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Roll-to-roll configuration, Substrate Load/Unload

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The above illustration shows the substrate loaded with the printed face outwards on both input and output rolls. You can also load substrate with the printed face inwards on either or both rolls, in which case the spindle will turn in the opposite direction. The printer asks you for the winding direction if it cannot detect it automatically. Each of the spindles has its own motor. The motors maintain tension on the substrate. Some vacuum is applied at the level of the platen to keep the substrate flat. The substrate is moved forwards by the drive roller motor, on which there is a pinch mechanism to prevent the substrate from slipping. Before loading a roll into the printer, you must have a roll loaded onto a spindle (the input roll) and an empty core loaded onto another spindle (the output roll). See Load a roll onto the spindle on page 45. NOTE: For the output roll, use a single empty core the same length as the input core. Do not place two or more shorter cores on the same spindle, which could cause substrate-advance problems. TIP: The spindle and a roll of substrate can be heavy. You are recommended to use a forklift or some other equipment to move it into position; otherwise, lift one end into the printer, and then the other end. Roll-to-roll configuration The following steps provide the complete procedure for this topic. 1. Go to the Internal Print Server and select Substrate Load/Unload, then select the correct configuration. 2. In the Internal Print Server, choose from the list of substrate types the type that you have loaded. 3. If they are installed, remove the substrate edge holders from the print platen so that they do not get in the way while loading the substrate. CAUTION: Loading the substrate on top of the edge holders could severely damage the printheads and carriage. 4. Bring the new roll on its spindle to the rear of the printer, with the geared end of the spindle on the left. 5. Rest the ends of the spindle on the platforms provided at the rear of the printer; plastic pads are provided to absorb the impacts. 6. In the same way, load the spindle with the empty core into the front of the printer. In this case, the geared end of the spindle should be on the right. 48 Chapter 5 Handle the substrate ENWW

