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Table of contents 1 Introduction ...1 Welcome to your printer ...2 Printer accessories and consumables ...2 Documentation and useful links ...3 Safety precautions ...3 Main components ...13 Printer software ...17 Turn on the printer for the first time ...17 Turn the printer on and off ...18 Move the printer ...18 2 HP Internal Print Server ...20 Start the Internal Print Server ...21 Internal Print Server widgets ...22 Printer status and alerts ...23 Update the firmware and the Internal Print Server ...23 Internal Print Server settings and preferences ...24 3 Install and configure the RIP software ...26 Create a shared folder ...26 Install ONYX software and set up the driver ...28 Install Caldera software and set up the driver ...30 4 Printing workflows integration ...32 Introduction to JDF and JMF ...33 Working with JDF ...33 5 Handle the substrate ...37 Introduction ...38 Rigid substrate types ...38 Flexible substrate types ...39 Substrate tips ...39 Printer configurations ...42 Substrate configuration ...43 ENWW iii

Section	Page
Introduction	9
Welcome to your printer	10
Printer accessories and consumables	10
Documentation and useful links	11
Safety precautions	11
General safety guidelines	11
Important operating notes	12
Electrical shock hazard	12
Heat hazard	13
Fire hazard	13
Mechanical hazard	14
Light radiation hazard	15
Sound pressure level	15
Chemical hazard	15
Heavy substrate hazard	15
Ink and condensates handling	15
Ventilation	15
Air conditioning	16
Use of tools and keys	16
Warnings and cautions	17
Warning labels	17
Emergency stop buttons	20
Main components	21
Front view	21
Rear view	22
Carriage view	23
Platen light	23
Printer status beacon	24
Extension tables	24
Quick-access buttons	24
Printer software	25
Turn on the printer for the first time	25
Turn the printer on and off	26
Move the printer	26
HP Internal Print Server	28
Start the Internal Print Server	29
Internal Print Server widgets	30
Printer status and alerts	31
Update the firmware and the Internal Print Server	31
Update the firmware	31
Update the Internal Print Server	32
Internal Print Server settings and preferences	32
Change the language of the Internal Print Server	32
Change the units of measurement in the Internal Print Server	33
Install and configure the RIP software	34
Create a shared folder	34
Install ONYX software and set up the driver	36
Install Caldera software and set up the driver	38
Printing workflows integration	40
Introduction to JDF and JMF	41
What is JDF?	41
Benefits of working with JDF for file submission	41
Working with JDF	41
Creating JDF job tickets	41
What information is captured by the printer and what can be communicated by JMF to an MIS?	41
Guidelines for integration	42
How to integrate the printer series into the Caldera RIP	42
How to integrate the printer into the Onyx RIP	42
Job submission methods	43
How to integrate the printer into an MIS system or production control software	44
Handle the substrate	45
Introduction	46
Rigid substrate types	46
Flexible substrate types	47
Substrate tips	47
Maintain the substrates	47
General tips	48
Color consistency	49
Rigid substrate handling guidelines	49
Rigid substrate properties	50
Static electricity	50
Printer configurations	50
Substrate configuration	51
Substrate parameters	51
Substrate type dialog	52
Automatic measurements	52
Substrate status	53
Substrate dimensions	53
Job properties	53
Load substrate into the printer	54
Load rigid substrate	54
Multi-sheet N-up	60
Multi-sheet printing (same dimensions)	60
Multi-sheet printing (different dimensions)	61
Load flexible substrate	61
Place a roll onto the spindle	61
Load a roll into the printer	63
View information about the loaded substrate	64
Substrate edge holders	65
Usage considerations	65
Substrate edge holders setup	65
Contents of the kit	66
Setup procedure	67
Using the substrate edge holders	68
How to install shims	68
How to position the edge holders	70
Install the edge holders	70
Uninstall the edge holders	73
Main maintenance tasks	75
Clean the substrate edge holders	75
Replace a strap	75
Replace part of an edge holder	76
Replace the low-friction protective film	76
How to print	76
Unload a roll	78
Take-up reel	78
Create and manage print jobs	80
Add a new print job	81
Substrate presets	82
Use a new substrate	83
Prepare the printer for a new substrate	83
Add a substrate preset	83
Edit a substrate preset	89
Optimize the preset for higher print speed	89
Action	89
Possible risks and compensations	89
Optimize for best print quality and/or widest gamut	90
Actions	90
Considerations	90
Optimize for ink consumption	90
Actions	90
Considerations	90
Recommended print modes	90
Adjust the printing workflow for optimum color performance	91
Remove a substrate preset	91
Set the carriage beam position	91
Handle the ink system	93
