HP DESIGNJET 3D Service Manual Download Page 169

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-153

Material sagging on curved parts

Characteristics: Surface finish not smooth.

Corrective actions:

1. Reprocess the part using the latest version of HP Designjet 3D Software

Solution software.

2. Reprocess part with CAD software.
3. Check for bad bearings in X/Y table. Replace XY table if needed.
4. Check Z stage:

A. Check Z belt tension.
B. Verify Z stage tray is level.
C. Verify the Z stage guide rods are not loose. Tighten as

needed.

D. Check for play on Z lead screw, move up and down.

Replace Z stage if needed.

Summary of Contents for DESIGNJET 3D

Page 1: ...HP Designjet 3D HP Designjet Color 3D Service Guide ...

Page 2: ... liable for technical or editorial errors or omissions contained herein 2012 Hewlett Packard Development Company L P Rev C Microsoft and Windows are U S registered trademarks of Microsoft Corporation Conforms to ANSI UL std 60950 1 2003 Certified to CAN CSA C22 2 no 60950 1 03 HP Designjet 3D and HP Designjet Color 3D conform with the following standards in accordance with the EU Machinery Low Vol...

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Page 5: ... 8 Voltage Generation 8 Dual Port Memory Interface 8 X Y Z Axis Control 8 Material Motor Control 8 Temperature Control 8 Liquefier Temperature Control 9 Actuators Switches Optical Sensors 9 Safety Devices 10 Controller Board Layout 10 Reset Button 11 Dip Switches 11 SW2 12 SW5 12 SW6 12 Memory 12 LEDs 12 Power Distribution Board PDB 14 Chamber Temperature Control 15 Test Points and LED s 16 I O Ca...

Page 6: ...e on printer 30 Adding the second HP Designjet 3D Material Bay 31 Installing the HP Designjet 3D Material Bay 31 Operation 37 Display panel and keypad 37 System firmware overview 38 HP Designjet 3D Software Solution overview 39 Processing your STL file for printing 40 Opening your STL file with HP Designjet 3D Software Solution 40 Selecting layer resolution 40 Selecting model interior fill style 4...

Page 7: ...3 Resuming operations from Standby mode 53 Updating printer firmware 53 Installing the firmware 53 Software 55 Software Architecture 55 Operating System 55 Display Driver 55 Comm Server 56 System Manager 56 Move Compiler 56 Feeder 56 Event Command Monitor 56 HP Designjet 3D Software Solution Help 57 HP Designjet 3D Software Solution overview 57 Conventional help file 57 Dynamic help 57 Maintenance...

Page 8: ... Jam 80 Recovering from loss of extrusion 82 Service Troubleshooting 86 1 0 How to use this Guide 86 2 0 Special Notes 87 3 0 Code Errors 88 Major Codes with Minor Codes 90 4 0 Non Code Errors 107 What happens during Power Up Boot 119 5 0 Connector Pinouts and Signals 129 Umbilical cable diagram 129 Umbilical cable pinouts 129 Upper harness 131 Upper harness pinouts 132 Lower harness 133 Lower har...

Page 9: ...that are order able as a service part 160 Pre Maintenance Procedures 160 Exterior Components 161 Top Panel 161 Removing the top panel 161 Installing the top panel 162 Side Panels 162 Removing the side panels 162 Removing the right side panel 164 Installing the side panels 164 Display Panel 165 Removing the display panel 165 Installing the display panel 166 Front Panel 166 Removing the front panel ...

Page 10: ...ntroller board 181 Single Board Computer SBC 182 Removing the single board computer 182 Reinstalling the single board computer 184 Power Distribution I O Card 184 Removing the I O card 185 Installing the I O card 186 Power Distribution Board PDB 187 Removing the power distribution board 187 Installing the power distribution board 190 Hard Drive 191 Removing the hard drive 191 Installing the hard d...

Page 11: ...nstalling the toggle head assembly 217 Substrate Sensor 220 Removing the substrate sensor 220 Installing the substrate sensor 222 Z Foam Level Assembly 223 Removing the Z Foam Level Assembly 223 Installing the Z Foam Level Assembly 224 Toggle Sensor 225 Removing the toggle sensor 225 Installing the toggle sensor 226 Toggle Bar 227 Removing the toggle bar 228 Installing the toggle bar 232 Head Boar...

Page 12: ...e Y motor 262 Y Motor Belt 263 Removing the Y Motor Belt 263 Installing the Y Motor Belt 271 Y Drive Rod 272 Removing the Y Drive Rod 272 XY Table 281 Removing the XY table 282 Installing the XY table 291 Z Stage Components 304 Z Home Sensor 304 Removing the Z home sensor 304 Installing the Z home sensor 305 Z EOT End of Travel Sensor 305 Removing the Z EOT sensor 305 Installing the Z EOT sensor 3...

Page 13: ... Firmware version 9 1 or newer 338 Z tip to base ZT2B 338 Z tip to tip ZT2T 339 XY Tip Calibration 340 Entering XY Tip Calibration values manually Firmware version 9 1 or newer 341 Part Based Calibration 343 When to Perform Part Based calibration 343 Performing part based calibration for HP Designjet 3D from the Service Calibration menu Firmware version 9 1 or newer 343 Performing part based calib...

Page 14: ...e Re Assembly of the Toggle Head Assembly 401 Tip wipe assembly 402 Adjusting tip wipe assembly height 402 Appendix 405 Appendix Overview 405 Front door area components 406 Electronics bay components 407 Head area components 409 XY Table area components 413 Z Stage area components 415 Chamber heater area components 416 Cables 417 Material Bay Components 418 Tools 419 Consumables 419 Hard Drive Ins...

Page 15: ...er 427 Materials 427 Adjusting XY Tip Offset 427 Gantry 428 Temperatures 428 Temperature Limits 428 Outputs 429 Get Calibration 429 Send Calibration 430 Get Configuration 430 Test Parts 430 Reset Password 430 Connect 430 Tera Term 431 Using Tera Term 431 Connecting with Tera Term 431 Tera Term Commands 434 ...

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Page 17: ...rt Technology SST your completed parts are quickly available for review and test Designjet 3D and Designjet Color 3D are an innovative combination of proprietary hardware software and material technology Welcome to the new dimension of 3D modeling How to use this guide This User Guide is laid out in easy to follow sections which cover Set up Operation Maintenance and Troubleshooting Read each sect...

Page 18: ...of devices with high temperatures Always use extra care and wear safety gloves when working around heated components GLOVES When performing some maintenance procedures the machine may be hot and gloves will be required to avoid burns SAFETY GLASSES Wear safety glasses to avoid injury to your eyes LIFTING HAZARD Hazard Lift with two or more people to avoid serious injury RECYCLE Use proper recyclin...

Page 19: ...T sensor 2 Moves head to X home BOT sen sor 3 Moves head to Y home BOT sen sor 4 Moves head to Y EOT sensor Head and chamber heaters begin to heat up via the th tr and tx commands BIOS starts and loads the OS operating system from the hard drive to the SBC RAM OS boots performs check disk chkdsk and loads Linux OS from hard drive to RAM Loads printer software from hard drive to RAM SBC send second...

Page 20: ...ll ask the controller board to unload the carriers requested by the operator The most recent value for material remaining is written to the cartridge EPROM The material is run in reverse to unload the liquefier When filament is clear of the filament sensor the controller board tells the SBC that the command is complete The SBC sends REMOVE CARRIER to the display the carriers are unlatched and the ...

Page 21: ...e is displayed C Start Model is blinking Press the Start Model button to begin building the displayed part Regardless of the method used to start building a part the printer will perform the same sequence of steps 1 The printer drops lowers the substrate sensor 2 System touches down six times which measures the height of the sub strate 3 SBC converts the model file CMB into the motion commands tha...

Page 22: ...e State the printer can be resumed material can be loaded and unloaded the build can be canceled and printer maintenance may be performed Electronics Overview Figure 1 Electronics Overview detail PDB Controller Board SBC AC Input 5 and 12 VDC Power Supply Support heater 120 VDC power supply 24 VDC power supply 120 240 VAC in 120 240 VAC I O ...

Page 23: ...ribbon cable The HDD contains the Linux operating system and all the control software needed to run the system except the controller firmware This is also where all the downloaded models are stored in the queue The LCD Control Panel connects to the I O Card The signals then travel though the PDB and on to the SBC All user entered commands from the control panel buttons are routed through the I O a...

Page 24: ... X Y Z Axis Control The controller takes the flow rate information from the SBC and sends it to the PMD processor The PMD 2840 processor services the X and Y stepper motors and the model and support head servo motors The 3410 processor services the Z axis stepper motor There is no feedback from the stepper motors to the system they are open loop controlled Material Motor Control The controller tak...

Page 25: ...e is maintained at Model 310 C Support 300 C Temperature control is accomplished using pulse wide modulation Figure 3 Figure 3 Pulse Width Modulation PWM Actual power to the liquefier heater is supplied by the PDB which is controlled by the controller board The head heaters are turned off and on 1000 times a second pulses The duration of the 120 VDC pulse determines the average power being supplie...

Page 26: ...ard monitors these switches Z limit switches upper and lower X end of travel EOT switch Y end of travel ETO switch The controller board monitors the following optical sensors X home BOT sensor Y home BOT sensor Top of modeling base sensor Safety Devices The controller board monitors the following safety devices Chamber T C alarm activated for a bad or missing T C Liquefier T C alarm activated for ...

Page 27: ...rd Before continuing with normal operation after resetting the board system power must be cycled before building The reset button should only be used after using Tera Term Dip Switches There are three dip switch banks SW2 SW5 SW6 located on the top right side of the board Dip switches are factory set and should not be changed unless noted to be in another position ...

Page 28: ...oller board 4 State information which stores printer state when it is powered off includes things like the type of gantry whether material is loaded the UDN etc LEDs There are 1 1 LEDs located on the controller board A grouping of three D1 D3 are located on the lower left side The other group of eight D6 D13 are located on the upper right side D1 D3 are lit when their associated voltage as shown i...

Page 29: ...oftware download progress During normal operation D13 will blink approximately once every two seconds to indicate that the watchdog is monitoring the system and everything is operational LED Label Description D1 3 3 VDC Supply D2 5 VDC Supply D3 12 VDC Supply D6 D12 Debug LEDs software use only D13 Coldfire processor heartbeat ...

Page 30: ... D J22 Auxillary 120VDC power supply E J8 Z BOT Z EOT Chamber Fans Frame ID Filament detect sensor not used F J9 Z motor G J10 I O board connection H J1 1 I O board connection I J7 24VDC input J Test points and LEDs see detail in this section K J4 5 12VDC input L Voltage indicator LEDs see detail in this section M J12 To material bay N J16 To external UPS optional O J18 LCD display from SBC P J15 ...

Page 31: ...ghts The 120 VDC circuit powers the model heater and a separate 120 VDC supply powers the support heater There are two fuses on the power distribution board Fuse F1 fuses the AC input to the 120 VDC supply Fuse F2 fuses the 120 VDC output Chamber Temperature Control The chamber thermocouple T C connects via the I O board to the PDB and is sent to the controller board The T C generates a variable l...

Page 32: ...able TP8 Enables power to circuitry normally high Model Toggle TP17 Toggle travel complete Chamber Thermocouple TP28 Voltage corresponds to chamber temperature 10 mV C Support Thermocouple TP20 Voltage corresponds to support temperature 10 mV C Model Thermocouple TP22 Voltage corresponds to model temperature 10 mV C HD Thermostat TP25 Chamber and head thermostat snap switches 5 VDC if both switche...

Page 33: ... VDC switches are wired normally closed NC Z EOT TP10 Z end of travel sensor 5 VDC switches are wired normally closed NC Z Home TP9 Z home sensor 5 VDC switches are wired normally closed NC Z Substrate TP23 Z substrate sensor 5 VDC HD Type A TP21 Not used HD Type B TP30 Not used Component Test Pt Description 5 VDC TP3 5VDC is present 12 VDC TP4 12VDC is present 12 VDC SW TP5 12VDC Switching is pre...

Page 34: ... Y EOT sensors G J504 Head blower fan power on off switch left and right chamber lights LCD display door solenoid door switch H J505 Umbilical cable to Model and support heaters toggle sensor X BOT and X EOT sensors I J506 Umbilical cable to Substrate detect sensor head drive motor chamber temperature alarm model thermocouple support thermocouple head temperature alarm ...

Page 35: ...303 Head Motor Ribbon Cable D J301 Umbilical Cable E J102 Support Heater F U303 X Home Sensor G J305 Toggle Sensor H D1 Support 120VDC LED 120 VDC present if on I D2 Model 120VDC LED 120 VDC present if on J U304 X EOT Sensor K J202 Model Heater G F J E K Rear view Front view D A B C I H ...

Page 36: ...ftware that runs on Windows XP Pro Windows Vista or Windows 7 platforms HP Designjet 3D Printer builds a maximum part size of 8 x 6 x 6 in 203 x 152 x 152 mm HP Designjet Color 3D Printer builds a maximum part size of 8 x 8 x 6 in 203 x 203 x 152 mm Each material carrier contains 40 cu in 700 cc of usable material enough to build continuously for about 48 hours without reloading You can add an opt...

Page 37: ...nterior chamber front view 1 Extrusion Head 2 Tip wipe assembly 3 Purge bucket 4 Z stage platen 5 Modeling base retainers x2 6 Modeling base 7 Z stage guide rods 8 Z stage lead screw 9 Extrusion Tips 1 2 3 4 5 6 7 8 9 ...

Page 38: ...terial Bay Cable Connector 4 Circuit Breaker 12 RJ 45 Network Connector 5 Material Bay 13 Diagnostics Cable Connector 6 Optional Model Material Tube 14 Material Bay Communications Cable 7 Optional Material Bay 15 Optional Material Bay Communica tions Cable 8 Support Material Y Connector 16 Optional Support Material Tube 1 2 3 4 5 6 7 8 9 10 1 1 12 13 14 15 16 ...

Page 39: ...CAUTION DO NOT reuse modeling bases If a modeling base is reused calibration errors poor part quality and loss of extrusion may occur Additional modeling bases are available from your HP reseller Support material carrier Model material carrier Modeling base ...

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Page 41: ...ding HP Designjet 3D Software Solution on the workstation Installing firmware to the workstation 1 Click the Install Firmware button to load firmware to your workstation You will be asked to load this firmware to your printer later 2 Follow prompts to finish installing firmware on the workstation 3 Install firmware to the printer see Installing Firmware on printer on page 30 Networking the printer...

Page 42: ...nd your printer and establish communication 1 Connect a network cable between the printer and a network hub 2 Make sure the printer is ON and determine the Unique Device Name UDN for your printer A From Idle or Ready to Build press Maintenance on the display panel The display will show Maintenance and the software version B From the display panel press System C From the display panel press Set Net...

Page 43: ...tatic network in Windows XP 1 From your workstation open the Control Panel and double click on Network Connections 2 Right click on Local Area Connection and then left click on Properties 3 Select Internet Protocol TCP IP from the list 4 Click on the Properties button 5 Click on the Use the following IP address option 6 Enter the IP Address Subnet Mask and Default Gateway Contact your IT Administr...

Page 44: ...d Close any open networking win dows Setting the static network on printer 1 Obtain your static network address from your Network Administrator 2 From Idle or Ready to Build press Maintenance on the display panel The display will show Maintenance and the software version 3 Press System 4 Press Set Network The top window displays Network Admin Static IP Address UDN 5 Press Static IP to display defa...