Section	Page
Introduction	9
Documentation	9
Safety precautions	10
General safety guidelines	10
Electrical shock hazard	10
Heat hazard	11
Fire hazard	11
Mechanical hazard	12
Light radiation hazard	13
Sound pressure level	13
Chemical hazard	13
Heavy substrate hazard	13
Ink and condensates handling	13
Ventilation	13
Air conditioning	13
Use of tools and keys	14
Warnings and cautions	15
Warning labels	15
Emergency stop buttons	17
Main components	18
Front view	18
Rear view	19
Carriage view	20
Printer software	21
Turn on the printer for the first time	21
Turn the printer on and off	22
Move the printer	23
Printer status beacon	24
HP Internal Print Server	25
Start the Internal Print Server	25
Change the language of the Internal Print Server	26
Change the units of measurement in the Internal Print Server	26
Set the Internal Print Server preferences	27
General tab	27
Queue Rules tab	27
Additional Settings tab	28
Remote Assistance tab	29
Internal Print Server menus	29
Printer status and alerts	30
Update the firmware and the Internal Print Server	30
Update the firmware	31
Update the Internal Print Server	31
Update the HP IPS Services	31
RIP distribution	33
Printing workflows integration	35
What is JDF?	35
Benefits of working with JDF for file submission	35
Working with JDF	35
Creating JDF job tickets	35
What information is captured by the HP Latex 1500 printer series and what can be communicated by JMF ...	35
Guidelines for Integration	36
How to integrate the HP Latex 1500 printer series into CALDERA RIP	36
How to integrate the HP Latex 1500 printer series into ONYX RIP	37
Job submission methods	39
How to integrate the HP Latex 1500 printer series into an MIS system or production control software	40
Handle the substrate	41
Supported substrate types	41
Check the porosity of your substrate	42
Supported HP substrates	43
Substrate tips	45
Maintain the substrates	45
General tips	46
Color consistency	47
Substrate configurations	47
Prepare to print	48
The substrate edge holders	50
Install an edge holder	51
Replace an edge holder strip	53
Load a roll onto the spindle	53
Single-roll printing	53
Load a roll into the printer	55
Load a roll (roll-to-roll configuration)	55
Roll-to-roll configuration	56
Loading substrate	57
Load a roll (dual roll-to-roll configuration)	63
Dual roll-to-roll configuration	65
Manual loading	66
Double-sided printing	68
Blockout (opaque substrate)	68
Side A: Load and print	69
Side A: Unload	70
Side B: Load and print	71
Print a double-sided job with dual-roll	73
View information about the loaded substrate	75
Unload a roll	75
Output platen light	76
Substrate presets	77
Export multiple presets	77
How to export multiple substrate presets	77
How to import the generated .oms file	78
Use a new substrate	78
Optimize for tiling	79
Prepare the printer for a new substrate	82
Create a new substrate preset with the Add New Substrate wizard	82
Material	82
Application	82
Optimized for	83
Test print	83
Edit a substrate preset	84
Editing a preset	85
Printing masks	87
On-the-fly adjustments	88
Optimize the preset for higher print speed	89
Possible risks and compensations	89
Optimize for best print quality and/or widest gamut	89
Considerations	89
Optimize for ink consumption	90
Considerations	90
Recommended print modes for each substrate type	90
Adjust the printing workflow for optimum color performance	91
Remove a substrate preset	91
Online substrate manager	91
Sorting	92
Structured search	92
Free text search	92
Install new substrate	92
Update existing substrate	93
Substrate synchronization	94
Set the carriage beam position	94
Create and manage print jobs	97
Add a new print job	97
Single roll printing	97
Dual-roll printing	100
Rotate a print job	100
Manage the print queue	101
Delete a print job	102
Image composition	102
Tiling	102
Double-sided	103
Create a job	104
Define double-sided job	104
Preview (Image/Layout/Preview both)	106
Print	107
Nesting	111
The Choose Image File window	111
The Job Properties window	112
The Advanced Nesting Arrangement window	113
Restart and Print	113
Handle the ink system	115
Ink cartridges	115
Remove an ink cartridge	115
Insert an ink cartridge	116
Maintain the ink cartridges	118
Check the status of the ink cartridges	118
Aerosol filters	119
Left spittoon	119
Condensation collector bottle	119
Ink deposits	119
Printheads	119
Remove a printhead	120
Replacing the printheads	120
When removing the optimizer printhead	123
Insert a Printhead	125
When inserting the optimizer printhead	128
Maintain the printheads	129
Check and clean the printheads	130
Printhead cleaning roll	130
Replace the printhead cleaning roll, filters, and spittoon	130
Replacements	131
Replace the aerosol filters	132
Replace the left spittoon	135
Replace the printhead cleaning roll	137
Safe mode	144
Printer calibration	145
Align the printheads	145
Automatic alignment procedure	145
Manual Alignment procedure	146
Aligning the optimizer printhead	148
Possible difficulties with printhead alignment	149
The optimizer ink is invisible or hardly visible	149
The optimizer printhead is still misaligned in the substrate axis after alignment	149
A pattern shows more than one good correction	149
Printhead alignment diagnostics plot	149
Zone 1: Printhead alignment check Scan Axis and Substrate Axis	150
Zone 2: Optimizer printhead alignment check	150
Zone 3: Scan-axis bidirectional alignment check	151
Color calibration	152
Color consistency between different HP Latex printers	154
Color emulation of other printer models	154
Emulating an HP Latex 15xx or 3xxx printer	155
Color profiles	156
Substrate-advance compensation	156
Manual substrate-advance compensation	157
Substrate-advance test print	158
Calibrations specific to one substrate preset	159
Recommended calibrations after particular events	159
HP Print Care	161
Print Care diagnostics	162
Accessories	165
Compatibility table	165
Dual roll printing	165
In-line slitters	168
Substrate saver	171
HP Latex Double-sided Day and Night Kit	177
Roll-to-Free-Fall Kit	177
Introduction	177
Substrate configurations	178
Hardware maintenance	181
Clean the roll-to-free-fall roller and pinchwheels	181
Prepare to clean the roll-to-free-fall roller and pinchwheels	182
Clean the roll-to-free-fall roller	182
Clean the pinchwheels	182
Ink collector	184
Use the ink collector	184
Kit components	184
Recommended solution space	185
Assemble the protector	185
Install the kit	187
Install the six ink-collector modules	188
Install assembled protector modules	192
HP Latex 1500 Ink Collector Serial Number LabelAccessory serial number label location	195
Uninstall the kit	196
Uninstall the protector modules	197
Uninstall the six ink-collector modules	199
Maintain the ink collector	199
Clean the aerosol nozzle plate and filters	200
Wipe the top of the protector	200
Wipe the ribs of the ink collector modules	202
Clean the output platen	202
Wipe the protector modules	202
Wipe the ink collector modules	202
Printer maintenance	203
Curing lip	203
Bottom plate	205
Diverter interwheels	206
Clean the print zone	206
Clean the curing fans	206
Replace the ink collector foams	207
Clean curing module plate and airlet plate	208
Check and clean condensates, window rubber and bottom plate sides	208
Troubleshooting for Ink Collector enabled substrates	208
There are marks on ink collector enabled substrate	209
Grain and text sharpness	209
Color consistency	209
Hardware maintenance	211
Safety precautions	211
Maintenance resources	211
HP Latex 1500 Printer Series maintenance kits and tools	211
Up-time user spare parts kits	212
HP Latex 1500 Printer Cleaning Kit contents K4T88-67255	212
HP Latex 1500 Printer Maintenance kit contents K4T88-67259	213
Maintenance tools recommended but not provided	213
Summary of repairs kits and maintenances	214
How to perform maintenance operations	219