Ink system components	94
Ink cartridges	94
Printheads	95
Printhead cleaning roll	96
Printhead-cleaning rubber blades	96
Aerosol filters	96
Left spittoon	97
Waste bottle	97
Distilled water tank	97
Drop-detector spittoon foam	97
How to work with ink system components	97
Ink cartridges	97
Remove an ink cartridge	97
Insert an ink cartridge	98
Maintain the ink cartridges	100
Check the status of the ink cartridges	100
Printheads	101
Remove a printhead	101
Insert a printhead	103
Maintain the printheads	105
Check and clean the printheads	105
Safe mode	106
Replace the components of the printhead cleaning roll kit	106
Replace the left spittoon foam	108
Replace the left printhead cleaning blade	109
Refill the water tank	110
Replace the aerosol filters	112
Empty the printhead cleaning waste bottle	115
Replace the drop-detector spittoon foam	115
Replace the printhead cleaning roll	116
Printer calibration	122
Align the printheads	123
Automatic alignment procedure	123
Manual alignment procedure	125
Aligning the optimizer printhead	129
Possible difficulties with printhead alignment	129
The optimizer or overcoat ink is invisible or hardly visible	129
A pattern shows more than one good correction	129
Printhead alignment diagnostics plot	129
Zone 1: Bidirectional alignment for color printheads	130
Zone 2: Printhead-to-printhead alignment for color printheads	130
Zone 3: Bidirectional alignment for optimizer and overcoat	130
Zone 4: Printhead-to-printhead alignment for optimizer and overcoat	131
Zone 1: Bidirectional alignment for white printheads	131
Zone 2: Printhead-to-printhead alignment for white printheads	131
Zone 3: Bidirectional alignment for optimizer and overcoat	131
Zone 4: Printhead-to-printhead alignment for optimizer and overcoat	132
Color calibration	132
Color consistency between different HP Latex R series printers	135
Color emulation	135
Color profiles	135
Substrate-advance compensation	136
Substrate-advance test print	136
Recommended calibrations after particular events	137
Hardware maintenance	138
Safety precautions	139
Maintenance resources	139
Maintenance kits and tools	139
Up-time user spare parts kits	140
Cleaning kit contents	140
Printer maintenance kit (PMK) contents	141
Maintenance tools recommended but not provided	141
Summary of maintenance operations	143
How to perform maintenance operations	145
Perform maintenance tasks	145
Perform maintenance without guidance	146
Printer-system movements	146
How to turn the printer off and on for maintenance operations	146
Turn the printer off	147
Turn the printer on	147
Daily recommended maintenance	148
Check and clean the printheads	148
Clean the left printhead cleaning blade	148
Daily recommended maintenance (white ink only)	150
Check and clean the white caps	150
Check and clean the FI tower	150
Check and clean the white ink from the belt	150
Weekly maintenance	151
Clean the aerosol nozzle plate and filters	151
Clean the printhead cleaning roll diverter and rods	155
Clean the service-station caps	158
Monthly maintenance	160
Clean the drop-detector rods	160
Clean the substrate-advance belt	162
Clean the printhead-cleaning pinchwheel	162
Clean the line sensor and the crash sensors	164
Every 4 months (white ink only)	165
Replace the white-ink service-station caps	165
Replace the white-ink intermediate tank	165
Clean the auxiliary printhead	165
Check the plastic needles in the auxiliary printhead storage box	167
375 liter maintenance	170
Replace the right printhead cleaning blades	170
750 liter maintenance	174
Check the printhead cleaning system	174
Check the printhead-cleaning fluid-dispenser nozzle	176
Clean the carriage cooling fan grid	180
Clean the curing perforated plate	182
Check and replace an intermediate tank	183
Replace a damaged service-station cap	184
Replace the oiling felts	186
Clean the carriage rails	189
Clean the substrate-advance sensor	193
Replace a curing PCA fan filter	196
Clean the power-box fan filter	199
Clean a curing PCA fan filter	201
Clean the e-box fan filter	204
When required	207
Clean the printhead contacts	208
Replace a spindle valve	211
Replace the curing fan and resistor module	212
Replace the spectrophotometer shutter	214
Grease the printhead primers	216
Replace the left printhead cleaning blade	218
Empty the printhead cleaning waste bottle	219
Replace the left spittoon foam	220
Replace an intermediate tank	221
Replace the e-box fan filter	221
Replace the power-box fan filter	222
Replace an alignment-bar wheel	224
Replace the right printhead cleaning blades	226
Replace the scan-axis bumps	226
Replace the aerosol fan module	228
Replace the crash sensor legs	230
Replace the alignment bar	234
Replace the print-zone lights	235
Replace the printhead cleaning waste bottle	236
Replace the plastic needles in the auxiliary printhead storage box	238