Page 45: ...ower portion of the window D Click Add Printer to complete Close the Add 3D Printer window 2 If your printer is not displayed in the Add 3D Printer window you will need to add the printer IP address manually A From the General tab click the Manage 3D Printers button B Click the Add Manually button in the lower right corner of the window C In the Add 3D Printer window enter a name and location of y...

Page 46: ...Software Solution to the directory where the firmware file is located and select the HP Designjet 3D upg file for HP Designjet 3D or select the HP Designjet Color 3D upg file for HP Designjet Color 3D Firmware will now begin to download to the printer 8 When firmware verification is complete the printer display will show Reboot to complete upgrade Press Yes The printer will then load the firmware ...

Page 47: ...ols to rewind the material leaving 2 inches 50mm remaining at the material guide See Figure 15 Figure 15 Rewinding the material spool 8 Using a cutters cut the excess 2 inches 50mm of material from the material guide leaving a blunt end 9 Power the printer off at the power switch 10 When the printer has powered down switch the circuit breaker to the OFF position 1 1 Disconnect the power cable netw...

Page 48: ...material bay on top of the existing material bay Be sure the feet and pins are properly aligned See Figure 17 Figure 17 Positioning material bays 15 With 2 people position the printer on to the top of the material bays Be sure the feet and pins are properly aligned See Figure 18 ...

Page 49: ...See Figure 19 Figure 19 Removing the Y block plugs 17 Connect the short red striped material tube M1 from model M coupler of upper material bay to left side of model Y block by inserting firmly into red couplers Gently pull the tube to ensure it is properly inserted 18 Repeat with the short black striped S1 material tube for support side See Figure 20 ...

Page 50: ...the tube to ensure it is properly inserted 20 Repeat with long black striped S2 material tube for support side See Figure 21 Figure 21 Connecting the long material tubes 21 Connect a material bay cable between the printer and the top connector on the upper material bay 22 Connect the other material bay cable between the bottom connector of the upper material bay to the top connector of the lower m...

Page 51: ... Display will show Add Remove 29 Open material bay doors and push both red handled model carriers into right side of the material bays until they latch 30 Push both black handled support carriers into left side of the material bays until they latch 31 Press Load Selected The printer will load the first material bay and pre pare the second material bay for automatic loading When the printer has fin...

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Page 53: ... display panel and keypad consist of a multiple line LCD window with two buttons used for scrolling through messages and four single line windows each with one button for making selections The top line in the upper window always shows the printer status NOTE If an item is blinking in the lower displays the blinking item is usually the next most logical selection Upper window Lower windows Keypad b...

Page 54: ... either ON or OFF view the print time or material remaining and set the printer to auto power down Material From this section you can load material unload material or replace material Standby From this section you can set the printer to Standby mode Maintenance From this section you can make changes to the Sys tem Setup or Machine Figure 24 Display panel hierarchy Idle Standby Maintenance Machine ...

Page 55: ...From this section you can check the printer his tory set the printer time set the printer password update printer software get printer info and export configuration files files contain ing specific operating information regarding the printer Figure 25 HP Designjet 3D Software Solution hierarchy NOTE For detailed information refer to HP Designjet 3D Software Solution Dynamic Help HP Designjet 3D So...

Page 56: ... an STL is smaller than the limit the modeler will increase the size of the feature to the minimum wall thickness Selecting model interior fill style This establishes the type of fill used for the interior areas of the part There are three types of model interior that you can choose from Solid Used when a stronger more durable part is desired Build times will be longer and more material will be us...

Page 57: ...ope Every part has a pre defined size within the STL file After you have opened the file you can change the size of the part produced from the STL file by changing the scale The scale always relates to the original STL file size definition For example a cube that is defined as 2 X 2 X 2 can be built to be 4 X 4 X 4 by simply changing the scale to 2 0 If after changing the scale to 2 0 you decide t...

Page 58: ...a smoother surface finish than building it on its side STL File Repair It is possible for an STL file to have errors while appearing to be trouble free If the STL file contains errors HP Designjet 3D Software Solution may have problems processing the file HP Designjet 3D Software Solution has the ability to automati cally correct some STL file errors How the part is oriented can impact this automa...

Page 59: ...uild the part Starting a build from the display panel If Wait for Part has not been activated you can send the part to the printer and start the part from the display panel after the part has been sent to the printer 1 From your HP Designjet 3D Software Solution workstation send a part to the printer The display will show Idle Ready to Build and the name of the first file that is in the queue wait...

Page 60: ...e chamber lights on permanently however the chamber lights will return to factory settings when power is cycled 1 From Idle or Ready to Build on the display panel press Maintenance 2 Press Setup 3 Press Lights Always On Repeat this process to turn this option off NOTE If a material amount is flashing it indicates that the remaining material will not be enough to complete the current build Printer ...

Page 61: ...building press Cancel Build 3 The display will ask Are you Sure Press Yes 4 The display will show Build Stopped followed by the file name You will then be prompted to remove the part and replace the modeling base 5 Remove the part and replace the modeling base 6 Once the chamber door has been opened and closed the display will ask Part Removed Press Yes ONLY after you have removed the part and rep...

Page 62: ... the modeling base 1 After removing the modeling base from the printer firmly flex the modeling base back and forth with your hands to loosen the part 2 Pull the part off of the modeling base or use a putty knife to completely remove the part Removing support material HP Designjet 3D and HP Designjet Color 3D use soluble support material which is designed to dissolve in a soap and water based solu...

Page 63: ...lay will show Add Remove and S1 remaining and M1 remaining Asterisks will mark the currently active material bays the material bays that are currently loaded to the head 2 Press Unload 3 Select Unload both Unload Model or Unload Support 4 The printer will now unload material from the head When the material has unloaded you will need to replace the material carriers 5 Open the material bay doors by...

Page 64: ...ded to the head press Done Replacing material for dual material bays 1 From the display panel press Material The display will show Add Remove and S1 remaining S2 remaining and M1 M2 remaining Asterisks will mark the currently active material bays the material bays that are currently loaded to the head 2 Press Unload 3 Press Unload both Unload Model or Unload Support 4 The printer will now unload m...

Page 65: ...o load to the head by selecting Next Model or Next Support When done selecting press Load Selected 15 The printer will now load the selected material bays and prepare the other bays for automatic loading After they are done loading and pre paring press Done the display will show Wait for Part or Ready to Build Material bay LEDs The table below will show the status indicated by the LEDs CAUTION Do ...

Page 66: ... than 72 hours unload and store model and support material in the storage bags provided to prevent moisture absorption 1 Unload material from the printer 2 Open the material bay doors by gently pressing in to release and pull ing outwards 3 Remove the material carriers by first pushing them in to unlatch and then pulling them outwards 4 Place the carrier on a flat stable surface 5 Open the carrier...

Page 67: ...ving a blunt end 8 Locate the two material retaining clips on the carrier See Figure 31 Figure 31 Material retaining clips 9 Place the material guide in the material guide slot on the spool See Fig ure 32 10 Place the material in the material notches See Figure 32 Figure 32 Material guide slot and notches Material retaining clips ...

Page 68: ... storage bag that came with the material carrier Auto power down You can set the printer to automatically power down when a build is complete This option will save energy usage 1 While the printer is building press the Auto Power Down button 2 Turn the power switch located on the left side of the printer to the OFF position The printer will display Auto Power Down Mode and the printer will power d...

Page 69: ...stem 3 Press Load Upgrade The printer will then display Send upgrade from workstation followed by the printer s IP address 4 Open HP Designjet 3D Software Solution and click on the Printer Ser vices tab 5 Click on the Update Software button HP Designjet 3D Software Solution will now connect to the printer and will prompt you to locate the upgrade file Navigate HP Designjet 3D Software Solution to ...

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Page 71: ...ollowed by the system s application components Figure 35 Software Architecture Diagram Operating System The printer s software currently runs on RedHat Linux The operating system is multi tasking allowing the software components to run fairly independently The operating system also provides support for the TCP IP network interface and the hard drive Display Driver This software interacts with the ...

Page 72: ...e move compiler The move compiler retrieves the cmb file from the top of the queue The CMB file defines the tool path for the part on a layer by layer basis The move compiler calculates the proper extrusion rate for the road thus combining tool path and extrusion The resulting motion control is saved in a PCB file Feeder This driver takes the output of the move compiler and feeds the motion contro...

Page 73: ...ignjet 3D Software Solution provides Help information in two ways through a conventional help file and through a Dynamic Help system Conventional help file The entire Help file is accessible through the menu bar Help Contents This will open HP Designjet 3D Software Solution help in a separate window containing standard help tools table of contents search index and personally selected favorites Dyn...

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Page 75: ...rial build up on the tip wipe assembly can cause part quality issues See Tip wipe assembly on page 60 Inspect the tip shields After each build you should inspect the tip shields for damage or material build up If there is material build up remove it as needed If the material will not break free or there is damage to the tip shield replace the tip shield See Tip shield replacement on page 62 Remove...

Page 76: ...tive Maintenance Alert Tip wipe assembly The tip wipe assembly should be replaced approximately every 500 hours 1 Completely power down the printer 2 Move the head to the right of the printer to gain access to the tip wipe assembly Figure 37 Move the toggle head to the right 3 Remove the tip wipe assembly by lifting the assembly up and out of the printer Discard this tip wipe assembly See Figure 3...

Page 77: ...eplacing the tip wipe assembly 4 Place the new tip wipe assembly over the two mounting posts making sure the assembly is fully installed See Figure 39 Figure 39 Installing tip wipe assembly 5 Power the printer back up ...

Page 78: ...A From the display panel press Maintenance B Press Machine C Press Head The head will come to rest in the center of the chamber and the Z platform will change position 2 Remove the head cover by pressing the tabs in and pulling away from the head See Figure 41 Figure 41 Head cover tab locations GLOVES The head area is hot wear gloves when working in this area of the printer New shield Worn shield ...

Page 79: ...ld removal 4 Clean the tip using the wire brush supplied with the Startup Kit to remove any debris See Figure 43 Figure 43 Clean tips with wire brush 5 Install a new tip shield by pushing it by hand over the exposed tip keeping the slotted end towards the back of the tip See Figure 44 Insert small standard screwdriver to pry tip shields from tips Tip shield Tip plate Clean the tips using a wire br...

Page 80: ...panel the recommendation may be to clear debris from the Filament present switch 1 Unload material from the printer and remove the material carriers 2 Open the material bay doors by gently pressing in to release and pull ing outwards 3 Remove the material carriers by first pushing them in to unlatch and then pulling them outwards 4 Disconnect the material tubes from the rear of the material bay s ...

Page 81: ...ng the Filament Present Switch 9 Squeeze the spray nozzle for one quick burst approximately 2 seconds to clear each Filament Present Switch on the model and support sides of the material bay If an optional material bay is installed repeat this pro cedure for the second bay 10 Reconnect the material tubes to the rear of the material bay s 1 1 Replace the material carriers and load material Support ...

Page 82: ...lay panel press Maintenance 3 Press Machine 4 Press Tip 5 Press Replace 6 The printer will display Load Model Unloading 7 You can now open the printer door and replace the tips or you can Cancel the tip replacement procedure 8 Remove plastic head cover by squeezing raised pads on sides of cover See Figure 48 NOTE Tips can also be damaged by improper care while performing maintenance in the area ar...

Page 83: ... metal cover DO NOT remove the screws entirely See Figure 49 Figure 49 Tip Removal B Use needle nose pliers to grasp the stainless steel shield of the tip C Pull the tip shield toward you then pull down to remove the tip from the heater block Discard the used tip See Figure 50 Press tabs in to remove head cover Head cover Loosen but do not remove heater block screws Loosen but do not remove heater...

Page 84: ...e to install the proper tip See Figure 51 Figure 51 Tip shield alignment 2 With gloved hand insert the new tip into the heater block With the slot ted side towards the rear of the printer See Figure 52 Pull tips down to remove Align the tip shield so the slotted end is facing the back of the printer Slotted end Slotted end ...

Page 85: ...ard the back of the printer once it is all the way up against the heater block 6 Verify the tip is fully inserted into the heater block and that the stainless steel shield is aligned See Figure 53 7 Use 7 64 T Handle Allen wrench to firmly tighten the heater block clamp screws See Figure 53 NOTE Make sure the tip remains all the way up against the heater block as you tighten the screws ...

Page 86: ...n push it forward again to latch Because the material unloaded during the tip replacement the printer is in the material replacement mode You must unlatch and then latch the carriers to continue If there is a delay in the unlatch latch process the printer will display Both Carriers Not Replaced Or Invalid Select Retry then unlatch and latch the carriers B The printer will now begin to load materia...

Page 87: ... 0 Y 0 3 Remove the XY tip calibration part from the printer 4 Inspect the part and calibrate the X and Y axis See Figure 54 A Use the magnifier from the Startup kit to view the support road shown in red B Identify the location on the X or X side of the part where the support road is best centered within the model boundaries shown in blue C Read the number closest to this location This is the requ...

Page 88: ...quires an adjustment of X 2 Y 4 5 Select Done after you have input the X and Y offsets The printer will return to Maintenance Run the XY calibration a second time to be sure the values changed the offset properly 6 When finished press Done until back at Idle ...

Page 89: ... harness by squeezing the wiring harness clip while pulling down 4 Remove the light bar by removing the three attachment screws top mid dle bottom use the 7 64 T handle wrench supplied in the startup kit 5 Install a replacement light bar with the three attachment screws do not overtighten the screws 6 Re attach the wiring harness lead Figure 55 Chamber light bar locations ...

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Page 91: ...inter through network or crossover cable 1 Make sure network cables are connected at the printer at the PC or where cables connect to network hubs 2 Re configure network settings 3 If using a static network address verify that the IP address entered in HP Designjet 3D Software Solution matches the IP address entered in the printer 4 Your network configuration may have changed Contact your Network ...

Page 92: ...t Present Switch See Remove debris from the Filament Present switch on page 64 4 Reload material Material Error Carrier invalid 1 Remove carrier and verify it is not empty 2 Replace material spool 3 Reload material Material Error Filament broken 1 Remove the carrier and verify material is coming out of the material guide 2 Verify material pulls freely from the carrier 3 Verify the material tubes a...

Page 93: ...ontinue operation However if the printer continues to shut down and display the same error contact technical support Load Error Purge failed 1 Remove the carrier and verify material is coming out of the material guide 2 Verify the material pulls freely from the carrier 3 Verify the material tubes are free of mate rial 4 Check for and clear any excess material build up around the tips Unload Error ...

Page 94: ... materials are not equal Sagging structures due to lack of support materials 1 From the display panel press Cancel and remove parts from the printer 2 Insert a new modeling base 3 From Idle press Maintenance 4 Press Machine 5 Press Head The head will move to the center of the chamber and the Z platform will change position The display will read Model Drive Motor Stopped 6 Determine if there is a m...

Page 95: ...tip Occasionally a tip may clog with material This will often result in a loss of extrusion LOE A clogged tip will prohibit material load and part building 1 Remove the head cover by pressing the tabs in and pulling away from the head See Figure 56 Figure 56 Remove the head cover 2 Inspect top of tips for material build up If there is excess material build up see Recovering from loss of extrusion ...

Page 96: ...n on page 82 9 Press Done 10 Display will ask Which Materials Loaded Press Both 1 1 Press Done until back to Idle Material Jam Occasionally material may become jammed in the head The printer will notify you of a material jam through a message shown on the display panel If a material jam is detected follow these steps to clear the jam 1 From the display panel press Continue 2 Press Maintenance 3 Pr...