Perform maintenance with Print Care wizards	219
Perform maintenance without Print Care wizards	220
How to turn the printer off and on for maintenance operations	222
Turn the printer off	222
Turn the printer on	223
Weekly maintenance	224
Introduction	224
Check and clean the printer, printzone and output platen	225
Check and clean the printer	225
Clean the print zone	226
Prepare to clean the print zone	226
Remove the edge holders (if they are in use)	227
Clean the platen	227
Clean the substrate-advance sensor	229
Clean the output platen lights	229
Clean the output platen	229
Prepare to clean the output platen	229
Pull out the curing assembly	229
Clean the output platen	231
Finish off cleaning the output platen	231
Clean the bottom of the carriage and the line sensor	231
Prepare to clean the carriage bottom	231
Clean the carriage bottom	233
Clean the line sensor	234
Finish off cleaning the carriage bottom	234
Replace protector and textile substrate edge holders	234
Clean the aerosol nozzle plate and filters	234
Clean the substrate-advance sensor	238
Prepare to clean the substrate-advance sensor	238
Clean the substrate-advance sensor	239
Finish off cleaning the substrate-advance sensor	241
Clean the drop detector and the capping station	241
Prepare to clean the substrate-advance sensor	241
Finish off cleaning the drop detector and the capping station	244
Clean the drive roller and pinchwheels	245
Prepare to clean the pinchwheels and drive roller	245
Clean the pinchwheels	245
Clean the drive roller	246
Clean the perforated plate and curing entrance cover	247
Prepare to clean the perforated plate	247
Pull out the curing assembly	248
Clean the perforated plate	250
Finish off cleaning the perforated plate	252
Clean the e-box fan filters	253
Prepare to clean the E-box fan filter	253
Clean the E-box fan filter	255
Clean the e-cabinet fan filters	258
Check and clean the heat exchanger air entrance filter	261
Check and empty the condensation collector bottle	262
450 liter maintenance	265
Introduction	266
Clean the scan axis and mechanical transmissions	266
Prepare to clean the carriage rails	266
Clean the carriage rails	267
Replace the oiler felts	268
Finish cleaning the carriage rails	271
Clean and lubricate the drop detector rods	271
Clean the carriage cooling fan	274
Prepare to clean the carriage cooling fan	274
Clean the carriage cooling fan	275
Finish cleaning the carriage cooling fan	275
Clean two dryer PCA fan filters	275
Replace the printhead cleaning blade	280
900 liter maintenance	285
Introduction	285
Clean the substrate drive transmission	285
Grease the printhead primers	286
Clean scan axis encoder	288
Clean impelling dust in scan axis chain	290
Clean the drying fans and diffuser	291
Clean the drop detector encoder strip	294
Replace the curing module side rubbers	298
Removal	298
Installation	298
Replace the carriage oil wicks, felts, and clean and oil the scan axis rods	299
Removal	299
Installation	300
Replace damaged diverter wheels	300
Removal	301
Installation	301
Replace an intermediate tank	302
Replace the e-cabinet fan filters	304
Replace the E-box fan filter	307
Replace dryer fan filter	311
When required	312
Introduction	312
Printer safety check	313
Check and clean the printheads	314
Clean the scan-axis beam	315
Clean the printhead contacts	318
Clean the carriage rails manually	322
Check and clean dirt from scan axis and mechanical transmissions	325
Replace a pinchwheel submodule	326
Replace a primer and latch	329
Replace the aerosol fan module (expert users only)	332
Replace a service station cap	338
Replace an intermediate tank (trained users only)	342
Replace an e-cabinet fuse	345
Replace a spindle valve	348
Replace the pinch clamp	349
Removal	350
Installation	350
Replace the rocker pads	351
Removal (same for all four sides)	351
Installation	351
Replace spindle gear and end cap	351
Removal	352
Installation	353
Replace the in-line slitter blades	359
Removal	360
Installation	361
Replace the curing fan and resistor module	361
Preparation	361
Removal	361
Installation	363
Conclusion	364
Replace the drying fan and resistor module	364
Preparation	364
Removal	365
Installation	366
Conclusion	368
Replace the spectrophotometer shutter	368
Removal	368
Installation	370
Empty the printhead cleaning waste bottle	370
Removal	371
Installation	371
Troubleshoot substrate issues	373
The substrate cannot be loaded successfully	373
The substrate has jammed	373
The substrate is not attached to the core and/or spindle	374
The substrate is not flat	375
A spindle latch suddenly opens during printer operation	375
The substrate advances with a loud continuous sound of vibration	375
There is skew or telescoping on the output spindle	376
There are wrinkles and ink smears on the substrate	377
There are ink marks on the substrate	379
The substrate sticks to the platen	379
There are physical marks on the substrate	380
There are drops of ink on the substrate	380
Dual roll printing issues	381
Calibrate the dual-roll center support	381
The print is shorter than expected	385
How to achieve better consistency between jobs of the same length	386
The collector stops winding	386
The collector occasionally fails to work correctly	387
The collector winds in the wrong direction	387
The substrate is detached or winds around the collector in the wrong direction	387
There is skew or telescoping on the collector	387
The substrate has jammed on the collector	387
Slitter poor cutting quality	388
Troubleshoot print-quality issues	391
General advice	391
Image quality inspection plot	392
Basic and advanced troubleshooting	395
Basic print-quality troubleshooting	395
Identify the defect.	395
Printhead check and clean	396
Substrate-advance sensor check	396
Printhead alignment	397
Advanced print-quality troubleshooting	397
Print-quality artifacts troubleshooting	397
Horizontal banding	397
Thin dark lines	397
Thin white lines	398
Bands of light and dark zones	400
Gloss banding	401
Aeroworms	401
Vertical banding	402
Microbanding	402
Wide bands 2 cm (0.8 in)apart	403
Wide bands at least 4 cm apart	403
Color misalignment	404
Bleed, halo, wicking	405
Low gloss, haze	405
Color accuracy	405
Local color variations	406
Color variations when tiling	406
Edge roughness, text quality	407
Graininess	408
Physical deformation marks	411
Poor curing	411
Troubleshoot ink cartridge and printhead issues	413
Cannot insert an ink cartridge	413
The Internal Print Server does not recognize an ink cartridge	413
The Internal Print Server recommends replacing or reseating an ink cartridge	413
Bent ink cartridge connector	414
Cannot insert a printhead	414
The Internal Print Server recommends replacing or reseating a printhead	414
Problem due to overheating	414
Problem due to the primer system	414
Printhead health troubleshooting	416
Printhead status plot	416
Drop detector diagnostics	417
Decision table	417
Hard clean	418
New printhead is rejected	418
Automatic Printhead Alignment fails	418
Printhead cleaning roll errors	419
Troubleshoot other issues	421
The printer does not start	421
The printer does not print	421
The printer cannot be restarted from the Internal Print Server	421
The printer seems slow	421
Request to reinitialize the carriage	422
The Internal Print Server cannot detect the printer	422
Print Care spontaneously restarts	422
Color calibration fails	422
When you need help	423
HP Proactive Support	423
HP Customer Care	424
HP Customer Care Centers	424
Service information	424
Printer specifications	425
Functional specifications	425
Physical specifications	426
Memory specifications	426
Power specifications	427
Air supply requirements (pneumatic spindle)	427
Air pressure supply	427
Pneumatic connector	427
Ecological specifications	428
Environmental specifications	428
Acoustic specifications	428
Printer messages	429
Glossary	433