Replace the auxiliary printhead	239
Diagnostics	242
Troubleshoot substrate issues	244
Loading issues	245
The substrate cannot be loaded successfully	245
The substrate cannot be measured successfully	245
The substrate has jammed	245
The flexible substrate is not attached to the core and/or spindle	245
The substrate is not flat	246
Printing issues	246
There are physical marks on the substrate	246
Rigid substrate too close to the carriage bottom	246
A spindle latch suddenly opens during flexible substrate printing	247
The substrate advances with a loud continuous sound of vibration	247
There is skew or telescoping on the output spindle	247
There are wrinkles and ink smears on the substrate	248
There are ink marks on the substrate	249
There are drops of ink on the substrate	249
Flexible-substrate print-length issues	250
The print is shorter than expected	250
How to achieve better consistency between jobs of the same length	250
Troubleshoot print-quality issues	251
General advice	252
Basic and advanced troubleshooting	253
Basic print-quality troubleshooting	253
Printhead check and clean	254
Substrate-advance sensor check	254
Printhead alignment	254
Advanced print-quality troubleshooting	254
Print-quality artifacts troubleshooting	255
Horizontal banding	255
Thin dark lines	255
Thin white lines	256
Bands of light and dark zones	257
Gloss banding	258
Aeroworms	258
Banding in white-ink applications	258
Image content-dependent banding	258
Local color variations	259
Microbanding	259
Color misalignment	260
Bleed, halo, wicking	261
Low gloss, haze	261
Color accuracy	261
Color variations when tiling	262
Edge roughness, text quality	262
Graininess	263
Physical deformation marks	265
Poor curing	265
White-to-color misalignment	266
Static electricity	266
Dual-side marks	266
Troubleshoot ink cartridge and printhead issues	268
Ink cartridges	269
Cannot insert an ink cartridge	269
The Internal Print Server does not recognize an ink cartridge	269
The Internal Print Server recommends replacing or reseating an ink cartridge	269
Bent ink cartridge connector	269
Printheads	269
Cannot insert a printhead	269
The Internal Print Server recommends replacing or reseating a printhead	270
General recommendations	270
Problem due to overheating	270
Problem due to the primer system	270
Printhead health troubleshooting	271
Printhead status plot	271
Hard clean	272
Drop detector diagnostics	273
Decision table	273
New printhead is rejected	274
Automatic printhead alignment fails	274
Printhead cleaning roll errors	274
Troubleshoot other issues	276
The printer does not start	277
The printer does not print	277
The printer cannot be restarted from the Internal Print Server	277
The printer seems slow	277
Request to reinitialize the carriage	277
The Internal Print Server cannot detect the printer	278
Color calibration fails	278
When you need help	279
Open a support case at HP PrintOS	279
If you are not registered with HP PrintOS	279
HP Proactive Support	279
HP Customer Care	280
Accessories	281
White upgrade kit	282
White printhead maintenance wheel	282
Auxiliary white printhead insertion process	285
Preparing a white job in your design software	286
Preparing the job in the RIP	286
Printing a white job from the Internal Print Server	287
Choke functionality	288
White ink maintenance operations	289
Roll printing kit	289
Load flexible substrates with table-top roll holder	289
Hold-down plate	290
How to use the hold-down plate	291
Maintenance tasks	292
Velvet replacement	292
Lateral bracket replacement	295
Extension tables	295
Disposal instructions	297
Order supplies and accessories	299
Order ink supplies	299
Order accessories	300
Printer specifications	301
Functional specifications	302
Physical specifications	302
Memory specifications	302
Power specifications	302
Air supply requirements (pneumatic spindle)	303
Air pressure supply	303
Pneumatic connector	303
Ecological specifications	303
Environmental specifications	303
Ventilation	304
Air conditioning	305
Acoustic specifications	305
Rigid substrate recommendations	306
Recommended print modes (introduction)	307
Use Sensitive Mode with heat-sensitive substrates	307
Predefined substrate settings	308
Acrylic sheet (PMMA)	309
Aluminum composite panel (ACP)	311
Compressed cardboard or cardstock	313
Corrugated cardboard	314
Corrugated plastic	315
Foam board	317
Foam PVC	318
Glass and ceramics	320
Wood	321
Polycarbonate sheet	322
Polystyrene sheet	323
Polypropylene sheet	324
PVC rigid sheet (U-PVC)	325
PET (A-PET, PET-G) rigid sheet	326
PE (LDPE, HDPE) rigid sheet	327
Honeycomb panels	328
Metal panels	329
Flexible substrate recommendations	330
Predefined substrate settings	331
Self-adhesive vinyls	332
PVC banners	333
Papers	334
Textiles	335
Flexible films	336
Supported HP flexible substrates	337
Print-quality troubleshooting summary chart	340
Glossary	341

