Attachment J-1 - Canon ProStream 2000 Technical Guide.pdf

ProStream 2000 series

Technical guide Site Survey

A29246-X89-X-06-80 © 2024 Canon Production Printing

Copyright and Trademarks Copyright

Copyright 2024 Canon Production Printing.

No part of this publication may be copied, modified, reproduced or transmitted in any form or by any means, electronic, manual or otherwise, without the prior written permission of Canon Production Printing. Illustrations and printer output images are simulated and do not necessarily apply to products and services offered in each local market. The content of this publication should neither be construed as any guarantee or warranty with regard to specific properties or specifications nor of technical performance or suitability for particular applications. The content of this publication may be subject to changes from time to time without notice.

CANON PRODUCTION PRINTING SHALL NOT BE LIABLE FOR ANY DIRECT, INDIRECT OR

CONSEQUENTIAL DAMAGES OF ANY NATURE, OR LOSSES OR EXPENSES RESULTING FROM

THE USE OF THE CONTENTS OF THIS PUBLICATION.

Marks

Canon is a registered trademark of Canon Inc.

DigiDot, InkSafe, PRISMA, PRISMAproduction, ProStream and SRA are trademarks or registered trademarks of Canon Production Printing Netherlands B.V.

Adobe is either registered trademark or trademark of Adobe Systems Incorporated in the United States and/or other countries.

All other trademarks are the property of their respective owners and are hereby acknowledged.

Edition V06_2024-11 EN

Data security Introduction

Security is about safeguarding communication and data and keeping our online society and economy secure. It is critical for our customer’s business and we take it seriously at Canon Production Printing. Security is incorporated in the early stages of our product development process. Our hardware and software products are developed according to industry security standard working methods, and equipped with the required features to protect our printing products and PRISMA workflow and application software against cyber security threats.

Policy / Guidelines / Rules

Canon's Secure Development Life Cycle (SDLC) process is an agile based development process that also models itself comparing with the National Institute of Standards and Technology (NIST) and Open Web Application Security Project (aka OWASP).

It uses the practice of sprints to take advantage of the continuous delivery and flexibility that an agile process enables.

Our back office support program (development of service tools and online services) is ISO/IEC 27001:2013 certified.

Regulation notices

For more detailed information on the security of our products, services and solutions please refer to your local Canon representative or to https://cpp.canon/security .

https://cpp.canon/security

Source code

The listed open source components are governed by different licenses. Some of the licenses contain regulations regarding the provision of the pertaining source code.

Policy / Guidelines / Rules

If you would like to obtain a machine-readable copy of the source code of an open source component, which is made available under applicable license terms, you may request such copy of the source code by sending an e-mail to opensource@cpp.canon indicating the following:

1. Name and version of the Canon Production Printing software you licensed.

2. Name and version of open source software modules contained in the above identified Canon

Production Printing software of which you legitimately would like to obtain the source code.

We will provide you with a find place where you can obtain a machine-readable copy of the source code or we will deliver a complete machine-readable copy of the corresponding source code of the respective open source software component, as available and as is, on a medium of our choice which can be customarily used for software interchange. You may be required to pay the cost incurred for the source code distribution, however, the cost will in no event excess the cost incurred for physically performing the source code distribution.

Regulation notices

This offer is valid to anyone in receipt of this information.

Contents

Chapter 1 Introduction

Introduction Notes for the reader

Chapter 2 Checklist

Customer data Delivery data Technical delivery data Installation Requirements Declaration of conformity in accordance with the Machinery Directive Training Notes Required actions Confirmation

Chapter 3 Technical Data

Introduction Technology Productivity Paper Dimensions and Weight Installation Plans and Maintenance Areas Electrical Connection and Power Input Environmental Conditions Exhaust air Cooling Water, Compressed Air and Fiber-Optic Connections Interfaces

Overview Type 1 E-Stop IN E-Stop OUT Permission to move web (PTMW) Speed

Dryer Inline Quality Control (IQC)

Chapter 4 Additional devices

Additional devices

Index

Contents

Contents

Chapter 1

These instructions have been created for the global marketplace. They may contain information on accessories and licensed functions that are not supported by your local Canon organization or their dealer.

In some regions where this product is sold, the trading name may be registered as the model number.

Trade name Model number Designation

ProStream 2000 series 01500 Printing system

NOTE

As of the version dated 2024-07, this document is only available in English.

Introduction

8 Chapter 1 - Introduction

Notes for the reader

Safety symbols

Before you use this product, make sure you read and understand the safety information that belongs to the product. You can find the safety information in this manual. Also be sure to follow all warnings and instructions marked on the product.

This manual uses the following safety symbols to indicate hazards and precautions.

Symbol Type of symbol Indicates

WARNING Indicates a warning concerning operations that may lead to death or injury to persons if not performed correctly. To use the machine safely, always pay attention to these warnings.

CAUTION Indicates a caution concerning operations that may lead to injury to persons if not performed correctly. To use the ma-chine safely, always pay attention to these cautions.

IMPORTANT Indicates an operational requirement or restriction. Read these items carefully in order to prevent damage to equip-ment, software, data, media, or property.

NOTE Indicates a clarification of an operation or contains additional explanations for a procedure. Reading these notes is highly recommended.

Notes for the reader

Chapter 1 - Introduction 9

Notes for the reader

10 Chapter 1 - Introduction

Chapter 2 Checklist

Customer data

Participant at the site inspection

Name Status Company

Customer information

Call up address

Contact Status Telephone

Canon Service information

Service area

Contact Name Telephone

Date of the site inspection

Customer data

12 Chapter 2 - Checklist

Delivery data

Printer configuration

Printer type

Pre- and post-processing units

Mandrel size (Unwind/rewind unit)

NOTE

An unwind and rewind unit are required for the time of the installation.

Delivery conditions

Delivery date

Installation time period

Approval test

Start of production

Delivery data

Chapter 2 - Checklist 13

Technical delivery data

No. Topic Action?

(if action is required, fill out the table under Required actions on page 25)

1 Space for unloading (from delivery vehicle) avail-able?

yes no yes

1a Customer delivery acceptance times?

________ to ________ yes

2 Does the customer have an (un)loading ramp available for the delivery vehicle?

yes no yes

2a Maximum delivery vehicle length?