Page 97: ...ower Off this will turn the head cooling fan off for 10 seconds allowing the tip to heat up beyond operating temperature If material starts to extrude the tip is no longer clogged If material does not extrude see Recovering from loss of extrusion on page 82 If material extrudes you can continue building your part 10 Reinstall the head cover 1 1 Press Done 12 Display will ask Which Materials Loaded...

Page 98: ... head See Figure 56 3 Place the toggle bar in neutral position bar will extend equally from both sides of head This can be done manually push on the extended bar end See Figure 60 Figure 59 Head Components NOTE It is recommended that you read and understand this entire procedure before performing any of the work GLOVES The head area is hot Use gloves when working in this area of printer Support si...

Page 99: ...rench between the toggle spring post and the idler wheel post as illustrated in Figure 61 model side shown NOTE Material fed to the tip can sometimes jam causing a build up of material under the head cover CAUTION The end of the tip where the material enters is called the extrusion tube Extrusion tubes are fragile Use care when working in this area so as to avoid damage to the tubes NOTE Move only...

Page 100: ... a 1 8 T handled Allen wrench from startup kit into the fixture hole See Figure 62 Figure 62 Holding access space open model side shown Position toggle bar to same side of head as T Handle Toggle spring post Idler wheel post Insert 1 8 inch T Handle into fixturing hole To create space move Idler assembly by pushing with 7 64 T Handle Allen wrench against spring tension ...

Page 101: ... spring tension and remove the 1 8 T handled Allen wrench G Remove the 7 64 T Handle Allen wrench 5 Repeat for the opposite side as needed 6 Replace the head cover 7 Press Done on the display panel 8 Display will ask Which Materials Loaded Press Model if only model material is loaded press Support if only support material is loaded or press Both if both model and support material are still loaded ...

Page 102: ... Follow the corrective actions to fix the error D Complete and verify each step before proceeding to the next step 3 If you experience a Non Code Error A Refer to the Non Code Error Section of the guide 4 0 Non Code Errors B If the display on the machine displays an error message match that message to one of the non error codes in the guide C If a message does not appear match the problem to one o...

Page 103: ...s using chassis ground E Check reseat appropriate cables as part of the troubleshooting process F Tera Term move commands are in inches G Check limit switch states using the test points and or LED s on the power distribution board H Replacement hard drive may take up to 45 minutes to boot The hard drive is running check disk chkdsk I Ignore multiple error code listings at end of a CFG file LE outp...

Page 104: ...will not be displayed Cycle power 08 Manager Disconnected Socket from manager internal manager process was off SBC Software error will not be displayed 09 Manager Send Failed to send from manager SBC Software error 10 Command Failed Sent legal command that was rejected exp Move Z command with door open Cycle power 1 1 Queue Communication Socket from queue process was interrupted broken Software er...

Page 105: ... within 7 min See 18 error code below 19 Controller Initialization Failed Controller failed to reboot or start See detailed 19 error code section below 20 Door Latch Command Failed See detailed non error code section of this guide 21 Ldrool Failed Cycle power 22 Controller Communications Failed Not used 23 Universal Device Name error Cycle power Code Error Definition Recommendation ...

Page 106: ...ram on page 129 7 Using LED s check to see Z home box toggles when switch is activated If not check Z home switch and lower harness J8 pins 1 1 1 12 See Lower harness on page 133 14 03 Report modeling base sensor up when it should be down 1 Cycle power 2 Check the substrate sensor assembly for free operation 3 Check to see if the sensor arm is broken 4 Check connector J506 pins 2 and 7 on the I O ...

Page 107: ...see if door latch is activating using LED s 2 Check J504 pins 8 and 20 on the I O card for loose contacts or bent pins 3 Look at LCD display should show Door Open when machine is idle and door is open 4 Using LED s check to see Door Open toggles when switch is activated If not check door switch and or Mid Unit Harness 5 Wiggle the door make sure the sensor reads the magnet with movement to the doo...

Page 108: ...bort X axis command error PMD error 14 25 Abort Y axis command error PMD error 14 26 Abort Z axis command error PMD error 1 Power cycle machine 2 If error continues possible memory problem replace SBC 3 If the frequency of the error is greater than once every three months replace the controller board 14 27 Abort X axis motion error PMD error 14 28 Abort Y axis motion error PMD error 14 29 Abort Z ...

Page 109: ...mper the WDT to retrieve CFG to find additional errors 14 39 Abort Head thermocouple fault 1 Verify ambient temperature is above 18 C 64 4 F 2 Check thermocouple wire for damage 3 Using a meter check to see if thermocouple is open at head 4 Check reseat the connectors on the head board 5 Open may be in umbilical head cable Check and reseat J505 and check pins 7 and 17 on the I O card 6 Check and r...

Page 110: ...Unable to write to support material guide tube 1 Try a different material spool 2 Clean contacts on carrier and material bay with an eraser 3 Replace carrier 4 Replace material bay 14 48 Abort Vertex command error 1 If this message is displayed on LCD ONLY possible memory problem replace SBC If this message is not displayed on the LCD seen in cfg file RAM is NOT the root cause 2 If the frequency o...

Page 111: ... Y home not tripped 1 Power cycle machine remember to move head away from switches 2 Using LED s check to see home toggles when sensor is activated If not check sensor and or Umbilical Cable for X and Y cable for Y 3 X errors Check pins and reseat connector J505 on the I O Card Y errors Check pins and reseat connector J503 on the I O Card 14 61 Abort Find home failed X home tripped 14 62 Abort Fin...

Page 112: ...e controller board 14 70 Abort XY PMD Write Checksum error 1 If error occurs more than once a month replace the controller board 14 71 Abort Z PMD Read Checksum error 1 If error occurs more than once a month replace the controller board 14 72 Abort Z PMD Write Checksum error 1 If error occurs more than once a month replace the controller board 14 73 Abort Head TC Board Configuration error Not used...

Page 113: ...roperly aligned 1 Cycle power 14 92 Message too big for queue 1 Cycle power 14 93 Data unit size violation 1 Cycle power 14 94 Checksum bad 1 Cycle power 2 Check 5 12 VDC power 5 and 12VDC LEDs will repeatedly dim Replace 5 12 VDC power supply 3 If error code is displayed again within 3 months replace controller board 14 95 PMD Host IO Error 1 Cycle power 14 96 Unidentified interrupt occurred 1 Cy...

Page 114: ... Use HP Designjet 3D Diagnostic Software to zero the Z offset value 2 Run tip Z calibration 3 Check Z home sensor 14 107 End model command while not modeling Software error will not be displayed 14 108 Operation was killed Software error will not be displayed 14 109 Out of memory Software error will not be displayed 14 1 10 Cartridge communication error 1 Replace material spool 2 Replace material ...

Page 115: ...and send again 3 If the frequency of the error is greater than once every three months then replace the SBC or hard drive 14 121 Processor Exception 1 Cycle power 14 122 Processor halted 1 Cycle power 14 123 Watchdog timeout 1 Cycle power 2 Check all cable connections including thermocouples 3 Escalate the case providing cfg file 14 124 Stack overflow 1 Cycle power 2 If problem persists replace co...

Page 116: ...gle LED s on PDB Verify high and low states On head board for toggle signal TP201 Model TP101 Support 9 Using Tera Term run AH to toggle the head Monitor system movement to help determine root cause of issue 10 Replace Toggle Sensor Board 1 1 Replace Head Board 12 Replace Toggle Head assembly 14 130 Temperature setback is active 1 Cycle power 14 131 Toggle when head motor is running 1 Check Model ...

Page 117: ...ace 120VDC power supply If no 120VDC at model side replace power distribution board 4 The umbilical cable to the heater is broken or has a bad connector 5 Make sure the machine is plugged directly into a wall outlet 6 Check the thermocouple connectors heater connectors 7 Verify that hard drive has not lost its CAL values If values are lost download CAL files 14 134 Invalid packet size Software use...

Page 118: ...B end of filament event End of filament detected when loading carrier 1 Cycle power 14 141 MCB filament loaded event Attempted to retract filament while it is loaded in the head 1 Cycle power 14 142 Auto purge detect failure Failed to detect any material purge after loading Software use only 14 143 Model filament not present at EOF switch Currently unused Software use only 14 144 Support filament ...

Page 119: ...ncorrectly 3 If printer is in Dynamic Mode a Issue may be a network timeout due to improper DHCP settings on the network Verify by looking at CFG if code reads MASTER logger Punching nameserver xxx xxx xxx xxx through the firewall b If using printer firmware version 2230 try workaround Contact CS for workaround instructions c Upgrade printer firmware to a version newer than 2230 4 Material Bay Con...

Page 120: ...e model LED lower is illuminated replace the 120VDC power supply If only the support LED upper is illuminated replace the power distribution board 3 If head board with LED s is not present use volt meter to check for 120 VDC at head board If 120VDC present at both model and support side heater is bad Replace head If no 120VDC at support side replace 120VDC power supply If no 120VDC at model side r...

Page 121: ...ouple wire and or Heater wires 3 Check for torn or damaged insulation on the liquefier especially at the tip 4 Check head T C and umbilical cable for a loose connection Replace umbilical cable 18 03 Incorrect model head temperature 1 Using HP Designjet 3D Diagnostic Software set model temperature to default of 310C 2 See also 18 01 18 04 Incorrect support head temperature 1 Using HP Designjet 3D D...

Page 122: ...ard 3 Replace hard drive Code Description Corrective Actions 20 01 Unlatch command rejected 20 02 Timeout period expired waiting for head to stop 1 Check door latch solenoid wiring 2 Check ability of door to latch Code Description Corrective Actions 22 01 FC_SERVICE event not received 22 02 Insufficient material to complete job Not used on HP Designjet 3D printers Code Description Corrective Actio...

Page 123: ...ature Q Calibration issues R Z Calibration failure S Noise A Build Error displayed on LCD 1 Part stops building before complete 1 Partial or bad model file sent to unit Check and reprocess the STL and redownload B Tip depth is incorrect 1 Tip Depth is wrong too deep or above the modeling base 1 Run Z tip calibration 2 Check and or clean the Z foam sensor 3 Replace the Z foam assembly and sensor C ...

Page 124: ... 1 Door doesn t latch unlatch 1 The door is open Close the door 2 Verify the magnet mounted to door frame is not misaligned or missing 3 Door is misaligned adjust door hinge brackets 4 Door switch is bad replace door switch G Download 1 Model sent to system but did not appear in queue 1 Verify the IP address on the printer and in HP Designjet 3D Software Solution match 2 Send the file again Check ...

Page 125: ...s and Y block for debris Remove debris b Inspect for kinked filament tubes Replace filament tubes c Check for twisted feed tubes in energy chain If twisted replace filament tubes 1 Filament Missing at Drive Wheel 6 Excess Material Inside Head Remove head cover and inspect liquefier inlet Are both filaments present at drive wheel 3 Filament Present but Won t Extrude Enter head maintenance and try t...

Page 126: ...ny debris from bottom of carrier c Filament is tangled on spool Replace spool 3 High pull force in filament tubes a Inspect filament tubes and Y block for debris Remove debris b Inspect for kinked filament tubes Replace filament tubes c Check for twisted feed tubes in energy chain If twisted replace filament tubes 4 System did not detect end of filament EOF Cycle power If repeats verify FP switch ...

Page 127: ...ill a Toolpaths should not overlap by more than 50 If so reorient and reprocess STL b If model curl has caused the part to contact the tip reprocess part with less dense fill Re run tip Z cal if part is separating from supports 4 Check for loose heater block clamp screws 5 Plugged Liquefier replace tips 6 Check idler wheel gap 7 Check liquefier alignment 8 Head idler spring is deformed or installe...

Page 128: ...from supports 8 Check idler wheel gap 9 Check liquefier alignment 10 Head idler spring is deformed or installed improperly Replace head idler spring 1 1 Possible head temperature issue a Replace head board and TC Amp board b Replace toggle head assembly 12 Head motor power wires or encoder failure replace toggle head 13 Blower fan not supplying enough air flow weak or stalling Replace fan 14 Repla...

Page 129: ...rt with less dense fill Re run tip Z cal if part is separating from supports c If part curl continues see part curl section 9 Check idler wheel gap 10 Check liquefier alignment 1 1 Head idler spring is deformed or installed improperly Replace head idler spring 12 Possible head temperature issue a Replace head board and TC Amp board b Replace toggle head assembly 13 Head motor power wires or encode...

Page 130: ... the material guide 2 Verify material pulls freely from the carrier 3 Verify the material tubes are free of material 5 Load Error Filament blocked 1 Remove the carrier and verify material is coming out of the material guide 2 Verify material pulls freely from the carrier 3 Verify the material tubes are free of material 6 Load Error Purge failed 1 Remove the carrier and verify material is coming ou...

Page 131: ...age is not hitting the lower Z limit switch Manually raise the Z stage several inches above the lower Z limit switch 2 Reload material 1 1 Filament makes it to drive wheel pinch point but Material Error is displayed 1 Retry loading material 2 Perform the drive wheel alignment procedure 3 Idler wheel stuck on axle Realign idler wheel If wheel remains stuck replace toggle 4 Check that pivot block sp...

Page 132: ...bad Plug network cable directly into SBC to test 6 Network interface on SBC has failed green LED on SBC should blink when system is pinged or green LED stays on when network cable is unplugged Replace the SBC 7 OS on hard drive maybe corrupt replace the hard drive 2 Cannot communicate using a crossover cable with XP Microsoft Small Business Server adds a piece of software called Firewall Client Th...

Page 133: ...odel and support 120VDC LEDs at head board If both model upper and support lower LEDs are illuminated head heater is bad Replace head If only the model LED lower is illuminated replace the 120VDC power supply If only the support LED upper is illuminated replace the power distribution board 7 If head board with LED s is not present use volt meter to check for 120 VDC at head board If 120VDC present...

Page 134: ...ues 1 Check CFG for multiple EEprom write errors If errors are noted a Select Resume from display panel b Unload Reload carrier c Replace spool d Replace carrier e Replace material bay 4 STOPS during build display still shows building does not start to build again 1 Cycle power 2 Reprocess and resend the part 3 If issue continues replace SBC ...

Page 135: ...X home BOT sen sor 3 Moves head to Y home BOT sen sor 4 Moves head to Y EOT sensor 5 Unlocks door Reads Carriers Head and chamber heaters begin to heat up via the th tr and tx commands BIOS starts and loads the OS operating system from the hard drive to the SBC RAM OS boots performs check disk chkdsk and loads Linux OS from hard drive to RAM Loads printer software from hard drive to RAM SBC send s...

Page 136: ...nd support lower LEDs are illuminated head heater is bad Replace head If only the model LED lower is illumi nated replace the 120VDC power supply If only the support LED upper is illumi nated replace the power distribution board 5 If head board with LED s is not present use volt meter to check for 120 VDC at head board If 120VDC present at both model and support side heater is bad Replace head If ...

Page 137: ...e thermal snap switches are open If snap switches are open verify chamber fans are operating correctly Replace chamber fans 4 Verify chamber fans are operational If not replace 24VDC power supply 5 Check cable from 24VDC supply to PDB 6 PDB has failed no 24 volt output Replace PDB 4 No fans lights text and LCD back light is ON 1 Verify chamber fans are operational If not replace 24VDC power supply...