Match case Limit results 1 per page

The above illustration shows the substrate loaded with the printed face outwards on both input and output rolls.

You can also load substrate with the printed face inwards on either or both rolls, in which case the spindle will

turn in the opposite direction. The printer asks you for the winding direction if it cannot detect it automatically.

Each of the spindles has its own motor. The motors maintain tension on the substrate. Some vacuum is applied

at the level of the platen to keep the substrate ﬂat. The substrate is moved forwards by the drive roller motor,

on which there is a pinch mechanism to prevent the substrate from slipping.

Before loading a roll into the printer, you must have a roll loaded onto a spindle (the input roll) and an empty

core loaded onto another spindle (the output roll). See

Load a roll onto the spindle

on page

NOTE:

For the output roll, use a single empty core the same length as the input core. Do not place two or more

shorter cores on the same spindle, which could cause substrate-advance problems.

TIP:

The spindle and a roll of substrate can be heavy. You are recommended to use a forklift or some other

equipment to move it into position; otherwise, lift one end into the printer, and then the other end.

Roll-to-roll conﬁguration

The following steps provide the complete procedure for this topic.

Go to the Internal Print Server and select

Substrate Load/Unload

, then select the correct conﬁguration.

In the Internal Print Server, choose from the list of substrate types the type that you have loaded.

If they are installed, remove the substrate edge holders from the print platen so that they do not get in the

way while loading the substrate.

CAUTION:

Loading the substrate on top of the edge holders could severely damage the printheads and

carriage.

Bring the new roll on its spindle to the rear of the printer, with the geared end of the spindle on the left.

Rest the ends of the spindle on the platforms provided at the rear of the printer; plastic pads are provided

to absorb the impacts.

In the same way, load the spindle with the empty core into the front of the printer. In this case, the geared

end of the spindle should be on the right.

Chapter 5

Handle the substrate

ENWW