Number of delivery vehicles?

yes

3 Load-bearing capacity of the loading ramp?

yes

4 Has a forklift been arranged for unloading/depal-letizing?

• Weight of the heaviest part: see section Dimen-sions and Weight on page 37

• Minimum fork length: 2400 mm (94.49 inch)

• Maximum fork height: 70 mm (2.76 inch)

• Maximum fork width: 100 mm (3.94 inch)

IMPORTANT

Liability and insurance details must be clarified in advance!

yes no yes

5 Are the dimensions of the main entrance suita-ble?

Dimensions of the largest part (L x W x H):

See section Dimensions and Weight on page 37 yes no yes

6 Are the dimensions of all doors and corridors leading to the installation area sufficiently large?

Dimensions of the largest part (L x W x H):

See section Dimensions and Weight on page 37

NOTE

When transported with the pallet truck, the modules are lifted by approx.

150 mm (5.9 inch) yes no yes

7 Is the use of an elevator required?

If "no", go to item 10.

yes no

8 Load-bearing capacity of the elevator?

yes

Technical delivery data

14 Chapter 2 - Checklist

9 Are the dimensions of the elevator suitable?

Dimensions of the largest part (L x W x H):

See section Dimensions and Weight on page 37

NOTE

The length of the pallet truck that is used must also be taken into account.

When transported with the pallet truck, the modules are lifted by approx.

150 mm (5.9 inch) yes no yes

10 Is the floor on which the delivery is to be trans-ported suitable?

yes no yes

11 Will floor protection be necessary? yes no yes

12 Will metal plates be required in certain areas?

NOTE

Metal plates should be used when the load-bearing capacity of the floor is in-sufficient.

yes no yes

13 Are pallet trucks available for the installation?

Minimum fork length: 2500 mm (98.43 inch) Additional standard pallet truck, fork length:

1150 mm (45.28 inch) Minimum load-bearing capacity:

2500 kg (5511.6 lb) If not, who is organizing this for the time of the installation?

yes no yes

14 Are the packaging materials (paper, cardboard, etc.) to be disposed of by the customer?

yes no yes

Technical delivery data

Chapter 2 - Checklist 15

Installation Requirements

(if action is required, fill out the table under Required actions on page 25)

15 Is the available floor for the printing area suffi-cient to hold the printer weight?

IMPORTANT

Load (maximum point load) that the printer places on the base area:

See section Dimensions and Weight on yes no yes

16 Load-bearing capacity of the floor?

yes

17 Do any other devices need to be moved?

Along the route from the delivery vehicle to the installation area In the installation area (for example, other printers) yes no yes

18 Are any other devices in the direct vicinity of the printer?

e.g. air heater, humidifier, etc.

yes no yes

Installation Requirements

16 Chapter 2 - Checklist

19 Is an installation plan being worked on?

The contents should include:

Space for the printer in the printing room Unwinder Peripherals* Controller Paper post-processing unit³ Paper web cleaning system Electrical connection to the printer, controller and post-print processing system/pre-print pro-cessing system

Compressed-air connection to the printer and post-print processing system/pre-print processing system

Coolant connections to CCUs Connection area for extraction system Table for printouts

NOTE

*) CCU, PCI, supply duct The positions of the components can-not be changed, see section: Installa-tion Plans and Maintenance Areas on page 40.

³) When installing or replacing the print head, a rewind unit is required, or it must be possible to remove entire sheets from the paper post-processing unit.

yes no yes

20 Does the available power correspond to the speci-fication?

NOTE

See section:

• Electrical Connection and Power In-put on page 43

• Additional devices on page 68

For printer For controller For post-print processing system/pre-print pro-cessing system yes no yes

21 Is the customer providing all cables?

Cable to the printer, controller, post-print process-ing system/pre-print processing system.

• Electrical Connection and Power Input on

• Additional devices on page 68 yes no yes

Installation Requirements

Chapter 2 - Checklist 17

22 Are cables laid between the controller cabinet and the printer?

NOTE

Laying cables above the ceiling must be carried out by the customer.

Above ceiling Above floor

Length of the optical fiber cable? 25 m (984.25 inch) 50 m (1968.5 inch) 100 m (3937 inch) 150 m (5905.5 inch)

23 Is the air conditioning system sufficient?

See section Environmental Conditions on yes no yes

23a Is an external cooling assembly available for sup-plying the CCU with cold water?

See section:

Cooling Water, Compressed Air and Fiber-Optic Connections on page 53 yes no yes

23b Is there enough demineralized water (50 l) with a conductivity of max. 10 μS/cm (0.10 CF) to fill the

CCU?

yes no yes

24 Is a ventilation/extraction system available?

NOTE

• A system for extracting exhaust air to the outside is required

• The customer's exhaust duct must be impervious to liquid and vapor.

• The flue must be equipped with a deflector to prevent the exhaust air from condensing on the roof.

• See section Exhaust air on page 49 yes no yes

24a Is there feedback from the exhaust air system?

NOTE

• Feedback from the exhaust air sys-tem is required if the signal for switching on the customer's exhaust air system is connected.

• See section Exhaust air on page 49 yes no yes

25 Is there a supply of compressed air available ac-cording to the specification for the printer and post-print processing system/pre-print processing system?

See section:

• Cooling Water, Compressed Air and Fiber-Op-tic Connections on page 53

• Additional devices on page 68 yes no yes

Installation Requirements

18 Chapter 2 - Checklist

26 Has the waste disposal system been coordinated?

• e.g. for filters, waste ink, condensates

• Ink and cleaning fluid: see safety data sheet at

Downloads yes no yes

27 Has the availability of consumables been ensured following confirmation of installation and order placement?

NOTE

Ink, ColorGrip, cleaning fluid, filter, etc.

yes no yes

28 Is a remote connection to the controller available?

NOTE

• Speed: 4 Mbit/s upload.

• VPN tunnel via the customer network or direct DSL connection

• See "On Remote Service (ORS) white paper" at Downloads

IMPORTANT

If "yes", please fill out the ORS connec-tion information — see white paper.

yes no yes

29 Is an Internet connection available for the installa-tion?

yes no yes

30 Are a table/chairs available in the vicinity of the installation area for the print sample evaluation?

yes no yes

31 Is a power supply available in the vicinity of the installation area?

yes no yes

32 Has a PRISMA connection to the controller been coordinated?

10-gigabit network (standard configuration) 10-gigabit optical SMF/LR 10-gigabit optical MMF/SR

NOTE

• Additional network cards may be re-quired for the server.