Page 138: ...IOS drive listing show HD as primary if not reseat IDE ribbon cable on both ends Verify red line is to the right b Disk Boot Failure shown on monitor software not seeing the hard drive Reseat IDE ribbon cable on both ends Verify red line is to the right c Kernel Panic Init Failed shown on monitor Replace hard drive d If monitor displays dev hdaXX UNEXPECTED INCONSISTENCY RUN fsck MANUALLY An error...

Page 139: ...er board 5 Replace single board computer 6 Replace hard drive 9 System displays Initializing Halted in Initializing 1 Cycle Power at the Circuit Breaker 2 Verify the Substrate Sensor is in the correct position 3 Reseat the I O Board 4 Reseat the controller SBC 10 System displays Starting Up Calibrating Halted in Starting Up Calibrating 1 Cycle Power at the Circuit Breaker 2 Verify the Substrate Se...

Page 140: ...ut of operating range Check adjust value using HP Designjet 3D Diagnostic Software 3 Flatness check may have failed Use Tera Term to read the touchdown values Compare these values to the tolerance value displayed If this value is over 1728 replace the modeling base 4 If failure reoccurs check XY table level using the head bracket and dial indicator Values should be a band of 0 010 total for the fo...

Page 141: ... the SBC 2 Replace the PDB 3 Replace power switch 5 Shuts down after part is complete 1 Auto power down was enabled normal operation P System VERY slow to reach temperature 1 Envelope takes unusually long over 40 minutes to reach temperature 1 Verify all covers and panels are properly installed 2 Envelope heater s bad Check heater resistance should be about 36 ohms 3 Replace PDB 4 See error codes ...

Page 142: ...ing base Part layer shifted 1st layer May be visible but looks choked off Etches may be visible in modeling base 1 Add 010 to Z offset value 2 First layer tip too high off modeling base Diagnostic details Left square SS Upper layers Missing or barely stuck to modeling base 1st layer Missing or barely stuck to modeling base Right square model Upper layers Missing or barely stuck to modeling base 1s...

Page 143: ... SS Upper layers Built OK 1st layer OK Right square model Upper layers Did not build completely may be some wisps of model material 1st layer May be visible but roughed up from the support tip 1 Add 010 to Z offset value 5 Possible worn bad tip shield Diagnostic details Left square SS Upper layers Part built but surface looks rough or looks OK but cal failed 1st layer OK Right square model Upper l...

Page 144: ...e SS Upper layers Missing No evidence of SS extrusion 1st layer Missing No evidence of SS extrusion Right square model Upper layers Missing or barely stuck to modeling base 1st layer Missing No evidence of SS extrusion 1 Load material 8 Continued difficulty calibrating 1 Replace Z motor 2 Replace XY table Failed bearings in the Y drive shaft possible root cause S Noise 1 Buzzing noise from XY moto...

Page 145: ... Board Cable 205680 0004 I O card Head board P505 P301 Pin Signal Pin P505 17 HD_ALARM_IN P301 14 P505 7 12V P301 6 P301 5 P505 4 HD_SUPPORT_HEATER P301 17 P505 3 120VDC 2 P301 16 P505 1 HD_MODEL_HEATER P301 19 P505 2 120VDC 1 P301 20 P505 5 GND P505 6 GND P301 2 P505 21 MODEL_TOGGLE_IN P301 1 P505 10 SUPPORT_TOGGLE_IN P301 11 P505 11 XEOT_IN P301 12 P505 22 XHOME_IN P301 13 P301 22 P301 7 P301 8 ...

Page 146: ...o sensor Head Motor Encoder P506 8 HD_MTR_PH0_1 Encoder signal phase 1 from head drive motor encoder P506 3 HD_MTR_PH1_1 Encoder signal phase 2 from head drive motor encoder Head Motor Power P506 9 HD_MOTOR_OUT_1 Power to head drive motor 12 VDC P506 4 HD_MOTOR_OUT_2 Power to head drive motor 12 VDC Over Temp Alarm P506 10 CHAMBER_TEMP_ALARM Chamber Head area is over temp 100C Chip located on T C ...

Page 147: ...ght P504 21 24V LAMP 1 RT P14 P14 1 P504 9 RTN LAMP 1 RT P14 4 Chamber light left P504 22 24V LAMP 2 LF P16 P16 1 P504 10 RTN LAMP 2 LF P16 4 Door switch P504 7 DRSW P10 P10 1 P504 19 GND P10 2 On Off switch P504 6 ON OFF SW SW T6 NC P504 18 ON OFF GND SW T5 COM Head cooling fan P504 24 24V HEAD COOL FAN P50 P50 1 P504 12 SWITCHED RTN HEAD FAN P50 2 LCD display P504 1 12V 2 P1 10 P504 13 GND P1 P1...

Page 148: ... 10 BLACK RTN LAMP 2 LF Light on 0 V Light off 24 V Door Switch P504 7 YELLOW DRSW Door closed 0 V Door open 5 V P504 19 GREEN GND GND On Off Switch P504 6 YELLOW ON OFF SW Requesting shutdown to contoller board LED on PDB is on when powering down P504 18 GREEN ON OFF GND GND Head Cooling Fan P504 24 RED 24V HEAD COOL FAN 24 VDC P504 12 BLACK SWITCHED RTN HEAD FAN Blower on 0 V Blower off 24 V LCD...

Page 149: ...BOT Z EOT chamber fans frame ID Cable 102598 0004 PBD Pin Signal Z home BOT sensor P8 11 ZHOME_C P8 P2 4 ZHOME_C P8 1 ZHOME_E_GND P2 P2 2 ZHOME_E_GND P8 12 ZHOME_A P2 1 ZHOME_A P8 13 ZEOT_C Z EOT sensor P8 3 ZEOT_E_GND P3 4 ZEOT_C P8 14 ZEOT_A P3 P3 2 ZEOT_E_GND P3 1 ZEOT_A P8 5 3 3V P8 15 I2C CLOCK Frame ID P8 6 GND P1 1 3 3V P8 16 I2C DATA P1 P1 2 I2C CLOCK P1 4 GND P8 18 24V L R FAN P1 3 I2C DA...

Page 150: ...ignal SN CAL file etc Left Chamber Fan P8 18 RED 24V L R FAN 24VDC P8 8 BLACK RTN L R FAN GND Right Chamber Fan P8 20 RED 24V R F FAN 24VDC P8 10 BLACK RTN R F FAN GND Purge Detect not used P8 17 BLACK PURGING Not used P8 7 GREEN GND Not used P8 19 WHITE DETECTED Not used P8 9 RED 5VDC Not used Pin Wire Color Signal Signal Description ...

Page 151: ...ove 2 Build the part using the Minimal support option 3 Material is built up on the shields Using a brush to remove the excess material 4 Replace tip shields 5 Check brush flicker assembly for damage or wear If worn or damaged replace brush flicker assembly 6 Tip s are loose check if tip screws are loose Tighten tip screws 7 Replace support material Example of embedded support Problem corrected af...

Page 152: ... an extended period of time Change the part orientation 2 Worn tip shrouds replace tip shrouds 3 Material build up behind the tips remove excess material 4 Check brush and flicker for damage or wear Replace brush and flicker if needed 5 Check and adjust the brush and flicker height 6 Tip s are loose check if tip screws are loose Tighten tip screws ...

Page 153: ...place the toggle head assembly if needed 4 Liquefier heater has higher than normal resistance value should be between 175 and 216 ohms If resistance is too high replace the toggle head assembly 5 Check for twisted or worn filament guide tubes If worn replace tubes NOTE Also reference Troubleshooting Guide for diagnosing and correcting LOE issues Here the support material has had a loss of extrusio...

Page 154: ...able 8 Check umbilical hose for proper alignment and connection to the head cooling fan 9 Head cooling fan has low air flow replace the head cooling fan 10 Z table could be jammed Check for debris build up around lead screw and guide rods Replace Z stage if needed 1 1 Irregular XY table movement loose guide rods or loose drive belts Ver ify the guide rods are securely fastened and the drive belt t...

Page 155: ...support Characteristics Difficult to remove the support material Corrective actions 1 Run Z and Offset Calibrations 2 Check for loose tip screws Tighten screws if required 3 Check for loose modeling base Use a new modeling base ...

Page 156: ... material Characteristics Material will appear to rough or stringy Corrective actions 1 Material is older than one year Replace with newer material 2 Moisture in material Replace using new material spool Stringy Rough ...

Page 157: ...2 Verify wall thickness is greater than 0 040 for 0 010 slice 3 Reprocess the part using the latest version of HP Designjet 3D Software Solution and check STL report for errors 4 Repair STL file with original CAD program 5 Possible bad head motor cable Replace umbilical cable 6 Possible bad head motor Replace toggle head assembly ...

Page 158: ...rse Fill option in HP Designjet Software Solution 2 Modeling base has been re used or is defective Replace with unused modeling base 3 Run Z Calibrations 4 Verify proper operation of all chamber fans Replace fans as needed 5 Verify chamber heaters are secured and operating properly Replace heaters as needed 6 Verify X Y and Z level is within specification If not level re level and calibrate ...

Page 159: ...heck for material build up on tips brush and flicker Remove excess material 3 Verify brush flicker height Adjust if required 4 The part does not have sufficient support material Reprocess the part using basic or surround support in HP Designjet Software Solution 5 The base support layer is separating from the substrate Run Z calibra tion 6 Model material is separating from the support base top lay...

Page 160: ...The modeling base is defective or is not latched tightly Replace modeling base and latch properly 2 Check XY table A Verify X and Y guide rods are securely fastened B Verify the toggle head moves freely C Verify proper belt tensions for X and Y axis Tension the belts as needed D With X and Y motors unplugged make sure the motors will spin freely ...

Page 161: ... A Clean the Z stage lead screw B Bad Z stage motor and belt Replace Z motor and belt as needed C Verify Z stage is level Re level as needed D Verify the Z stage guide rods are not loose Tighten as needed E Z stage may have too much play replace the Z stage as needed ...

Page 162: ...all thickness 2 Reprocess the part using the latest version of HP Designjet 3D Software Solution software and check STL report for errors 3 Check for STL errors in CAD software 4 Replace the tip shrouds 5 Loose tips screws tighten the screws 6 Replace the tips 7 Deformed toggle spring replace the toggle spring 8 Check X Y guide rods for loose hardware Replace XY table as needed ...

Page 163: ...isture in material replace with new cartridge 2 Reprocess the part using the latest version of HP Designjet 3D Software Solution software 3 Check for STL errors with CAD software 4 Replace the tip shrouds 5 Loose tips screws tighten the screws 6 Replace the tips 7 Deformed toggle spring replace the toggle spring ...

Page 164: ...e excess material 2 Verify brush flicker height Adjust if required 3 Run Z and Offset Calibrations 4 Check X and Y drive belt tensions 5 Umbilical cable may have bad connection or broken wire replace the umbilical cable 6 Head motor is not stopping when it is supposed to Replace the toggle head assembly 7 Head motor is not stopping when it is supposed to Replace the control ler board ...

Page 165: ... 149 Witness marks Characteristics Small void on one side of the part Corrective actions 1 Run Z and Offset calibrations 2 Replace the tips 3 Rotate the part 45 degrees in HP Designjet Software Solution ...

Page 166: ...ng the latest version of HP Designjet 3D Software Solution software and check STL report for errors 3 Check for STL errors in CAD software 4 Replace the tip shrouds 5 Loose tips screws tighten the screws 6 Replace the tips 7 Deformed toggle spring replace the toggle spring 8 Check X Y guide rods for loose hardware Replace XY table as needed Normal Wavy ...

Page 167: ...he appearance of waves Corrective actions 1 Verify X and Y guide rods are securely fastened 2 Check and adjust X Y and Z belt tensions 3 Verify the Z stage is properly leveled 4 Verify the Z pulley is in the correct position 5 Replace the Z stage 6 Replace the XY table ...

Page 168: ...olpaths Corrective actions 1 Verify wall thickness is greater than 0 040 for 0 010 slice 2 Reprocess the part using the latest version of HP Designjet 3D Software Solution software 3 Check for material build up around head and tips 4 Replace tips 5 Replace the head board ...

Page 169: ...P Designjet 3D Software Solution software 2 Reprocess part with CAD software 3 Check for bad bearings in X Y table Replace XY table if needed 4 Check Z stage A Check Z belt tension B Verify Z stage tray is level C Verify the Z stage guide rods are not loose Tighten as needed D Check for play on Z lead screw move up and down Replace Z stage if needed ...

Page 170: ...ns to Z motor B If head is digging in to the part check Z motor belt tension C Check to see if Z stage is jamming D Verify the Z stage is level E Verify proper operation of the Z jamming flag May have become magnetized F If Z stage is running in to the head verify correct position of the travel sensors 2 Run Z calibration ...

Page 171: ... Z layers not bonding properly Corrective actions 1 Check Z stage A Verify Z motor is tightly secured B Verify Z stage is level C Replace the Z motor D Replace the Z stage if substrate is lower in the back failed to find home 2 Replace the tips ...

Page 172: ... 156 ...

Page 173: ...oling Fan page 177 Controller Board page 179 Single Board Computer SBC page 182 Power Distribution I O Card page 184 Power Distribution Board PDB page 187 Hard Drive page 191 Line Filter page 194 Circuit Breaker page 196 AC Input page 197 Power Switch page 199 24VDC Power Supply page 201 5 12VDC Power Supply page 205 120VDC Power Supply page 208 Head Components page 210 Head Cooling Fan page 210 T...

Page 174: ...OT End of Travel Sensor page 250 X Motor page 252 Y Motor page 260 Y Motor Belt page 263 XY TableY Drive Rod page 272 XY Table page 281 Z Stage Components page 304 Z Home Sensor page 304 Z EOT End of Travel Sensor page 305 Chamber Fans page 307 Chamber Heaters page 310 Thermal Fuses page 315 Chamber Thermocouple page 319 Z Motor page 321 Z Stage page 325 ...

Page 175: ... injury WARNING The Power Switch does NOT remove power from the printer The Breaker Switch located on the rear of the printer MUST be off before service is performed on the printer It is recommended that the AC power cord be disconnected before performing maintenance outlined in this chapter WARNING Use extreme caution when the door solenoid is disabled Axes may move unexpectedly which may cause s...

Page 176: ...ing XY table drive belts 2 Y Motor belt tensioning tool for adjusting belt Y table motor belt 3 Head dial indicator bracket for XY table and Z stage leveling 4 Spring Removal Tool 5 Drive Wheel Alignment Rod 6 Set of Shims Feeler Gauges 7 Liquefier Alignment Rod 8 Filament Guide Alignment Rod For SST Only 9 Service Guide CD and Hardcopy 10 HP Designjet 3D Diagnostic Software CD 1 1 HP Designjet 3D...

Page 177: ... 2 slotted screws x3 Removing the top panel 1 Using a 5 16 nut driver or standard screwdriver remove the 3 mounting screws See Figure 63 Figure 63 Top panel mounting screw location 2 Lift up and slide the top panel towards the back of the printer to remove See Figure 64 Remove the 3 top panel mounting screws ...

Page 178: ...ounting screws Side Panels Required Tools 5 16 nut driver or standard screwdriver Hardware 10 32 x 1 2 slotted screws x6 Removing the side panels Removing the left side panel 1 Remove the top panel See Removing the top panel on page 161 2 Using a 5 16 nut driver or standard screwdriver remove the 3 mounting screws See Figure 65 Slide top panel toward the back of the printer and lift up to remove ...

Page 179: ...lide panel towards the back of the printer and pull outward to remove See Figure 66 Figure 66 Removing the left side panel Remove the 3 left side panel mounting screws Slide top panel toward the back of the printer and pull outward to remove the left side panel ...