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Table of contents

Introduction

...............................................................................................................................................................................................

Welcome to your printer

..........................................................................................................................................................

Printer accessories and consumables

...................................................................................................................................

Documentation and useful links

............................................................................................................................................

Safety precautions

...................................................................................................................................................................

Main components

...................................................................................................................................................................

Printer software

.....................................................................................................................................................................

Turn on the printer for the ﬁrst time

...................................................................................................................................

Turn the printer on and oﬀ

...................................................................................................................................................

Move the printer

.....................................................................................................................................................................

HP Internal Print Server

.........................................................................................................................................................................

Start the Internal Print Server

..............................................................................................................................................

Internal Print Server widgets

................................................................................................................................................

Printer status and alerts

.......................................................................................................................................................

Update the ﬁrmware and the Internal Print Server

..........................................................................................................

Internal Print Server settings and preferences

.................................................................................................................

Install and conﬁgure the RIP software

................................................................................................................................................

Create a shared folder

...........................................................................................................................................................

Install ONYX software and set up the driver

......................................................................................................................

Install Caldera software and set up the driver

...................................................................................................................

Printing workﬂows integration

.............................................................................................................................................................

Introduction to JDF and JMF

.................................................................................................................................................

Working with JDF

....................................................................................................................................................................

Handle the substrate

.............................................................................................................................................................................

Introduction

.............................................................................................................................................................................

Rigid substrate types

.............................................................................................................................................................

Flexible substrate types

........................................................................................................................................................

Substrate tips

..........................................................................................................................................................................

Printer conﬁgurations

............................................................................................................................................................

Substrate conﬁguration

........................................................................................................................................................

ENWW

iii