• Laying cables above the ceiling must be carried out by the customer.

yes no yes

33 The electrical test for the entire printer can be carried out on the basis of the local NSO require-ments.

Responsible for installation: @ NSO project man-ager

NOTE

Germany: DIN VDE 0105-100 / DGUV 3 yes no yes

Installation Requirements

Chapter 2 - Checklist 19 ProStream 2000 series http://downloads.cpp.canon/ https://service.cppintra.net/public/CP/SitePages/Security%20Documents.aspx

34 Are special service tools available for the installa-tion?

NOTE

These are described in the TSM, in the printer/tools section.

The TSM can be accessed by Service personnel once training has been com-pleted.

yes no yes

35 Is adjustment paper available for the installation?

NOTE

The 558 mm (21.9 inch)-wide adjust-ment paper must be ordered if the Inline Quality Control with Nozzle Uni-formity Correction is used and the en-tire print width of 556 mm (21.8 inch) is to be used.

540 mm (21.25 inch)

558 mm (21.9 inch) yes

36 SPO PC: Installation discussed?

See document with the order number A29246- X69-X-80: Single Point of Operation (SPO), com-missioning/operator manual yes no yes

37 Are mobile phones, USB tools and notebooks al-lowed in the printing area?

yes no yes

38 Does the customer have a stepladder available for maintenance?

• Stepladder with five steps

• Height: 100 – 110 cm (39.37 – 43.3 inch)

• Width: 88 – 110 cm (34.64 – 43.3 inch)

NOTE

If not, the ladder must be included in the order (S29312-F2162 / 2100057268) or an alternative ladder must be pur-chased from NSO.

yes no yes

39 Has the operator manual for the printing system been handed over to the local Service representa-tive?

yes no yes

Installation Requirements

20 Chapter 2 - Checklist

Declaration of conformity in accordance with the Machinery Directive

Interlinking to the assembly of machines

No. Topic Action?

(if action is required, fill out the table under Required actions on page 25)

40 Which machines are to be spatially connected to each other?

yes

41 Are there declarations of conformity or installa-tion for each of these machines?

yes no yes

42 Is there technical documentation for the respec-tive machines?

yes no yes

43 Do these machines work together in terms of pro-duction technology?

yes no yes

The machines are installed connected to each other; they work together and are operated to-gether. The machines form a unit and have a common purpose, such as producing a product.

yes no

The machines are linked mechanically or by the same control system.

A common or higher-level control system is re-quired for the production sequence.

yes no

44 Are these machines connected in terms of safety mechanisms?

yes no yes

Can an event on one machine lead to a hazard on another machine in the system?

If this is the case, safety measures must be ap-plied to the whole assembly, for example by means of a common safety control system and common emergency stop control devices.

yes no

45 Should these machines work together as an as-sembly of machines like "a single machine"?

yes no yes

46 Who creates the operating manual for the assem-bly of machines?

CPP

3rd party Customer yes

Declaration of conformity in accordance with the Machinery Directive

Chapter 2 - Checklist 21

47 Who is the manufacturer of this assembly of ma-chines?

NSO

3rd party Customer yes

48 Who is to issue the declaration of conformity? NSO 3rd party Customer yes

49 Is there a contractual agreement on this? yes no yes

Significant changes to machines and systems

No. Topic Action?

(if action is required, fill out the table under Required actions on page 25)

50 Should significant changes be made to an exist-ing product at the customer's premises by instal-ling the existing machines with the aim of modi-fying the product's original performance, use or design?

yes no yes

51 Will the change lead to new hazards that cause significantly new risks for the installation as a whole and not just for individual (incomplete) ma-chines in the installation?

yes no yes

Declaration of conformity in accordance with the Machinery Directive

22 Chapter 2 - Checklist

Training

Operator/key operator training

Number of operators/key operators:____________

Training location: ITC Poing At the customer's site

Date: _____________

Training during installation is only possible in ITC.

Service training

Post-print processing and/or pre-print processing

Training conducted by: _____________

Training

Chapter 2 - Checklist 23

Notes

Notes

24 Chapter 2 - Checklist

Required actions

No. Performs Responsibility Date/ Status

Required actions

Chapter 2 - Checklist 25

No. Performs Responsibility Date/ Status

Required actions

26 Chapter 2 - Checklist

Confirmation

Customer Canon

Infrastructure must be completed before the installation is started

Customer

Chapter 2 - Checklist 27

28 Chapter 2 - Checklist

Chapter 3 Technical Data

Technical Data

This section contains the most important technical data for the printing system.

Overview

You will find information on the following topics:

• Technology on page 31

• Productivity on page 33

• Paper on page 34

• Dimensions and Weight on page 37

• Installation Plans and Maintenance Areas on page 40

• Electrical Connection and Power Input on page 43

• Environmental Conditions on page 47

• Exhaust air on page 49

• Cooling Water, Compressed Air and Fiber-Optic Connections on page 53

• Interfaces on page 56

• Overview on page 56

• Type 1 on page 58

• E-Stop IN on page 60

• E-Stop OUT on page 61

• Permission to move web (PTMW) on page 62

• Speed on page 63

• Dryer on page 64

• Inline Quality Control (IQC) on page 66

NOTE

For information on spare parts or safety components, please contact your Service engineer.

Introduction

30 Chapter 3 - Technical Data

Technology

Printing method

DigiDot, drop-on-demand, piezoelectric

• pigment-based polymer ink with ColorGrip

• InkSafe technology

Print Resolution

1200 x 1200 dpi with print speed:

• 80 m/min (262 ft/min)

• 60 m/min (196 ft/min)

• 40 m/min (131 ft/min)

1200 x 720 dpi with print speed:

• 133 m/min (436 ft/min)

• 110 m/min (360 ft/min)

Multilevel with variable droplet sizes at all print speeds

EdgEnhance RIP option

Quality control

Inline Quality Control (IQC) including:

• Nozzle Activity Control (NAC)

• Nozzle Uniformity Control (NUC)

Controller

SRA MP, with most current Adobe PDF Print Engine (APPE) (Scalable Raster Architecture, Massively Parallel)

Data streams:

• via PRISMAproduction:

• PDF (PDF/X, PDF/VT)

• AFP/IPDS (IS/3)

• and others

Color management conforms with AFP color consortium

Network connection

PRISMAproduction:

• 10 Gigabit Ethernet (copper, optic MMF/SR, optic SMF/LR)

Print mode/page layout

• 2-up simplex

• 2-up duplex

Technology

Chapter 3 - Technical Data 31

Color configurations

• 4/4

• 1/1

• 4/1

• 1/4

• 4/0

• 0/4

NOTE

If none of the CMYK colors are printed in a printer, this printer will also not print with ColorGrip.