Page 180: ...panels 1 Slide the left side panel towards the front of the printer and push into place 2 Using a 5 16 nut driver or standard screwdriver Reinstall the 3 mounting screws 3 Slide the right side panel towards the front of the printer and push into place 4 Using a 5 16 nut driver or standard screwdriver Reinstall the 3 mounting screws 5 Reinstall the top panel See Installing the top panel on page 162...

Page 181: ... 2 Gently pry open the display panel access hatch with a standard screw driver See Figure 69 Figure 69 Opening the display panel access hatch 3 Reach behind the display panel and press the tab to release the display panel See Figure 70 Figure 70 Removing the display 4 Disconnect J1 connector See Figure 71 ...

Page 182: ... panel access hatch 4 Close the chamber door Front Panel Required Tools 5 16 nut driver or standard screwdriver Hardware 10 32 x 1 2 slotted screws x8 Removing the front panel 1 Open the chamber door 2 Remove the display panel See Removing the display panel on page 165 3 Using a 5 16 nut driver or standard screwdriver remove the 2 mounting screws from behind the display panel See Figure 72 ...

Page 183: ...standard screwdriver remove the 6 mounting screws from the front panel See Figure 73 Figure 73 Front panel mounting screw locations 5 Remove the front panel by pulling outward Remove the 2 mounting screws from behind the display panel Remove the 6 mounting screws for the front panel ...

Page 184: ...splay panel on page 166 5 Close the chamber door Door Solenoid Required Tools 5 16 nut driver or standard screwdriver Removing the door solenoid 1 Remove the display panel See Removing the display panel on page 165 2 Remove the front panel See Removing the front panel on page 166 3 Disconnect the door solenoid DRSOL cable by pressing down on the tab See Figure 74 Figure 74 Door solenoid connector ...

Page 185: ...l See Installing the display panel on page 166 Door Sensor Required Tools 5 16 nut driver or standard screwdriver Removing the door sensor 1 Remove the display panel See Removing the display panel on page 165 2 Remove the front panel See Removing the front panel on page 166 3 Disconnect the DRSW cable See Figure 76 Figure 76 Door sensor cable location 4 Gently pull the door sensor out of the mount...

Page 186: ...ntly push the door sensor into place on the mounting plate 2 Connect the door sensor DRSW cable 3 Install the front panel See Installing the front panel on page 168 4 Install the display panel See Installing the display panel on page 166 ...

Page 187: ...top panel on page 161 2 Remove the side panels See Removing the side panels on page 162 3 Remove the filament tubes from the Y connectors by pushing down on the ring and pulling back on the filament tubes See Figure 78 Figure 78 Removing the filament tubes from the Y connectors 4 Using a 5 16 nut driver or standard screwdriver remove the 3 mounting screws on the top of the electronics bay cover Se...

Page 188: ...ctronics bay 1 Gently push the electronics bay cover back in to the closed position 2 Using a 5 16 nut driver or standard screwdriver reinstall the 3 mounting screws 3 Reconnect the filament tubes to the Y connectors 4 Reinstall the side panels See Installing the side panels on page 164 5 Reinstall the top panel See Installing the top panel on page 162 Remove the 3 mounting screws ...

Page 189: ... 161 2 Remove the side panels See Removing the side panels on page 162 3 Using a 5 16 nut driver or standard screwdriver loosen but do not remove the top left and right mounting screws See Figure 81 Figure 81 Upper electronics bay cover top mounting screw locations 4 Using a 5 16 nut driver or standard screwdriver remove the bottom left and right mounting screws See Figure 82 Loosen but do not rem...

Page 190: ... right side mounting screws 2 Using a 5 16 nut driver or standard screwdriver reinstall the bottom left and right side mounting screws 3 Using a 5 16 nut driver or standard screwdriver tighten the top left and right side mounting screws 4 Install the side panels See Installing the side panels on page 164 5 Install the top panel See Installing the top panel on page 162 Remove the bottom left and ri...

Page 191: ...r See Removing the upper elec tronics bay cover on page 173 4 Touch the metal plate of the electronics bay cover to discharge any static electricity 5 Disconnect the 6 I O card cables by pressing down on the long tabs and pulling out See Figure 83 6 Disconnect the chamber thermocouple wire See Figure 83 Figure 83 I O card cable locations 7 Remove the left and right side electronics bay mounting sc...

Page 192: ...aving 3 inches 76mm 2 Connect the 4 rear power distribution board cables 3 Slide the electronics bay back into position 4 Using a 5 16 nut driver or standard screwdriver reinstall the 4 left and 4 right side mounting screws 5 Connect the I O card cables 6 Reinstall the upper electronics bay cover See Installing the upper elec tronics bay cover on page 174 7 Reinstall the side panels See Installing...

Page 193: ...anel on page 161 2 Remove the side panels See Removing the side panels on page 162 3 Open the Electronics Bay See Opening the electronics bay on page 171 4 Touch the metal plate of the electronics bay cover to discharge any static electricity 5 Disconnect the P1 cable from the fan See Figure 86 Figure 86 Electronics bay cooling fan connector location 6 Using a 5 64 allen wrench remove the 4 mounti...

Page 194: ...lign the cooling fan with the 4 mounting holes 2 Using a 5 64 allen wrench reinstall the 4 mounting screws 3 Reconnect the P1 cable 4 Close the electronics bay See Closing the electronics bay on page 172 5 Install the side panels See Installing the side panels on page 164 6 Install the top panel See on page 162 Remove the 4 mounting screws ...

Page 195: ...Touch the metal plate of the electronics bay cover to discharge any static electricity 3 Remove the 3 ribbon cables by pressing the tabs outward and gently pulling the ribbon cables out of the sockets See Figure 88 Figure 88 Controller board ribbon cable locations 4 Using a standard screwdriver loosen the 2 screws that hold the diagnos tics DB 9 cable in place Then gently pull the cable out of the...

Page 196: ...r remove the 6 controller board mounting screws See Figure 90 Figure 90 Controller board mounting screw locations 6 Gently lift the controller board up from the single board computer SBC at the P104 connector DO NOT bend any pins on the board See Figure 91 Remove the DB 9 connector Remove the 6 mounting screws ...

Page 197: ...river tighten the 2 mounting screws 5 Reconnect the 3 ribbon cables to the PDB 6 Close the Electronics Bay See Closing the electronics bay on page 172 7 From the workstation open the HP Designjet 3D Software Solution 8 Connect to the printer 9 Insert the printer firmware CD into the workstation CD drive 10 From the Printer Services tab click on the Update Software button 1 1 Navigate HP Designjet ...

Page 198: ...e electronics bay on page 171 2 Touch the metal plate of the electronics bay cover to discharge any static electricity 3 Remove the controller board See Removing the controller board on page 179 4 Disconnect the J2 power connector See Figure 92 5 Disconnect the SATA cable by pressing the tab in and pulling outwards See Figure 92 Figure 92 J2 power and SATA connector locations Disconnect the J2 con...

Page 199: ... Phillips screwdriver remove the 4 mounting screws See Figure 94 Figure 94 SBC mounting screw locations 8 Using a standard screwdriver loosen the display cable mounting screws See Figure 95 9 Disconnect the display cable from the SBC See Figure 95 Disconnect the RJ45 connector Remove the 4 mounting screws ...

Page 200: ...einstall the 4 mounting screws 5 Reconnect the RJ 45 network cable 6 Reconnect the SATA cable 7 Reconnect the J2 power cable 8 Reinstall the controller board See Installing the controller board on page 181 9 Close the electronics bay See Closing the electronics bay on page 172 Power Distribution I O Card Required Tools 5 16 nut driver or standard screwdriver Phillips screwdriver Hardware 6 32 x 1 ...

Page 201: ... discharge any static electricity 5 Disconnect the 6 cables from the I O card by pushing in on the locking tabs and pulling outward See Figure 96 Figure 96 I O card cable locations 6 Disconnect the thermocouple from the back side of the I O card by pull ing outward See Figure 97 Figure 97 Chamber thermocouple wire location 7 Using a Phillips screwdriver remove the 3 mounting screws from the I O ca...

Page 202: ...e viewing slots See Figure 99 Figure 99 I O card viewing slot location 3 Using a Phillips screwdriver reinstall the 3 mounting screws 4 Reconnect the thermocouple to the back side of the I O card 5 Reconnect the 6 cables to the I O card 6 Close the electronics bay See Closing the electronics bay on page 172 7 Reinstall the side panels See Installing the side panels on page 164 8 Reinstall the top ...

Page 203: ...ove the side panels See Removing the side panels on page 162 3 Open the electronics bay See Opening the electronics bay on page 171 4 Touch the metal plate of the electronics bay cover to discharge any static electricity 5 Remove the I O card See Removing the I O card on page 185 6 Using a 5 16 nut driver or standard screwdriver remove the 4 screws on the left and right side of the electronics bay...

Page 204: ...bution board See Figure 101 Figure 101 Power distribution board rear cable locations 8 Slide the Electronics Bay back into place 9 Disconnect the 10 cables from the front of the PDB See Figure 102 Remove the 4 right side mounting screws Remove the 4 left side mounting screws Disconnect the 4 cables on the back of the PDB ...

Page 205: ...Phillips screwdriver remove the 12 mounting screws See Figure 103 Figure 103 Power distribution board mounting screw locations 1 1 To remove gently pull the power distribution board outward Disconnect the 3 ribbon cables Disconnect the 3 ribbon cables Disconnect the 4 cables ...

Page 206: ...mm and reconnect the 4 cables to the back of the PDB 5 Carefully slide the electronics bay back into position 6 Using a 5 16 nut driver or standard screwdriver reinstall the 8 mounting screws on the left and right sides 7 Reinstall the I O card See Installing the I O card on page 186 8 Close the electronics bay See Closing the electronics bay on page 172 9 Reinstall the side panels See Installing ...

Page 207: ...ee Opening the electronics bay on page 171 2 Touch the metal plate of the electronics bay cover to discharge any static electricity 3 Disconnect the power input cable by pressing the metal tab in and pull ing down See Figure 104 Figure 104 Hard drive power cable location 4 Disconnect the SATA cable by pressing the metal tab in and pulling down See Figure 105 Disconnect the power input cable ...

Page 208: ...s See Figure 106 Figure 106 Hard drive mounting screw locations 6 Slide the hard drive up and out of the electronics bay 7 Using a Phillips screwdriver remove the mounting brackets from the hard drive See Figure 107 Disconnect the SATA cable Remove the mounting screws Remove the mounting screws ...

Page 209: ...sc command before you see anything on the display panel 8 After the printer has rebooted and is idle press Maintenance System Set Network 9 Select either Dynamic networking or Static networking 10 If using Static networking enter the printers IP Address Default Gateway and Subnet Mask values 1 1 From the PC open the HP Designjet 3D Software Solution 12 Connect to the printer 13 Insert the printer ...

Page 210: ...h the metal plate of the electronics bay cover to discharge any static electricity 3 Remove L1 1 and N1 1 spade connectors from the right side of the board by pulling back on the connector See Figure 108 Figure 108 L1 1 and N1 1 spade connector locations 4 Remove L2 1 and N2 1 Spade connectors from the left side of the board by pulling up on the connector See Figure 109 Disconnect the N1 1 spade c...

Page 211: ... filter 1 Align the line filter with the mounting holes 2 Using a Phillips screwdriver reinstall the 3 mounting screws 3 Reconnect the L2 1 and N2 1 spade connectors to the left side of the board 4 Reconnect the LF2 P and LF2 N spade connectors to the right side of the board 5 Close the electronics bay See Closing the electronics bay on page 172 Disconnect the L2 1 spade connector Disconnect the N...

Page 212: ...he electronics bay cover to discharge any static electricity 3 Remove the Load and CB1 spade connectors from the circuit breaker by pulling up on the connectors See Figure 1 1 1 Figure 1 1 1 Load and CB1 spade connector locations 4 Remove the CB1 Line and CB2 spade connectors from the circuit breaker by pulling up on the connectors See Figure 1 12 Figure 1 12 CB1 Line and CB2 spade connector locat...

Page 213: ...ay panel until it locks in place 2 Reconnect the CB1 and CB2 spade connectors to the circuit breaker 3 Reconnect the Load and CB1 spade connectors to the circuit breaker 4 Close the electronics bay See Closing the electronics bay on page 172 AC Input Required Tools 5 16 nut driver or standard screwdriver Phillips screwdriver Hardware 1 2 x 6mm Phillips pan head screws x2 Press tabs and push the ci...

Page 214: ...igure 1 14 Figure 1 14 AC input connection locations 6 Using a Phillips screwdriver remove the 2 mounting screws and remove the AC Input See Figure 1 15 Figure 1 15 AC input mounting screw locations Installing the AC Input 1 Install the 2 AC Input mounting screws with a Phillips screwdriver 2 Connect the LF P black spade connector 3 Connect the LF N white spade connector 4 Connect the LF G green s...

Page 215: ...r or standard screwdriver remove the 2 power switch housing mounting screws See Figure 1 16 Figure 1 16 Power switch housing mounting screw locations 4 Remove the white SW2 wire from the spade connector labeled 3 See Figure 1 17 5 Remove the black SW3 wire from the spade connector labeled 1a See Figure 1 17 6 Remove the yellow NC wire from the spade connector labeled 2a See Figure 1 17 7 Remove th...

Page 216: ...led 2a 3 Connect the green COM wire to the spade connector labeled 2 4 Connect the black SW3 wire to the spade connector labeled 1a 5 Connect the white SW2 wire to the spade connector labeled 3 6 Align the power switch housing with the mounting holes 7 Using a 5 16 nut driver or standard screwdriver reinstall the 2 mounting screws 8 Reinstall the left side panel See Installing the side panels on p...

Page 217: ...Remove the side panels See Removing the side panels on page 162 3 Remove the electronics bay See Removing the electronics bay on page 175 4 Using a 5 16 nut driver or standard screwdriver remove the 3 rear elec tronics bay mounting screws See Figure 1 19 Figure 1 19 Rear electronics bay mounting screw locations 5 Open the rear panel of the electronics bay 6 Touch the metal plate of the electronics...

Page 218: ...rough 4 connectors using a Phillips screwdriver Note the position of the wires for reinstallation See Figure 121 Figure 121 J3 1 through 4 connector locations 9 Close the rear panel of the electronics bay and remove the 2 board mounting screws using a Phillips screwdriver See Figure 122 Disconnect J1 Disconnect J3 1 through 4 ...

Page 219: ... the electronics bay and remove the 2 board mounting screws from the top of the panel using a Phillips screwdriver See Figure 123 Figure 123 Removing the 2 mounting screws from the top of the panel 1 1 Remove the 24VDC power supply Remove the 2 mounting screws Remove the 2 mounting screws ...

Page 220: ...electronics bay panel 4 Using a Phillips screwdriver reinstall the 2 mounting screws 5 Reconnect J3 1 through 4 connectors using a Phillips screwdriver 6 Reconnect J1 on the 24VDC power supply 7 Close the rear panel of the Electronics Bay 8 Using a 5 16 nut driver or standard screwdriver reinstall the 3 mounting screws 9 Reinstall the electronics bay See Installing the electronics bay on page 176 ...

Page 221: ...e side panels on page 162 3 Remove the electronics bay See Removing the electronics bay on page 175 4 Using a 5 16 nut driver or standard screwdriver remove the 3 rear elec tronics bay mounting screws See Figure 125 Figure 125 Rear electronics bay mounting screw locations 5 Open the rear panel of the electronics bay 6 Touch the metal plate of the electronics bay cover to discharge any static elect...

