oil tank – Filling and draining

Imaging System

• Scorotron functioning
• PIP theory
• Writing head functioning
• Auto bias and color
• Electrometer theory and concept
• Electrometer gap and board calibration

Scorotron

• Theory, location and parts
• Disassembly
• Replacing the dampers
• Replacing the ozone filters

Writing Head

• Theory and imaging process
• Electronics
• Main optical assemblies
• Installation
• Leveling the writing head
• Scaling
• Finetune Focus
• Laser uniformity
• Deskew
• Skew
• Line spacing
• Writing head connector panel
• Diagnostics
• Loading writing head parameters

Cleaning Station

• Theory, location, and parts
• Inspection process
• Cleaning procedure
• Replaceable components

Cooling/AC System

• Theory and requirements
• Chiller operating overview
• Chiller maintenance
• Imaging oil cooling assemblies
• Ink tank cooling assemblies
• Blower cabinet and air transport
• ITM air knife
• ITM hood
• Imaging oil vapor condensation
• Maintenance

Imaging Oil System

• Theory & physical overview
• Reservoir
• Float sensors
• Imaging oil flow rate
• Imaging oil cooling system
• Filters

Ink System

• Theory & physical overview
• Ink pump maintenance
• Ink pump impeller maintenance
• Ink flow adjustment
• Density & conductivity calibration
• Ink tank removal

Solid Add Compressor

• Physical overview
• Adjustments
• Maintenance

BID

• Theory, location, and parts
• Main parameters control
• BID support system
• BID pressure adjustment
• Replacement procedure
• BID engagement mechanism
• Homing sensor
• Engage and disengage adjustment
• High voltage BID connector replacement
• History of BID versions – 55, 56, 57
• New features of Version 6.0 software
• BID diagnostics
• Troubleshooting

Colors

• What is color?
• Printed colors
• Color density
• Dot size
• Dot gain
• HP indigo color control
• Color adjustment procedure
• Color Matching
• Job Look Up Tables (LUT)
• Color Screening
• Color adjustment vs. machine LUT
• Machine LUT generation
• Machine LUT validation
• Last machine LUT
• Substrate related parameters

In Line Densitometer (ILD)

• ILD calibration & color adjustment
• ILD replacement
• Manual color adjustment without ILD

Prepress

• Describe prepress workflow
• Overview of prepress tools – YTD, YTE, and SNAP
• Personalization
• Imposition
• RIP setups
• Job Editor
• Job Manager

Cylinders

• PIP cylinder theory and characteristics
• PIP engage mechanism
• PIP foil scratches
• Sofsub replacement
• Encoder replacement/calibration
• 1st Transfer adjust & calibration
• ITM theory and characteristics
• ITM bearings
• Thermal fuse and the RIT
• ITM lamp removal
• Replacing ITM heating lamp
• ITM IR sensor calibration
• Contact brush replacement
• Differences between old and new ITM cylinders
• Impression cylinder theory and characteristics
• 2nd Transfer adjust & calibration
• Replacing and adjusting the gripper assembly
• Impression cam, cam follower, and dummy cam followers
• Eccentric collar
• Remove and replace stop station assembly
• Stop station adjustment

Registration Issues

• Theory and analysis
• PIP brake
• Parameter configuration
• Dynamic prism and control
• Diagnostics and analysis

Weekly and Monthly Maintenance

• Review and explain procedures
• Perform maintenance routines

Testing and Troubleshooting

• Operator session troubleshooting
• Review sample press sheets
• Operator level - Self assessment
• Technician level - Self assessmen