Technology

32 Chapter 3 - Technical Data

Productivity

ProStream 2080

Print speed • 80 m/min (262 ft/min)

• 60 m/min (196 ft/min)

• 40 m/min (131 ft/min)

Throughput per minute (CMYK duplex)

• 1 076 A4 prints

• 112 B2 sheets

Throughput per hour (CMYK duplex)

• 64 500 A4 prints

• 6 800 B2 sheets

Maximum effective monthly utiliza-tion

• 35 000 000 A4 prints

• 3 700 000 B2 sheets

ProStream 2133

Print speed • 133 m/min (436 ft/min)

• 110 m/min (360 ft/min)

• 80 m/min (262 ft/min)

• 60 m/min (196 ft/min)

• 40 m/min (131 ft/min)

Throughput per minute (CMYK duplex)

• 1 790 A4 prints

• 188 B2 sheets

Throughput per hour (CMYK duplex)

• 107 500 A4 prints

• 11 300 B2 sheets

Maximum effective monthly utiliza-tion

• 58 000 000 A4 prints

• 6 100 000 B2 sheets

Productivity

Chapter 3 - Technical Data 33

Paper

The Media specifications ProStream series manual contains detailed information on the permissible paper types.

Paper

Paper transport • Roll to roll

• Pinless

• Highly tensioned paper web (Tight web) with auto-matic web tension control

Continuous paper • Offset uncoated papers

• Matt and glossy coated papers

• Inkjet-treated papers

• LWC (Light Weight Coated)

Paper input • Unwind unit from a Canon-certified partner with inte-grated paper web cleaning

• Connection: see section Interfaces on page 56

Paper Output • Rewind unit from a Canon-certified partner

• Barcode-controlled post-processing (cutting and stacking, signature-creation, dynamic perforation)

• Inline, offline or nearline

• Connection: see section Interfaces on page 56

Paper conditioning unit • Remoistening unit from a Canon-certified partner for variable water application to the front and rear side

• Inline or offline

Format width • Standard area:

406 – 558 mm (16 – 22 inch)

• Option Narrow Web:

292 – 406 mm (11.5 – 16 inch)

Maximum print width 556 mm (21.88 inch) Areas in which you cannot print:

• Data integrity marks, including protected areas

• Post-print processing marks, including protected areas

• every 1 mm (0.039 inch) on the lateral edges of the paper

Format height (Logical page length)

• 152 – 1524 mm (6 – 60 inch), dynamically variable

• Zero Gapfunction (virtually infinite pages)

Paper thickness 50 – 300 µm (1.97 – 11.8 mils)

Paper

34 Chapter 3 - Technical Data

Paper

Paper weight (grammage)

• Standard area: 60 – 300 g/m2

Maximum paper weight ProStream 2000 series at maximum print speed

300 g/m2 40 m/min (131 ft/min)

250 g/m2 80 m/min (262 ft/min)

150 g/m2 133 m/min (436 ft/min)

• Option Lightweight Paper: 28 – 60 g/m2

NOTE

For paper weights under 60 g/m², paper can be printed at a speed of 80 m/min (262 ft/min) or 133 m/min (436 ft/min). These lightweight papers generally require detailed evaluations of movement capability throughout the entire printing and finishing work procedure. For each of these lightweight papers, a working window with crease-free paper web and stable paper path must be found.

• Paper weights over 300 g/m² are permitted provided that the maximum permissible paper thickness is not exceeded and the media has passed the tests and has been approved by our media laboratory.

IMPORTANT

Before using new media, ensure that they comply with the Media specifications. If the paper weight is outside the standard range, the paper must be checked before releasing it for production:

• Under no circumstances may the paper touch the print heads:

• Is the distance between the paper web and the print heads great enough?

• Are there any creases or wrinkles in the paper, especially at print start?

• Is the splice sensor still working?

• The paper must be dry enough:

• Is there ink on the deflection rollers?

• Is the print image smeared?

• Is the print image being transferred onto the paper reverse side ("stamping") in the rewind unit?

• Is there any friction? Is the print image smeared in post print processing?

• If in doubt, please contact our media laboratory.

Paper path

• Unwind unit + printer 1 + turning unit + printer 2 + rewind unit:

Printing system Paper path

ProStream 2000 series 57 m (187 ft)

• Print the front side in printer 1 up to the rewind unit:

Printing system Paper path

ProStream 2000 series 42,9 m (140.7 ft)

Paper

Chapter 3 - Technical Data 35

Misprint

Depending on the configuration, the type of print stop and the relevant print speed, a certain length of paper misprint is produced. This misprint must be cut off and ejected by means of suitable devices during post-print processing.

NOTE

• The following lengths are rounded to whole numbers. Metric and imperial values may therefore differ slightly.

• The last printed page of the print job is transported to the rewind unit after the end of the print job.

After a stop due to an error message, all pages that have not arrived in the rewind unit are discarded. These pages need to be reprinted.