Page 222: ...the SK2 connector by pressing the tab and lifting up on the connector See Figure 127 Figure 127 SK2 connector location 9 Disconnect the power input cable by pressing the tab and lifting up on the connector See Figure 128 Figure 128 Power input cable location ...

Page 223: ...lips screwdriver reinstall the 3 mounting screws 3 Reconnect the SK2 connector 4 Reconnect the J2 spade connector 5 Close the rear panel of the electronics bay 6 Using a 5 16 nut driver or standard screwdriver reinstall the 3 rear elec tronics bay mounting screws 7 Reinstall the electronics bay See Installing the electronics bay on page 176 8 Reinstall the side panels See Installing the side panel...

Page 224: ...anels on page 162 3 Remove the electronics bay See Removing the electronics bay on page 175 4 Using a 5 16 nut driver or standard screwdriver remove the 3 rear elec tronics bay mounting screws See Figure 130 Figure 130 Rear electronics bay mounting screw locations 5 Open the rear panel of the electronics bay 6 Touch the metal plate of the electronics bay cover to discharge any static electricity 7...

Page 225: ...nting holes 2 Using a Phillips screwdriver reinstall the 3 mounting screws 3 Reconnect J601 4 Close the rear panel of the electronics bay 5 Using a 5 16 nut driver or standard screwdriver reinstall the 3 rear elec tronics bay mounting screws 6 Reinstall the electronics bay See Installing the electronics bay on page 176 7 Reinstall the side panels See Installing the side panels on page 164 8 Reinst...

Page 226: ... Removing the top panel on page 161 2 Remove the side panels See Removing the side panels on page 162 3 Remove the upper electronics bay cover See Removing the upper elec tronics bay cover on page 173 4 Disconnect the J258 cable by pressing the tab and pulling the connector apart See Figure 133 Figure 133 J258 cable location 5 Using a 7 64 allen wrench remove the 2 mounting screws See Figure 134 D...

Page 227: ...unting holes 2 Using a 7 64 allen wrench reinstall the 2 mounting screws 3 Reconnect the J258 cable 4 Install the upper electronics bay cover See Installing the upper electron ics bay cover on page 174 5 Install the side panels See Installing the side panels on page 164 6 Install the top panel See Installing the top panel on page 162 Remove the 2 mounting screws ...

Page 228: ...l See Removing the top panel on page 161 2 Remove the side panels See Removing the side panels on page 162 3 Using a 5 16 nut driver or standard screwdriver remove the right side access panel mounting screws and remove the panel See Figure 135 Figure 135 Right side access panel mounting screw locations 4 Remove the head cover by pressing the tabs in and pulling the cover out ward See Figure 136 Re...

Page 229: ...ir plenum tab locations 6 Disconnect the material tubes by pressing down on the retaining ring and lifting up the material tubes See Figure 138 Press tab in to release head cover Press tab in to release head cover Press in tab to release air plenum Press in tab to release air plenum Press in tab to release air plenum Press in tab to release air plenum ...

Page 230: ...0 Figure 139 Thermocouple locations Figure 140 Thermocouple wire retainer location 8 Disconnect the model and support heater cables by pressing the tabs in and pulling the cables outward See Figure 141 Press down on the retaining rings Lift the material tubes out of the rings Disconnect the 2 thermocouples from the TC Amp board Remove the thermocouple wires from the retainer ...

Page 231: ...ation 10 Disconnect the toggle sensor cable from the head board Figure 143 Toggle sensor cable location 1 1 Cut the wire tie holding the drive motor cables in place Disconnect the support side heater cable Disconnect the model side heater cable Disconnect the toggle sensor cable Disconnect the toggle sensor cable from the head board ...

Page 232: ...Figure 145 Figure 145 Rear head board cable locations 13 Using a 5 16 nut driver or standard screwdriver remove the 4 toggle head mounting screws Toggle the head to the left to remove the bottom right screw and toggle the head to the right to remove the bottom left screw Cut and remove the wire tie from the head motor Disconnect the 3 cables ...

Page 233: ...ables to the back of the head board 5 Replace the wire tie holding the head motor cables in place See Figure 147 Figure 147 Wire tie location 6 Reconnect the toggle sensor cable to the head board 7 Gently reconnect the toggle sensor cable to the toggle sensor 8 Reconnect the model and support heater cables to the head board 9 Reconnect the model and support thermocouples to the TC Amp board 10 Pla...

Page 234: ...9 1 or newer i While the printer is at Idle enter standby mode by pressing the Standby button ii Enter the Service Calibration menu by pressing the following button sequence on the display panel 3 2 3 3 1 See Figure 148 Figure 148 Service Calibration button sequence iii Press the Edit Configuration button iv Press the Next button v Press the Next button vi Press the ZT2T Z tip to tip button vii En...

Page 235: ...rinter location and printer IP address iv Click on the green check mark button v Connect to the printer in HP Designjet 3D Diagnostics Software by selecting it out of the Current Modeler drop down menu vi Click on the Tip Offset button vii Enter the value from Z Tip to Tip field on the tag that came with the toggle head assembly into the Z Tip to Tip field in the Tip Offset window viii Click on th...

Page 236: ...1 Remove the top panel See Removing the top panel on page 161 2 Remove the side panels See Removing the side panels on page 162 3 Using a 5 16 nut driver remove the 7 right side access panel mounting screws See Figure 149 Figure 149 Right side access panel mounting screw locations 4 Disconnect the substrate sensor wire from the head board by pressing in on the tab and pulling outward See Figure 15...

Page 237: ...ee Figure 151 Figure 151 Wire tie location 6 Using a 3 32 allen wrench remove the 4 substrate sensor mounting screws See Figure 152 Figure 152 Substrate sensor mounting screw locations 7 Remove the substrate sensor Disconnect the substrate sensor Cut and remove the wire tie from the head motor Remove the 4 mounting screws ...

Page 238: ... 4 Reinstall the wire tie around the head motor and wires See Figure 153 Figure 153 Wire tie location 5 Align the right side access panel with the mounting holes 6 Using a 5 16 nut driver reinstall the right side access panel mounting screws 7 Reinstall the side panels See Installing the side panels on page 164 8 Reinstall the top panel See Installing the top panel on page 162 Reinstall the wire t...

Page 239: ...m the rear of the printer 3 Remove the top panel See Removing the top panel on page 161 4 Remove the side panels See Side Panels on page 162 5 Remove the Substrate sensor See Removing the substrate sensor on page 220 6 Push the Z foam level assembly actuator up into the assembly and slide the Z foam level bar to the right until it is clear of the assembly See Fig ure 154 Figure 154 Removing the Z ...

Page 240: ...r and spring into the housing and push all the way up 4 Slide the bar to the left and into the housing when installed correctly the actuator will not come out of the housing 5 Reinstall the Substrate sensor See Installing the substrate sensor on page 222 6 Reinstall the side panels See Side Panels on page 162 7 Reinstall the top panel See Installing the top panel on page 162 8 Reconnect the AC pow...

Page 241: ...nsor 1 Remove the top panel See Removing the top panel on page 161 2 Remove the side panels See Removing the side panels on page 162 3 Remove the right side access panel See Figure 156 Figure 156 Right side access panel mounting screw locations 4 Gently disconnect the toggle sensor wire by pulling outwards See Fig ure 157 Remove the 7 mounting screws ...

Page 242: ...oles 2 Using a standard screwdriver reinstall the 2 mounting screws 3 Reconnect the toggle sensor wire to the toggle sensor 4 Align the right side access panel with the mounting holes 5 Using a 5 16 nut driver or standard screwdriver reinstall the right side access panel mounting screws 6 Reinstall the side panels See Installing the side panels on page 164 7 Reinstall the top panel See Installing ...

Page 243: ... or standard screwdriver 7 64 allen wrench Hardware 6 32 x 1 4 slotted screws x2 380 ID Closed and grounded spring x1 194 ID Closed and grounded spring x1 141 ID 625 OD x 031 Washer 8mm ID 18mm OD x 1mm Washer 195 ID 50 OD x 059 PEEK HPV Washer x2 ...

Page 244: ... head cover See Figure 159 Figure 159 Head cover tab locations 4 Using a 7 64 allen wrench loosen but do not remove the 4 tip mounting screws See Figure 160 Figure 160 Tip mounting screw locations 5 Remove the tips by pulling them downwards See Figure 161 Press tab in to release head cover Press tab in to release head cover ...

Page 245: ...nch loosen the 2 heat shield screws See Figure 162 Figure 162 Heat shield mounting screw locations 7 Remove the heat shield 8 Using a 7 64 allen wrench remove the upper spring screw Remove the screw washer and spring See Figure 163 Heat shield mounting screws ...

Page 246: ...move the lower spring screw Remove the screw spring and washer See Figure 164 Figure 164 Lower spring location 10 Pull the toggle assembly away from the translator until the toggle assem bly is at the end of the post See Figure 165 Upper spring screw Lower spring screw ...

Page 247: ... 231 Figure 165 Toggle assembly positioning 1 1 Remove the washer from the toggle bar 12 Remove the toggle bar by sliding out See Figure 166 Figure 166 Removing toggle bar ...

Page 248: ...ench reinstall the lower spring screw 5 Reinstall the upper spring and washer 6 Using a 7 64 allen wrench reinstall the upper spring screw 7 Using a 7 64 allen wrench reinstall the heat shield 8 Reinstall the model tip right side and support tip left side by pushing up into place 9 Using a 7 64 allen wrench tighten the tip mounting screws 10 Reinstall the head cover 1 1 Power the printer up 12 Per...

Page 249: ...ing the top panel on page 161 2 Remove the side panels See Removing the side panels on page 162 3 Using a 5 16 nut driver or standard screwdriver remove the right side access panel mounting screws and remove the panel See Figure 168 Figure 168 Right side access panel mounting screw locations 4 Remove the head cover by pressing the tabs and pulling the cover out ward See Figure 169 Remove the 7 mou...

Page 250: ... See Figure 170 Figure 170 Air plenum tab locations 6 Disconnect the model and support material tubes See Figure 171 Press tab in to release head cover Press tab in to release head cover Press in tab to release air plenum Press in tab to release air plenum Press in tab to release air plenum Press in tab to release air plenum ...

Page 251: ... retaining clip on the head board See Figure 172 Figure 172 Retaining clip location 8 Disconnect the umbilical cable by pressing in on the tab and pulling upwards See Figure 173 Press down on the retaining rings Lift the material tubes out of the rings Remove the thermocouple wires from the retaining clip ...

Page 252: ...e toggle sensor cable from the head board by pressing in on the tab and pulling outward See Figure 175 Figure 175 Toggle sensor cable location 1 1 Gently disconnect the toggle sensor cable from the toggle sensor by pull ing the cable outward See Figure 176 Disconnect the umbilical cable Disconnect the support side heater cable Disconnect the model side heater cable Disconnect the toggle sensor cab...

Page 253: ...ions 13 Feed the toggle sensor cable out through the head board See Figure 178 Figure 178 Removing the toggle sensor cable from the head board 14 Disconnect the substrate sensor cable and filament motor cables from the rear of the head board by pressing the tabs in and pulling outward See Figure 179 Gently disconnect the toggle sensor cable Remove the 2 toggle sensor cable retaining clips Feed tog...

Page 254: ... head board 5 Using a 1 4 nut driver or standard screwdriver reinstall the toggle sen sor wire clips 6 Reconnect the toggle sensor cable to the toggle sensor 7 Reconnect the toggle sensor cable to the head board 8 Reconnect the model and support heater cables 9 Reconnect the umbilical cable 10 Place the thermocouple wires in the wire retaining clip 1 1 Reconnect the model and support material tube...

Page 255: ...ing the top panel on page 161 2 Remove the side panels See Removing the side panels on page 162 3 Remove the right side access panel mounting screws with a 5 16 nut driver or standard screwdriver and remove the panel See Figure 181 Figure 181 Right side access panel mounting screw locations 4 Disconnect the umbilical cable by pressing in on the tab and pulling out ward See Figure 182 Remove the 7 ...

Page 256: ... Figure 183 Thermocouple wire locations 6 Using a 1 4 nut driver or standard screwdriver remove the 3 mounting screws and remove the TC Amp board See Figure 184 Figure 184 TC Amp board mounting screw locations Disconnect the umbilical cable Disconnect the support thermocouple Disconnect the model thermocouple Remove the 3 mounting screws ...

Page 257: ... panel on page 162 Umbilical Hose Required Tools 5 16 nut driver or standard screwdriver 1 4 nut driver 5 32 allen wrench Cutters Hardware Wire tie 10 32 x 3 8 slotted screws x7 1 4 20 x 1 2 button head cap screws x2 Removing the umbilical hose 1 Remove the top panel See Removing the top panel on page 161 2 Remove the side panels See Removing the side panels on page 162 3 Remove the upper electron...

Page 258: ...lical hose clamp See Figure 186 6 Disconnect the umbilical hose from the head cooling fan and remove the hose clamp See Figure 186 Figure 186 Umbilical hose clamp location 7 Remove the head cover by pressing the tabs in and pulling outward See Figure 187 Remove the 7 mounting screws Loosen the clamp screw and disconnect the hose ...

Page 259: ...gure 188 Figure 188 Air plenum tab locations 9 Disconnect the model and support material tubes See Figure 189 Press in tab to release head cover Press in tab to release head cover Press in tab to release air plenum Press in tab to release air plenum Press in tab to release air plenum Press in tab to release air plenum ...

Page 260: ...ion 1 1 Remove the energy chain mounting screws from the translator with a 5 32 allen wrench See Figure 191 Figure 191 Remove the energy chain mounting screws 12 Straighten the energy chain and feed the umbilical hose through to remove Press down on the retaining rings Lift the material tubes out of the rings Cut and remove the wire tie Remove the 2 mounting screws ...

Page 261: ...einstall the head cover 8 Reconnect the umbilical hose to the head cooling fan 9 Using a 1 4 nut driver or standard screwdriver tighten the umbilical hose clamp 10 Align the right side access panel with the mounting holes 1 1 Using a 5 16 nut driver or standard screwdriver reinstall the right side access panel mounting screws 12 Reinstall the upper electronics bay cover See Installing the upper el...

Page 262: ... bay cover on page 173 4 Remove the umbilical hose See Removing the umbilical hose on page 241 5 Feed the material tubes out through the energy chain Installing the material tubes 1 Feed the material tubes through the energy chain 2 Reinstall the umbilical hose See Installing the umbilical hose on page 245 3 Reinstall the upper electronics bay cover See Installing the upper elec tronics bay cover ...

Page 263: ...s on page 162 3 Remove the upper electronics bay cover See Removing the upper elec tronics bay cover on page 173 4 Remove the umbilical hose See Removing the umbilical hose on page 241 5 Disconnect the umbilical cable from the I O card See Figure 193 Figure 193 Umbilical cable connector locations 6 Disconnect the umbilical cable from the head board by pressing in on the tab and pulling upward See ...

Page 264: ...hain 2 Reconnect the umbilical cable to the TC Amp board 3 Reconnect the umbilical cable to the head board 4 Reconnect the umbilical cable to the I O card 5 Reinstall the umbilical hose See Installing the umbilical hose on page 245 6 Reinstall the upper electronics bay cover See Installing the upper elec tronics bay cover on page 174 7 Reinstall the side panels See Installing the side panels on pa...