ProStream 2000 series Print speed

40 m/min (131 ft/min)

80 m/min (262 ft/min)

133 m/min (436 ft/min)

Start of printing until the first line is printed

1,5 m (5 ft)

2,3 m (8 ft)

4,3 m (14 ft)

• Start of printing after powering on the printing system (including the paper in the printing system)

• between print jobs with halt of pa-per movement

• Print stop and restart

44 m (144 ft) 45 m (148 ft) 47 m (155 ft)

Splice detection during printing and start of printing

12 m (39 ft)

Affixing of a new paper web and start of printing

57 m (186 ft)

Paper

36 Chapter 3 - Technical Data

Dimensions and Weight

Complete printing system

ProStream 2000 series Length x Width x Height Weight (approximate)

Twin printing system 11263 x 4057 x 2025 mm (443.43 x 159.72 x 79.72 inch) Maximum height 2575 mm (101.4 inch) at the exhaust air connection

• Two printers: 10740 kg (23678 lb)

• Two cable bushings:

2x 270 kg (2x 595 lb)

• Two supply units:

2x 1010 kg (2x 2227 lb)

Twin printing system with roller to roller

16000 x 4057 x 2025 mm (629.92 x 159.72 x 79.72 inch)

13900 kg (30644 lb)

Transport Units (Including Palettes)

Length x Width x Height Weight (approximate) main module 2730 x 2310 x 2400 mm (107.48 x 90.94 x 94.49 inch)

2455 kg (5412 lb)

Paper transport module 2730 x 1720 x 2400 mm (107.48 x 67.72 x 94.49 inch)

1795 kg (3935 lb)

Turning unit 1850 x 1340 x 2400 mm (72.83 x 52.76 x 94.49 inch)

610 kg (1344 lb)

Base PCI 1400 x 800 x 1650 mm (55.12 x 31.5 x 64.96 inch)

300 kg (661.4 lb)

Logic unit 900 x 800 x 1650 mm (35.43 x 31.5 x 64.96 inch)

110 kg (242.5 lb)

Dryer PCI 1400 x 800 x 1650 mm (55.12 x 31.5 x 64.96 inch)

235 kg (518 lb)

Central cooling unit (CCU) 1800 x 980 x 2250 mm (70.87 x 38.58 x 88.58 inch)

560 kg (1235 lb)

Length x Width x Height Weight (approximate)

Controller, single-door 1650 x 1000 x 2400 mm (64.96 x 39.37 x 94.49 inch)

840 kg (1852 lb)

ProStream 2000 series Length x Width x Height Weight (approximate)

Cooling module 2730 x 1720 x 2400 mm (107.48 x 67.72 x 94.49 inch)

• With three cooling rollers:

1985 kg (4376 lb)

• With two cooling rollers:

1865 kg (4112 lb)

Dimensions and Weight

Chapter 3 - Technical Data 37

• The transport units are packed in wooden boxes.

• Some controller components are delivered separately and installed during installation.

• If necessary, the controller cabinet can be laid horizontally for a short time while it is transported through doorways. To do this, however, the servers and blades must be removed before tilting.

• In order to reduce environmental influences (temperature, paper dust), the controller can also be installed outside the production environment of the printing system. The maximum cable length is 150 m (492.13 ft).

• The double-door controller cabinet is used if an uninterruptible power supply or additional raster performance is required.

Transport units (without pallets)

Length x Width x Height Weight (approximate) main module 2550 x 2100 x 2030 mm (100.39 x 82.68 x 79.92 inch)

1990 kg (4387 lb)

Paper transport module 2550 x 1500 x 2030 mm (100.39 x 59.06 x 79.92 inch)

1430 kg (3153 lb)

Turning unit 1370 x 1150 x 2030 mm (53.94 x 45.28 x 79.92 inch)

530 kg (1168 lb)

Base PCI 1200 x 520 x 1410 mm) (47.24 x 20.47 x 55.51 inch

250 kg (551 lb)

Logic unit 600 x 520 x 1410 mm (23.62 x 20.47 x 55.51 inch)

75 kg (165 lb)

Dryer PCI 1200 x 520 x 1410 mm (47.24 x 20.47 x 55.51 inch)

185 kg (408 lb)

Central cooling unit (CCU) 1610 x 610 x 2020 mm (63.39 x 24.02 x 79.53 inch)

500 kg (1102 lb)

Length x Width x Height Weight (approximate)

Controller, single-door 1400 x 800 x 2200 mm (55.12 x 31.50 x 86.61 inch) up to 640 kg (1411 lb)

Controller, double-door (optional)

1400 x 1600 x 2200 mm (55.12 x 63 x 86.61 inch)

825 kg (1818.8 lb)

ProStream 2000 series Length x Width x Height Weight (approximate)

Cooling module 2550 x 1640 x 2030 mm (100.39 x 64.57 x 79.92 inch)

• With three cooling rollers:

1620 kg (3571 lb)

• With two cooling rollers:

1500 kg (3307 lb)

Load and ground condition

Surface load (approximate)

Printers 5000 N/m² (0.7252 psi)

Dimensions and Weight

38 Chapter 3 - Technical Data

Surface load (approximate)

Controller cabinet 6000 N/m² (0.87024 psi)

Concentrated load (maximum)

Printers 5000 N

Concentrated load (maximum)

Controller cabinet 1750 N

Floor conditions

Permissible floor unevenness • Angle: max. 16 mm (0.63 inch) open 15 m (16.4 yd)

• Evenness: max. 4 mm (0.157 inch) open 1 m (1.09 yd)

Dimensions and Weight

Chapter 3 - Technical Data 39

Installation Plans and Maintenance Areas

Between the Paper conditioning unit and the post-print processing system (rewind unit, buffer, etc.), it is recommended to run the web for 5 m (16.4 ft) without a pair of drive rollers.

NOTE

• When loading or unloading the paper using the unwinder or rewinder, an additional area of approx. 2 m (6.56 ft) is required.

The corresponding instructions from the manufacturer must be observed.

The entire space requirements and the total weight are dependent on the post print processing used.

• Locally applicable regulations and workplace guidelines must be adhered to. Sufficient space must be planned for rescue and escape routes.

• The necessary maintenance areas specified in the following graphics are to be understood as a minimum requirement.

Height

Minimum required height

Installation Plans and Maintenance Areas

40 Chapter 3 - Technical Data

ProStream 2000 series: Installation Plans and Maintenance Areas

ProStream 2000 series/I-Twin

* Complete printing system

** Maintenance area

Electrical connection

Exhaust air/extraction

Compressed air connection

Connection to external cooling water sup-ply

Fiber-optic connection

Base

A Unwinder with paper web cleaning

B Control cabinets transport unit (base PCI and dryer PCI) with central cooling unit

(CCU)

C Cooling module transport unit

IMPORTANT

Plug bars must not be rout-ed under the area of the cooling rollers in the cool-ing module.

This avoids the risk of a short circuit in the event of a possible leak in the hose connections to or from the cooling rollers.

D Paper transport module transport unit

E Main module transport unit

F Turning unit

H Controller cabinet A minimum distance of 0,5 m (1.64 ft) is required between the sides and the wall.

I Rewinder

Installation Plans and Maintenance Areas

Chapter 3 - Technical Data 41

ProStream 2000 series/I-Twin with Paper conditioning unit

* Complete printing system

** Maintenance area

Electrical connection

Exhaust air/extraction

Compressed air connection

Connection to external cooling water sup-ply

Fiber-optic connection

Base

A Unwinder with paper web cleaning

B Control cabinets transport unit (base PCI and dryer PCI) with central cooling unit

(CCU)

C Cooling module transport unit

IMPORTANT

Plug bars must not be rout-ed under the area of the cooling rollers in the cool-ing module.

This avoids the risk of a short circuit in the event of a possible leak in the hose connections to or from the cooling rollers.

D Paper transport module transport unit

E Main module transport unit

F Turning unit

H Controller cabinet A minimum distance of 0,5 m (1.64 ft) is required between the sides and the wall.

I Rewinder

J Paper conditioning unit

Installation Plans and Maintenance Areas

42 Chapter 3 - Technical Data

Electrical Connection and Power Input

Overview

Electrical connections

ProStream 2000 series

A Printer (base PCI)

B Dryer PCI

Printer (base PCI)

Connection A

ProStream 2000 series:

• per printer 400 V ± 10 % (3L+N+PE)

• Nominal value: 36 A

• Overcurrent protection device: 64 A

• Installed capacity: 25 kVA 4

Electrical Connection and Power Input

Chapter 3 - Technical Data 43

Connection A

• Where a power supply other than 400 V is in use, the required voltages can be generated by an optional transformer.

• The electrical cable must be connected on-site by trained electricians under the supervision of the Agent.

• Appropriate metric screw connections must be used and the hole must be drilled accord-ing to the diameter of the cable.

• The bushing must be impervious to light (check from the inside).

• If the electrical connecting cable is routed from the top to the PCI, the cable bushing through the aluminum plate and the tension relief must be installed in accordance with the applicable country-specific regulations.

• Torque for terminals (main switch PCI/conductor rails): each 30 Nm (265.5 inch.lb)

Dryer PCI

Connection B

ProStream 2000 series:

• containing 400 V ± 10 % (3L+PE)

• Nominal value: 145 A

• Overcurrent protection device: 160 A

• Installed capacity: 100 kVA

Apparent power

Complete printing system

ProStream 2000 series Apparent power: 270 kVA Rated power: 250 kVA Rated current at 400 V:

• Printer 1 dryer: 145 A

• Printer 1 basic: 36 A

• Printer 2 dryer: 145 A

• Printer 2 basic: 36 A

Electrical Connection and Power Input

44 Chapter 3 - Technical Data

Controller

Controller 400 V 50/60 Hz 208 V 50/60 Hz

Connection • 16 A

• Phases: 3L-N-PE

• Torque for terminals:

2,8 Nm (24,8 inch.lb)

• Phases: 3L-PE

• Torque for terminals:

2,8 Nm (24,8 inch.lb)

Connection pow-er

• Effective power: 3,178 kW

• Apparent power: 3,403 kVA

• Maximum power consumption per phase: 7,0 A

• Effective power: 3,34 kW

• Apparent power: 3,57 kVA

• Maximum power consumption per phase: 10,60 A

Average power (standby)

• Effective power: 2,117 kW

• Apparent power: 2,299 kVA

• Power consumption per phase:

3,3 A

• Effective power: 2,22 kW

• Apparent power: 2,41 kVA

• Power consumption per phase:

3,47 A

Average power (printing)

• Effective power: 2,69 kW

• Apparent power: 2,87 kVA

• Power consumption per phase:

4,1 A

• Effective power: 2,83 kW

• Apparent power: 3,01 kVA

• Power consumption per phase:

4,31 A

Grounding concept

Grounding concept

NOTE

This graphic depicts a ProStream 3000 series printing system; however, the information also applies to Pro- Stream 2000 series printing systems.

Legend

Controller Controller

PPU Post-print processing (variable — shown here as an ex-ample)

Single Entry Point

Electrical Connection and Power Input

Chapter 3 - Technical Data 45

IMPORTANT

Please note, when routing the grounding cable:

• Keep the length as short as possible.

• There must be no loops.

Minimum wire cross section

< 10 m (< 32.8 ft) 10 mm² (0.0155 inch²)

> 10 m (> 32.8 ft) 16 mm² (0.0248 inch²)

> 15 m (> 49.2 ft) 22 mm² (0.0341 inch²)

> 20 m (> 65.6 ft) 34 mm² (0.0527 inch²)

> 35 m (> 114.8 ft) 42 mm² (0.0651 inch²)

Residual Current Devices (RCD)

A maximum leakage current of 300 mA can occur per PCI. Residual current circuit breakers(RCCB) are not required.

Circuit Diagrams

Information on the circuits that are not switched off by the main switch can be found in the circuit diagrams supplied with the printing system.

Unwinder with external paper web cleaning/rewinder/external cooling

More detailed information about the electrical values for these devices can be found in the external original documentation.

Electrical Connection and Power Input

46 Chapter 3 - Technical Data

Environmental Conditions

A controlled and stable room environment for the printing system is of the utmost importance.

The temperature and humidity of both the print room and the print substrate affect the print quality, even when only black is printed. In color printing, this effect can quadruple (CMYK), making environmental conditions even more critical.

In addition, the room in which the printing system is installed should be relatively free of dust and other airborne particles. The printing system should not be installed in an area where milling cutters, grinders or trimmers are used.

Printing system

Temperature

Room temperature 20 °C – 26 °C (68 °F – 78.8 °F)

Relative humidity 40 % – 60 %

Air pressure 840 – 1060 hPa

Absolute humidity (dew point) < 15 g/m³

Height above sea level Below 1500 m (4921 ft)

Heat emission 37 kW (126000 BTU/h)

Sound

Noise level < 80 dB(A)

Storage and Transport

IMPORTANT

Condensation is not permitted under any circumstances.

Printing system (transport units)

Temperature range -10 °C – 50 °C (14 °F – 122 °F)

Relative humidity 5 % – 90 %

Temperature adjustment Maximum 1 K/min

Air pressure 450 – 1060 hPa

Papers

Relative humidity 35 % – 55 %

Ink/ColorGrip/cleaning fluids

Transport temperature range -10 °C – 40 °C (14 °F – 104 °F)

Storage temperature range 15 °C – 30 °C (39 °F – 86 °F)

Relative humidity 5 % – 90 % 4

Environmental Conditions

Chapter 3 - Technical Data 47

Ink/ColorGrip/cleaning fluids

Air pressure 450 – 1060 hPa

Temperature adjustment Maximum 1 K/min

Environmental Conditions

48 Chapter 3 - Technical Data

Exhaust air

Each inkjet printer emits a certain amount of VOC (volatile organic compounds), depending on the surface coverage of the printed image and the print speed.