Page 265: ...oving the Y home sensor 1 Remove the top panel See Removing the top panel on page 161 2 Disconnect the Y home cable by pressing in on the tab and pulling out ward See Figure 196 Figure 196 Y Home sensor cable location 3 Using a 1 4 nut driver or standard screwdriver remove the mounting screw See Figure 197 Disconnect the Y Home cable ...

Page 266: ...ting screw 3 Reconnect the Y Home cable 4 Install the top panel See Installing the top panel on page 162 Y EOT End of Travel Sensor Required Tools 1 4 nut driver or standard screwdriver Hardware 6 32 x 3 8 slotted screw x1 Removing the Y EOT sensor 1 Remove the top panel See Removing the top panel on page 161 2 Disconnect the Y EOT cable by pressing in on the tab and pulling out ward See Figure 19...

Page 267: ...nsor mounting screw location 4 Remove the Y EOT sensor Installing the Y EOT Sensor 1 Align the Y EOT Sensor with the mounting hole 2 Using a 1 4 nut driver or standard screwdriver reinstall the mounting screw 3 Reconnect the Y EOT cable 4 Install the top panel See Installing the top panel on page 162 Disconnect the Y EOT cable Remove the mounting screw ...

Page 268: ...16 10 32 x 1 2 slotted screws x4 8 32 x 1 2 socket head cap screws x4 Removing the X motor 1 Remove the top panel See Removing the top panel on page 161 2 Remove the side panels See Removing the side panels on page 162 3 Using a 5 16 nut driver or standard screwdriver remove the 7 left side access panel mounting screws and remove the left side access panel See Figure 200 ...

Page 269: ...move the right side access panel See Figure 201 Figure 201 Right side access panel mounting screw locations 5 Using a 1 2 box wrench remove the X belt tension adjuster by loosen ing the inside nut and then backing the bolt out of the mount See Figure 202 6 Remove the tensioning fork and pulley from the X motor belt Remove the 7 mounting screws Remove the 7 mounting screws ...

Page 270: ...Using a cutters remove the X motor cable connector wire tie See Figure 203 Figure 203 X motor wire tie locations 8 Disconnect the X motor cable by pressing in on the tab and pulling out ward See Figure 204 Loosen X belt adjustment bolt Cut and remove wire tie ...

Page 271: ...nergy chain mounting bracket mounting screws See Figure 205 Figure 205 X motor energy chain mounting bracket mounting screw locations 10 Using a 5 16 nut driver or standard screwdriver remove the 4 mounting screws from the X motor mounting bracket See Figure 206 Disconnect X motor cable Remove the 2 mounting screws ...

Page 272: ...Installing the X motor 1 Place the X belt around the X motor pulley 2 Align the X motor into the X motor mounting bracket making sure the X motor cable faces the front of the printer 3 Using a 9 64 allen wrench reinstall the 4 X motor mounting screws 4 Align the X motor mounting bracket with the mounting holes 5 Using a 5 16 nut driver or standard screwdriver reinstall the 4 X motor mounting brack...

Page 273: ...locations 10 Move the Head Assembly to the full right travel position within the build envelope as viewed from the front of the printer 1 1 Insert the zero gauge block into the gauge See Figure 209 12 Loosen the adjustment screw and slide the dial indicator assembly up or down to set the zero reading The large hand should be on 0 and the small hand on 5 13 Tighten the adjustment screw do not over ...

Page 274: ...ve belt cen tered between the Head Assembly and the left side of the build enve lope Figure 210 Figure 210 X belt tension location 16 Check the tension The large hand on the gauge should read between 25 and 35 mils and the small hand should read between 4 and 5 Figure 21 1 Adjustment screw Zero gauge block ...

Page 275: ...d above adjust the belt tension by turning the X belt tensioning nut on the X Drive Idler Tension Adjust gear Figure 212 Figure 212 X Drive Belt Tension Adjustment 18 Remove the belt fixture and run the head back and forth several times 19 Continue to adjust and check the tension until the tension meets specifi cation X belt tension bolt ...

Page 276: ... the top panel on page 161 2 Remove the side panels See Removing the side panels on page 162 3 Remove the upper electronics bay cover See Removing the upper elec tronics bay cover on page 173 4 Remove the left side access panel See Figure 213 Figure 213 Left side access panel mounting screw locations 5 Disconnect the Y motor cable by pressing in on the tab and pulling upward See Figure 214 Remove ...

Page 277: ...screwdriver remove the 4 Y motor mounting bracket mounting screws See Figure 215 Figure 215 Y motor mounting bracket mounting screw locations 7 Using a 9 64 allen wrench remove the 4 Y motor mounting screws See Figure 216 Disconnect the Y motor cable Remove the 4 mounting screws ...

Page 278: ... around the Y motor pulley 6 Slide the Y motor mounting bracket up until the Y belt is tight 7 Using a 5 16 nut driver or standard screwdriver securely fasten the Y motor mounting bracket mounting screws 8 Reconnect the Y motor cable 9 Align the left side access panel with the mounting holes 10 Using a 5 16 nut driver or standard screwdriver reinstall the left side access panel mounting screws 1 1...

Page 279: ...lotted screws x30 3 16 x 1 fender washer Removing the Y Motor Belt 1 Remove the top panel See Removing the top panel on page 161 2 Remove the side panels See Removing the side panels on page 162 3 Remove the upper electronics bay cover See Removing the upper elec tronics bay cover on page 173 4 Remove the left side access panel See Figure 217 ...

Page 280: ...right side access panel mounting screws and remove the right side access panel See Figure 218 Figure 218 Right side access panel mounting screw locations 9 Using a 5 16 box wrench remove the outer Y belt retaining clip mount ing screws from the left side See Figure 219 10 Using a 5 16 box wrench loosen but do not remove the inner Y belt retaining clip mounting screws from the left side See Figure ...

Page 281: ...inner Y belt retaining clip mounting screws from the right side See Figure 220 14 Pull the right side Y belt out from the retaining clip Figure 220 Right side Y belt retaining clip mounting screw locations 15 Decrease the Y belt tension by turning the tensioning nut see Figure 221 Remove the outer mounting screws Loosen but do not remove the inner mounting screws Remove the outer mounting screws L...

Page 282: ...onnect the head cooling fan See Figure 222 Figure 222 Disconnect head cooling fan J258 17 Using a 5 16 nut driver or standard screwdriver remove the head cool ing fan mounting bracket screws See Figure 223 Y Drive Belt Tension Adjusting Nut Disconnect J258 ...

Page 283: ... 16 nut driver or standard screwdriver remove the 4 foam insert retaining screws and washers See Figure 224 Figure 224 Foam insert retaining screw locations 20 Remove the foam insert 21 Using a 5 16 nut driver or standard screwdriver loosen but do not remove the 4 Y motor mounting bracket mounting screws See Figure 225 ...

Page 284: ...re 225 Y motor mounting bracket screw locations 22 Remove the Y motor belt from the Y motor pulley See Figure 226 Figure 226 Y motor belt location 23 Locate the 2 lower Y drive rod mounting screws See Figure 227 ...

Page 285: ...remove the 2 Y drive rod mounting screws See Figure 228 Figure 228 Y drive rod mounting screws 25 Locate and remove the 4 upper Y drive rod mounting screws with a 5 16 nut driver or standard screwdriver See Figure 229 Lower Y drive rod mounting screw locations Left side mounting screw Right side mounting screw ...

Page 286: ... 270 Figure 229 Upper Y drive rod mounting screw locations 26 Lift the Y drive rod and slide the Y motor belt out of the printer and dis card See Figure 230 Figure 230 Remove Y motor belt ...

Page 287: ...9 Reconnect the head cooling fan 10 Using a 5 16 nut driver or standard screwdriver reinstall the left side access panel 1 1 Using a 5 16 nut driver or standard screwdriver reinstall the right side access panel 12 Reinstall the Electronics Bay See Installing the electronics bay on page 176 13 Reinstall the upper electronics bay cover See Installing the upper elec tronics bay cover on page 174 14 P...

Page 288: ...lotted screws x30 3 16 x 1 fender washer Removing the Y Drive Rod 1 Remove the top panel See Removing the top panel on page 161 2 Remove the side panels See Removing the side panels on page 162 3 Remove the upper electronics bay cover See Removing the upper elec tronics bay cover on page 173 4 Remove the left side access panel See Figure 231 ...

Page 289: ...right side access panel mounting screws and remove the right side access panel See Figure 232 Figure 232 Right side access panel mounting screw locations 9 Using a 5 16 box wrench remove the outer Y belt retaining clip mount ing screws from the left side See Figure 233 10 Using a 5 16 box wrench loosen but do not remove the inner Y belt retaining clip mounting screws from the left side See Figure ...

Page 290: ...e inner Y belt retaining clip mounting screws from the right side See Figure 234 14 Pull the right side Y belt out from the retaining clip Figure 234 Right side Y belt retaining clip mounting screw locations 15 Decrease the Y belt tension by turning the tensioning nut Figure 235 Remove the outer mounting screws Loosen but do not remove the inner mounting screws Remove the outer mounting screws Loo...

Page 291: ...onnect the head cooling fan See Figure 236 Figure 236 Disconnect head cooling fan J258 17 Using a 5 16 nut driver or standard screwdriver remove the head cool ing fan mounting bracket screws See Figure 237 Y Drive Belt Tension Adjusting Nut Disconnect J258 ...

Page 292: ... 16 nut driver or standard screwdriver remove the 4 foam insert retaining screws and washers See Figure 238 Figure 238 Foam insert retaining screw locations 20 Remove the foam insert 21 Using a 5 16 nut driver or standard screwdriver loosen but do not remove the 4 Y motor mounting bracket mounting screws See Figure 239 ...

Page 293: ...re 239 Y motor mounting bracket screw locations 22 Remove the Y motor belt from the Y motor pulley See Figure 240 Figure 240 Y motor belt location 23 Locate the 2 lower Y drive rod mounting screws See Figure 241 ...

Page 294: ...remove the 2 Y drive rod mounting screws See Figure 242 Figure 242 Y drive rod mounting screws 25 Locate and remove the 4 upper Y drive rod mounting screws with a 5 16 nut driver or standard screwdriver See Figure 243 Lower Y drive rod mounting screw locations Left side mounting screw Right side mounting screw ...

Page 295: ... 279 Figure 243 Upper Y drive rod mounting screw locations 26 Lift the Y drive rod slide out through the Y belts and discard See Figure 244 Figure 244 Remove Y drive rod ...

Page 296: ...screws 9 Reconnect the head cooling fan 10 Using a 5 16 nut driver or standard screwdriver reinstall the left side access panel 1 1 Using a 5 16 nut driver or standard screwdriver reinstall the right side access panel 12 Reinstall the Electronics Bay See Installing the electronics bay on page 176 13 Reinstall the upper electronics bay cover See Installing the upper elec tronics bay cover on page 1...

Page 297: ...driver or standard screwdriver 5 16 box wrench 1 2 box wrench 5 32 allen wrench 3 32 allen wrench 1 8 allen wrench Cutters Z Guide rod stand off x2 Head bracket dial indicator and belt tension gauge assembly Y rod spacer x2 Leveling wrench ...

Page 298: ...d cap screws x2 Removing the XY table 1 Remove the top panel See Removing the top panel on page 161 2 Remove the side panels See Removing the side panels on page 162 3 Remove the front panel See Removing the front panel on page 166 4 Using a 5 16 nut driver or standard screwdriver remove the left side access panel mounting screws and remove the left side access panel See Figure 245 ...

Page 299: ...See Figure 246 Figure 246 Right side access panel mounting screw locations 6 Remove the toggle head assembly See Removing the toggle head assembly on page 212 7 Remove the head board See Removing the head board on page 233 8 Remove the TC Amp board See Removing the TC Amp board on page 239 9 Cut the wire tie from the umbilical hose See Figure 247 Remove the 7 mounting screws Remove the 7 mounting ...

Page 300: ...ing screw locations 1 1 Remove the substrate sensor See Removing the substrate sensor on page 220 12 Using a 1 2 box wrench remove the X belt tension adjuster by loosen ing the inside nut and then backing the bolt out of the mount See Figure 249 13 Remove the tensioning fork and pulley from the X motor belt Cut and remove the wire tie Remove the 2 mounting screws ...

Page 301: ...Using a cutters remove the X motor cable connector wire tie See Figure 250 Figure 250 X motor wire tie locations 15 Disconnect the X motor cable by pressing in on the tab and pulling out ward See Figure 251 Loosen X belt adjustment bolt Cut and remove wire tie ...

Page 302: ...tor energy chain mounting bracket mounting screw locations 17 Using a 5 16 box wrench remove the outer Y belt retaining clip mount ing screws from the left side See Figure 253 18 Using a 5 16 box wrench loosen but do not remove the inner Y belt retaining clip mounting screws from the left side See Figure 253 19 Pull the left side Y belt out from the retaining clip Disconnect X motor cable Remove t...

Page 303: ...ing screws from the right side See Figure 254 22 Pull the right side Y belt out from the retaining clip Figure 254 Right side Y belt retaining clip mounting screw locations 23 Move the translator to the rear of the printer 24 Using a 5 16 nut driver remove the right side X guide rod mounting screws See Figure 255 Remove the outer mounting screws Loosen but do not remove the inner mounting screws R...

Page 304: ... mounting screw See Figure 256 Figure 256 Right side front Y guide rod mounting screw location 26 Using a 5 32 allen wrench remove the right side rear Y guide rod mounting screws and remove the right side Y guide rod See Figure 257 Remove the 2 right side X guide rod mounting screws Remove the right front Y guide rod mounting screw ...

Page 305: ...nsor cable by pressing in on the tab and pull ing outward See Figure 258 Figure 258 Y EOT sensor wire connector location 28 Using a 5 32 allen wrench remove the left side front Y guide rod mount ing screw See Figure 259 Remove the right rear Y guide rod mounting screw Disconnect the Y Home cable ...

Page 306: ...30 Lift the front of the left Y guide rod upward until it is near the top of the frame 31 Rotate the left side Y guide rod towards the center of the printer and lower the guide rod 32 Pull the left side Y guide rod out towards the door opening 33 Angle the rest of the XY table out through the chamber door to remove from the printer Remove the left front Y guide rod mounting screw Remove the left r...

Page 307: ...ighten the adjustment screw do not over tighten the screw and recheck the reading 4 Remove the zero block gauge block from the fixture Figure 261 Tension gauge zero setting 5 Position the dial indicator on the top section of the Y Drive belt at the center point of the belt See Figure 262 Figure 262 Y Drive Belt Tension Check Adjustment screw Zero gauge block Dial Indicator position for Y Drive bel...

Page 308: ...crease the tension by turning the tensioning nut Fig ure 264 so that the dial indicator reads between 0 425 and 0 435 mils Figure 264 Y drive belt tension adjustment 9 Remove the belt fixture and move the belt forward and back several times 10 Reattach the belt tension gauge and recheck the tension 1 1 Continue to adjust and check the tension until the tension meets specifi cation Service Limit Ad...

Page 309: ...ht side rear Y guide rod mounting screw 20 Using a 5 32 allen wrench loosely reinstall the right side front Y guide rod mounting screw 21 Align the X guide rods with the mounting holes 22 Using a 5 16 nut driver or standard screwdriver loosely reinstall the right side X guide rod mounting screws 23 Align the X motor energy chain mounting bracket with the mounting holes 24 Using a 5 16 nut driver o...