The ProStream 2000 series printing systems have an integrated exhaust air cleaning system. The cleaned exhaust air is blown upward.

CAUTION

To ensure compliance with the occupational exposure limits (OELs), the Agent of the printing system must provide an external suction system.

Exhaust air

Overview (unit of measurement: meters)

NOTE

This graphic depicts a ProStream 3000 series printing system; however, the informa-tion also applies to ProStream 2000 series printing systems.

Exhaust air

Height of the connection Approximately 2577 mm (101.5 inch)

Exhaust air volume flow (customer-side)

The customer-side air volume flow contains the follow-ing volume fractions:

• Drying

• ColorGrip

• 20 % Additional fresh air at the flue

Values for exhaust air volume flow and internal diame-ter: see section Dryer on page 64

Exhaust air temperature Maximum 60 °C (140 °F)

Exhaust air control

With the aid of the optional exhaust air control, the Agent can control the external exhaust air system via a potential-free contact.

IMPORTANT

The connection of the optional exhaust air control must comply with the requirements of the applicable Functional Safety guidelines. After commissioning, the jumper must be removed from the optional exhaust air control.

Exhaust air

Chapter 3 - Technical Data 49

Process description:

1. The printing system requests the start-up of the exhaust air system.

2. The exhaust air system starts up within 30 seconds. This is reported back to the printing system by two redundant signals.

The two signals may have a maximum delay of 2500 ms between them.

3. As soon as the exhaust air system is running, printing starts.

4. After printing, the printing system stops and switches off the exhaust air system again.

Interface description

NOTE

The variants described outline two ways in which the exhaust air system of the printing system can be monitored. Other types of monitoring are possible, but they are dependent on the infrastructure and must be discussed with the Agent before commissioning the printing system.

NOTE

These graphics depict a ProStream 3000 series printing system; however, the information also applies to ProStream 2000 series printing systems.

Variant 1

Customer area of responsibility

Variant 1

Mandatory if exhaust air control 'B' is used:

Exhaust air status monitoring optional: Exhaust air control by the customer: potential-free contact (5 – 24 V / 1 A)

Per printer: 1 Sensor (24 V) for air flow control with Performance Level d (PLd) or Safety Integrity Level 2 (SIL2)

Printer interface

• 2 redundant pulsed 24 V circuits that must be closed when the exhaust air system is running. The two signals may have a maximum delay of 2500 ms between them.

• one potential-free relay contact for activating the exhaust air system 4

Exhaust air

50 Chapter 3 - Technical Data

Variant 1

Terminal block X990

6-pin

Cable shielded 6-core cable Maximum 50 m (164.04 ft)

Variant 2

Customer area of responsibility

Variant 2

Mandatory if exhaust air control 'B' is used:

Exhaust air status monitoring optional: Exhaust air control by the customer: potential-free contact (5 – 24 V / 1 A)

1 sensor each (24 V) for the air flow control

Printer interface

• 2 redundant pulsed 24 V circuits that must be closed when the exhaust air system is running. The two signals may have a maximum delay of 2500 ms between them.

• one potential-free relay contact for activating the exhaust air system

Terminal block X990

6-pin

Cable shielded 6-core cable Maximum 50 m (164.04 ft)

Exhaust air

Chapter 3 - Technical Data 51

Extraction inside the building

The customer's exhaust duct must be impervious to liquid and vapor (longitudinally welded pipes). The material of the pipes and the seals must be water- and glycerin-resistant.

IMPORTANT

The condensate accruing in the exhaust piping must be collected separately. The printing system is not designed to accommodate larger quantities of condensate from the exhaust piping.

The exhaust fan should be a radial fan in which the motor is not directly installed in the exhaust air flow:

Axial fan Fan

Example: Example:

Extraction outside the building

The country-specific regulations for the "Derivation of organic solvents" must be observed (for example in Germany: VDI 2280).

The following minimum requirements must be observed for the flue height:

• 3 m (9.84 ft) above the ridge of a saddle roof

• 5 m (16.40 ft) above flat roofs and pent roofs

• 5 m (16.40 ft) above the ridge height of residential buildings located at a distance of

50 m (164.04 ft)

• As a basic principle, at least 10 m (32.81 ft) above the ground.

The flue must be equipped with a deflector and point straight upwards (without a bend) to prevent the exhaust air from condensing on the roof.

The discharge speed of exhaust air (vertically upward) must be a minimum of 7 m/s (22.97 ft/s).

Exhaust air

52 Chapter 3 - Technical Data

Cooling Water, Compressed Air and Fiber-Optic Connections

NOTE

• The devices for pre-print processing and post-print processing must have separate power supplies.

• More detailed information about the cooling water, compressed air and fiber-optic connection points can be found in section Installation Plans and Maintenance Areas on page 40.

Coolant connection

Overview

ProStream 2000 series

S Printer 1

D Printer 2

NOTE

The values for temperature, pressure and flow refer to the inlet of the central cooling units (CCU) rather than to the outlet of the external coolant supply.

Coolant connection

DN 50 /2 inch thread/supply line with outer thread

Nominal pressure of the water sup-ply

PN 10 (ISO 7268 / EN 1333)

Buffer store (cooling assembly) 2x 350 l required 4

Cooling Water, Compressed Air and Fiber-Optic Connections

Chapter 3 - Technical Data 53

Coolant connection

Temperature at the intake 12 °C ± 2 °C (53.6 °F ± 3.6 °F)

Temperature at the drain maximum of 50 °C (122 °F) at switch-on minimum volume flow • 9 m³/h (317.83 ft³/h) per CCU (18 m³/h (635.7 ft³/h) total for CCU for printer 1 and CCU for printer 2)

• Pressure relief valve in the CCU enables mini-mum volume flow of 9 m³/h (317.83 ft³/h) at 0,8 bar (11.6 psi)

Maximum pressure 9 bar (130.53 psi)

IMPORTANT

A higher pressure is not permitted and must be prevented by the customer.

Maximum pressure loss of one cen-tral cooling unit (for printer 1 or printer 2)

1,0 – 1,5 bar (14.50 – 21,76 psi)

Water quality • pH value: 7 – 8 pH

• Conductivity: 10 – 500 µS/cm (0.10 – 5.00 CF)

• Water hardness: 6 – 15 °dH

Cooling water requirement for filling the primary circuits of the CCU for printer 1 and the CCU for printer 2

32 l

Central cooling unit interface (CCU) A floating interface for the external cooling assembly is available. These ports are bridged by default.

• Digital – OUT (central cooling unit -> external cooling assembly):

24 V, maximum 1 A

• Digital – IN (external cooling assembly -> central cool-ing unit):

24 V DC, 50 mA

IMPORTANT

As the printer only provides a floating contact, the 24 V for the signal must not be used by the printer.

Required cooling output (ProStream 2000 series)

• CCU for printer 1: 60 kW

• CCU for printer 2: 85 kW

• simultaneously for the printing system: 140 kW

Cooling Water, Compressed Air and Fiber-Optic Connections

54 Chapter 3 - Technical Data

Compressed air connection

Compressed air connection

Separate connection per printer, dry and oil free

Quality DIN ISO 8573-1 (Particles: 1, Water: 4, Oil: 1)

Hose pressure 6 – 12 bar (87,02 – 174,04 psi)

Inside diameter 8 mm (0.315 inch) Connection with quick coupling, thread 1/4 inch

Volume flow Twin printing system: 800 Nl/min (2 x 400 lS/min (@ 0°C, 1013 mbar)

Consumption Twin printing system: approximately 240 Nl per print head purge (120 Nl per connection/printer)

Fiber-optic connection

Fiber-optic connection

6x OFC connector (Y/M/Y/C/CG)

Cable length (standard) 25 m (82.02 ft)

Cooling Water, Compressed Air and Fiber-Optic Connections

Chapter 3 - Technical Data 55

Interfaces

Overview

Introduction

The post-print processing and pre-print processing devices are connected to the printing system via various interfaces.

• Normal operation is controlled via Type 1 interfaces.

• The printing system also has bidirectional emergency stop interfaces to the pre- and post-print processing devices in accordance with DIN EN ISO 13850. If the pre- or post-print processing devices will be integrated into a shared emergency stop circuit, these devices must provide two-channel emergency stop interfaces (E-Stop IN / E-Stop OUT) to the printing system. It is essential for any pre- or post-print processing devices that can trigger web movement in the printing system to be connected to the emergency stop circuit.

• The printing system provides additional Permission to move web (PTMW) interfaces.

• Higher resolution encoder signals (Speed interfaces) make it possible to connect up to four post-processing devices that require a more precise encoder signal (Tight web integration) owing to their functionality.

Interface overview

NOTE

This graphic depicts a ProStream 3000 series printing system; however, the information also applies to ProStream 2000 series printing systems.

Explanation

Type 1interface

E-Stop IN and Permission to move web (PTMW)

Interfaces

56 Chapter 3 - Technical Data

Explanation

Extended safety interface for connecting multiple post-print processing devi-ces to the safety circuit of the printing system

Interfaces in printer 1 for pre-print processing devices

Interfaces in printer 2 for post-print processing devices:

• 1x Type 1

• 1x E-Stop IN and

1x Permission to move web (PTMW)

• 2x Type 1

• 5x E-Stop IN and

5x Permission to move web (PTMW)

• 5x E-Stop OUT

• 4x Speed

Overview

You will find information on the following topics:

• Type 1 on page 58

• E-Stop IN on page 60

• E-Stop OUT on page 61

• Permission to move web (PTMW) on page 62

• Speed on page 63

Overview

Chapter 3 - Technical Data 57

Type 1

Connection

Connection

Type 1cable, for example T26312-H120-V100

Printer: X703 / X704 Post-print processing and pre-print processing devices

Plug-in connector: D1757 interface card

D-sub socket 37-pin

Plugs:

D-sub plug, 37-pin

Cable:

• LiYC 20 x 2 x 0,14 mm² (0.000217 inch²)

AWG26/7

• Shielded cable

• EMC cable category: EMV-5

• Maximum length: 15 m (16.4 yd)

Cable specification in accordance with legal and environmental requirements (for example resistance to oils, fluids, mechanical strength, RoHS, etc.)

Signals at the universal interface Type 1

Logic interface

A Printing system

B Additional device (post-print processing or pre-print processing)

C Universal interface

Signal from the printing system to the additional device (active high signal)

Signal from the additional device to the printing system (active low signal)

Type 1

58 Chapter 3 - Technical Data

Signal evaluation if multiple devices are connected

If multiple post-print processing or pre-print processing devices are connected, the printing system evaluates the different signals in accordance with the following table:

PIN Signal Direction Status Prerequisite for multiple devices

3 ADEVPE-

JECT-N

Recommended EJECT in response to a request by at least one unit.

4 ADEVRDY-N Mandatory Hard stop as soon as a unit is not ready.

Hard stop overwrites soft stop and pause.

5 AD1/6INCL-P Recommended on all devices

6 ADMOP-P optional on all devices

7 RELFORM-P optional on all devices/curl prevention mode

8 FEJECT-P Recommended on all devices

9 ADEVCONN-

N

Mandatory Each unit that is not connected is ig-nored.

10 ADEVSTOP-

N

Mandatory Soft stop as soon as a unit requests a soft stop.

11 BLOWER-

ON-P

Mandatory on all devices

12 JOBOFF-

SET-P

Recommended on all devices

13 ADEV-

PULSE-N

optional Only one device can send this signal to the printing system; the selection is switchable on the device.

14 ADEVSLOW-

REQ-N

optional The printing system transports the paper web slowly as soon as one unit requests ADEVSLOW.

Requirements: The printing system is in printing mode.

15 COPYOFF-

SET-P

optional on all devices

16 ADEV-

PAUSE-N

Recommended The printing system interprets this request as a hard stop.

17 JOGREQ-N optional The printing system transports the paper web slowly as soon as one unit requests JOG.

32 PAGE-

PULSE-P

Recommended on all devices

Type 1

Chapter 3 - Technical Data 59

E-Stop IN

Emergency stop interface from the pre- and post-print processing devices

The E-Stop…