Page 310: ... 222 36 Reinstall the toggle head assembly See Installing the toggle head assembly on page 217 37 Reinstall the toggle sensor See Installing the toggle sensor on page 226 38 Install the 2 XY table alignment brackets to the center of the Y guide rods See Figure 266 39 Adjust the alignment brackets as needed 40 Using a 1 8 allen wrench tighten the alignment bracket adjustment screws Figure 266 XY Ta...

Page 311: ... 16 nut driver or standard screwdriver securely fasten the left side X guide rod mounting screws 48 Slide the translator to the right side of the printer 49 Using a 5 16 nut driver or standard screwdriver securely fasten the right side X guide rod mounting screws WARNING Failure to center the Y guide rods before tightening the X guide rod screws will result in X guide rod misalignment Place an ali...

Page 312: ...ace using 2 Z guide rod stand offs See Figure 269 Figure 269 Z guide rod stand off locations 51 Using a black marker or pen mark the 4 corners of the Z stage as shown in Figure 270 Figure 270 Marking the 4 corners of the Z stage Mark the 4 corners of the Z stage ...

Page 313: ... dial indicator to the front left FL corner and write down the value 55 Move the dial indicator to the front right FR corner and write down the value 56 Move the dial indicator to the back right BR corner and write down the value 57 Enter the values that are written down into the XY level worksheet Use the 8x6 worksheet for HP Designjet 3D see Figure 272 Use the 8x8 worksheet for HP Designjet Colo...

Page 314: ... 298 Figure 272 HP Designjet 3D measurement points and worksheet BL FL FR BR ...

Page 315: ... 299 Figure 273 HP Designjet Color 3D measurement points and worksheet BL FL FR BR ...

Page 316: ...indicator to the rear right of the Z stage and zero the dial indicator 65 Using the XY guide rod leveling fixture adjust the rod up or down until the dial indicator reads the value the calculator has given 66 Using a 5 32 allen wrench securely fasten the rear right Y guide rod mounting screw 67 Repeat steps 53 66 until the XY table is completely level 68 Remove the XY guide rod alignment brackets ...

Page 317: ... rear section of the X Drive belt cen tered between the Head Assembly and the left side of the build enve lope See Figure 276 Figure 276 X belt tension location 76 Check the tension The gauge should read between 0 425 and 0 435 mils See Figure 277 Adjustment screw Zero gauge block ...

Page 318: ...oning nut on the X Drive Idler Tension Adjust gear See Figure 278 Figure 278 X Drive Belt Tension Adjustment 78 Remove the belt fixture and run the head back and forth several times 79 Continue to adjust and check the tension until the tension meets specifi cation 80 Repeat steps 68 71 to zero the dial indicator 81 Reinstall a wire tie around the umbilical hose See Figure 279 X belt tension bolt ...

Page 319: ...cover See Installing the front panel on page 168 87 Reinstall the side panels See Installing the side panels on page 164 88 Reinstall the top panel See Installing the top panel on page 162 89 Power up the printer 90 From the display panel press Maintenance Machine Tips 91 Perform Z calibration See Z Calibration on page 338 92 Perform XY Offset calibration See XY Tip Calibration on page 340 93 Perf...

Page 320: ...ng the Z home sensor 1 Open the chamber door 2 Lower the Z stage all of the way down 3 Disconnect the Z home sensor cable by pressing in on the tab and pull ing outward See Figure 280 Figure 280 Z home sensor cable location 4 Using a 1 4 nut driver or standard screwdriver remove the mounting screw See Figure 281 Disconnect Z Home cable ...

Page 321: ...iver or standard screw driver 3 Reconnect the Z home cable 4 Close the chamber door Z EOT End of Travel Sensor Required Tools 1 4 nut driver or standard screwdriver Hardware 6 32 x 3 8 slotted screw x1 Removing the Z EOT sensor 1 Open the chamber door 2 Raise the Z stage all of the way up 3 Disconnect the Z EOT sensor cable by pressing in on the tab and pulling outward See Figure 282 Remove mounti...

Page 322: ...83 Figure 283 Remove the mounting screw 5 Remove the Z EOT Sensor Installing the Z EOT sensor 1 Align the Z EOT sensor with the mounting hole 2 Using a 1 4 nut driver or standard screwdriver reinstall the mounting screw 3 Reconnect the Z EOT sensor cable 4 Close the chamber door Disconnect the Z EOT cable Remove the mounting screw ...

Page 323: ...anel on page 161 2 Remove the side panels See Removing the side panels on page 162 3 Using a 5 16 nut driver or standard screwdriver remove the 4 mounting screws from the right side heater panel See Figure 284 Figure 284 Right side heater panel mounting screw locations 4 Using a 5 16 box wrench remove the 2 chamber fan mounting screws See Figure 285 Figure 285 Right side chamber fan mounting screw...

Page 324: ...ight side heater panel 5 Reinstall the side panels See Installing the side panels on page 164 6 Reinstall the top panel See Installing the top panel on page 162 Removing the left side chamber fan 1 Remove the top panel See Removing the top panel on page 161 2 Remove the side panels See Removing the side panels on page 162 3 Using a 5 16 nut driver or standard screwdriver remove the 4 mounting scre...

Page 325: ...an with mounting holes 2 Using a 5 16 box wrench reinstall the 2 chamber fan mounting screws 3 Align the left side heater panel with the mounting holes 4 Using a 5 16 nut driver or standard screwdriver reinstall the 4 mounting screws for the left side heater panel 5 Reinstall the side panels See Installing the side panels on page 164 6 Reinstall the top panel See Installing the top panel on page 1...

Page 326: ... 10 32 x 1 2 slotted screws x4 10 32 x 1 8 nut x4 Removing the right side heater 1 Remove the top panel See Removing the top panel on page 161 2 Remove the side panels See Removing the side panels on page 162 3 Using a 5 16 nut driver or standard screwdriver remove the 4 mounting screws and remove the heater panel See Figure 288 ...

Page 327: ...white power wire from the left mounting post with a 3 8 nut driver See Figure 289 Figure 289 Power wire locations 6 Remove the left and right mounting screws with a 5 16 nut driver or stan dard screwdriver Do not lose the insulating washers as they are need for reinstallation See Figure 290 Remove the 4 mounting screws Remove the white power wire Remove the black power wire ...

Page 328: ...st using a 3 8 nut driver 5 Align the heater panel with the mounting holes 6 Using a 5 16 nut driver or standard screwdriver reinstall the 4 heater panel mounting screws 7 Install the side panels See Installing the side panels on page 164 8 Install the top panel See Installing the top panel on page 162 Removing the left side heater 1 Remove the top panel See Removing the top panel on page 161 2 Re...

Page 329: ...nut driver remove the black power wire from the left mount ing post See Figure 292 Figure 292 Power wire locations 6 Using a 5 16 nut driver or standard screwdriver remove the left and right mounting screws Do not lose the insulating washers as they are need for reinstallation See Figure 293 Remove the 4 mounting screws Remove the black power wire Remove the white power wire ...

Page 330: ...3 Reinstall the black power wire on the left mounting post using a 3 8 nut driver 4 Reinstall the white power wire on the right mounting post using a 3 8 nut driver 5 Align the heater panel with the mounting holes 6 Using a 5 16 nut driver or standard screwdriver reinstall the 4 heater panel mounting screws 7 Install the side panels See Installing the side panels on page 164 8 Install the top pane...

Page 331: ...e Removing the top panel on page 161 2 Remove the side panels See Removing the side panels on page 162 3 Using a 5 16 nut driver or standard screwdriver remove the 4 mounting screws and remove the right side heater panel See Figure 294 Figure 294 Right side heater panel mounting screw locations 4 Disconnect the RTH1 and RTH2 spade connectors by pulling outward See Figure 295 Remove the 4 mounting ...

Page 332: ...hermal fuse with the mounting holes 2 Using a standard screwdriver reinstall the mounting screws 3 Reconnect RTH1 and RTH2 spade connectors 4 Align the heater panel with the 4 mounting screws 5 Using a 5 16 nut driver or standard screwdriver reinstall the 4 mounting screws 6 Reinstall the side panels See Installing the side panels on page 164 7 Reinstall the top panel See Installing the top panel ...

Page 333: ...ve the 4 mounting screws from the left side heater panel and remove the heater panel See Figure 297 Figure 297 Left side heater panel mounting screw locations 4 Disconnect the LTH1 and LTH2 spade connectors by pulling outward See Figure 298 Figure 298 LTH1 and LTH2 spade connector locations 5 Using a standard screwdriver remove the 2 mounting screws See Figure 299 Remove the mounting screws Discon...

Page 334: ...andard screwdriver reinstall the 2 mounting screws 3 Reconnect LTH1 and LTH2 spade connectors 4 Align the heater panel with the 4 mounting holes 5 Using a 5 16 nut driver or standard screwdriver reinstall the 4 mounting screws 6 Reinstall the side panels See Installing the side panels on page 164 7 Reinstall the top panel See Installing the top panel on page 162 Remove the mounting screws ...

Page 335: ... on page 175 5 Push the strain relief clip out towards the front of the printer using a small standard screwdriver See Figure 300 Figure 300 Strain relief clip location 6 Bend the tip of the thermocouple straight and slide out through the strain relief clip 7 Remove the thermocouple Installing the chamber thermocouple 1 Push the thermocouple through the mounting hole until it is 3 4 19mm through t...

Page 336: ...talling the electronics bay on page 176 5 Reinstall the upper electronics bay cover See Installing the upper elec tronics bay cover on page 174 6 Reinstall the side panels See Installing the side panels on page 164 7 Reinstall the top panel See Installing the top panel on page 162 ...

Page 337: ...Z motor 1 Remove the top panel See Removing the top panel on page 161 2 Remove the side panels See Removing the side panels on page 162 3 Remove the upper electronics bay cover See Removing the upper elec tronics bay cover on page 173 4 Remove the electronics bay See Removing the electronics bay on page 175 5 Using a 5 16 nut driver or standard screwdriver remove the 4 Z stage panel mounting screw...

Page 338: ...303 7 Cut the tie wraps holding from around Z stage energy chain See Figure 303 Figure 303 Remove the Z motor energy chain 8 Loosen but do not remove the Z stage leadscrew mounting bracket set screws using a 9 64 allen wrench See Figure 304 Cut the wire tie Cut the wire tie Remove the 2 mounting screws Remove the 2 mounting screws ...

Page 339: ... until it is free of the motor See Fig ure 305 Figure 305 Remove the leadscrew 10 Remove the 4 Z stage motor mounting screws with a 3 32 allen wrench and remove the motor See Figure 306 Figure 306 Removing the Z stage motor Loosen set screws on both sides of the mounting bracket Remove the 4 mounting screws ...

Page 340: ...the mounting screws be sure not to overtighten and crush the energy chain 6 Attach and tighten the wire ties on both ends of the Z motor wire Figure 307 Remove the Z motor energy chain 7 Reinstall the Z stage panel and tighten the 4 mounting screws with a 5 16 nut driver or standard screwdriver 8 Reinstall the electronics bay See Installing the electronics bay on page 176 9 Reinstall the upper ele...

Page 341: ...ical replacement is the same for both printers When its time to calibrate they will have different procedures Required Tools 5 16 nut driver or standard screwdriver 5 16 socket driver or 5 16 box wrench 3 32 allen wrench 9 64 allen wrench Cutters Z Guide rod stand off x2 Head bracket dial indicator and belt tension gauge assembly Y rod spacer x2 Leveling wrench ...

Page 342: ...e Z stage 1 Remove the top panel See Removing the top panel on page 161 2 Remove the side panels See Removing the side panels on page 162 3 Remove the electronics bay See Removing the electronics bay on page 175 4 Remove the Z motor See Removing the Z motor on page 321 5 Tilt the printer forward 6 inches 152mm and prop up with a material carrier or something similar ...

Page 343: ...igure 309 Upper Z stage guide rod mounting screw locations 8 Remove the Z stage by pulling out of the printer through the chamber door Installing the Z stage 1 Align the Z stage guide rods with the upper and lower mounting holes 2 Using a 5 16 socket driver or 5 16 box wrench loosely fasten the lower Z stage guide rod mounting screws 3 Using a 5 6 nut driver or standard screwdriver loosely fasten ...

Page 344: ...9 Using a 5 16 nut driver or standard screwdriver securely fasten the upper Z stage guide rod mounting screws 10 Remove the upper and lower Z stage guide rod alignment fixtures 1 1 Using a 3 32 allen wrench reinstall the Z motor Do not tighten the screws completely at this time 12 Feed the Z stage leadscrew through the mounting brackets and through the Z motor Align the leadscrew with the set scre...

Page 345: ...urn the locking screws 1 4 turn counter clockwise to lock in place See Figure 312 Figure 312 Inserting the Z stage guide rod alignment fixture 17 Using a 5 16 socket driver or 5 16 box wrench securely fasten the lower Z stage leadscrew mounting bracket screws from the backside of the printer 18 Remove the Z stage leadscrew alignment fixture by pressing in the screws and turning 1 4 turn clockwise ...

Page 346: ... leadscrew alignment fixture by pressing in the screws and turning 1 4 turn clockwise to unlock 24 Move the Z stage to its lower limit 25 Using a 3 32 allen wrench securely fasten the Z motor mounting screws 26 Using a 5 16 nut driver or standard screwdriver reinstall the Z stage panel 27 Slowly lift the Z stage to the top of its travel making sure it has smooth movement 28 Let the Z stage travel ...

Page 347: ...3D 8in x 6in Z stage table location points Figure 315 HP Designjet Color 3D 8in x 8in Z stage table location points 30 Attach a dial indicator to the head bracket 31 Attached the head bracket to the toggle head assembly 32 Move the dial indicator to the back left BL corner over the marked loca tion BL Back Left BR Back Right FR Front Right FL Front Left BL Back Left BR Back Right FR Front Right FL...

Page 348: ...Move the dial indicator to the back left BL corner and zero the dial indicator 35 Move the dial indicator to the front left FL corner and write down the value 36 Move the dial indicator to the front right FR corner and write down the value 37 Move the dial indicator to the back right BR corner and write down the value 38 Enter the values that are written down into the XY level worksheet Use the 8x...

Page 349: ... 333 Figure 316 HP Designjet 3D measurement points and worksheet BL FL FR BR ...

Page 350: ... 334 Figure 317 HP Designjet Color 3D measurement points and worksheet BL FL FR BR ...

Page 351: ...e rod mounting screw 45 Move the dial indicator to the rear right of the Z stage and zero the dial indicator 46 Using the XY guide rod leveling fixture adjust the rod up or down until the dial indicator reads the value the calculator has given 47 Using a 5 32 allen wrench securely fasten the rear right Y guide rod mounting screw 48 Repeat steps 53 66 until the XY table is completely level 49 Remov...

Page 352: ... 336 ...

Page 353: ...age 343 Performing part based calibration for HP Designjet 3D with the HP Designjet 3D Diagnostic Software page 352 Performing part based calibration for HP Designjet Color 3D from the Service Calibration menu Firmware version 9 1 or newer page 360 Performing part based calibration for HP Designjet Color 3D with the HP Designjet Diagnostics Software page 371 Tensioning the X Y Drive Belts page 381...

Page 354: ...ration part one square of model and one of support The system will then measure and calibrate the Z Axis for tip depth and tip level Build time is approx imately 5 minutes 6 Repeat steps 1 5 to verify proper calibration Entering Z Calibration values manually Firmware version 9 1 or newer Z tip to base ZT2B ZT2B is the Z distance from the support tip to the Z substrate sensor activation point If un...

Page 355: ...pport tip A positive ZT2T means the support tip is higher than the model tip If a support layer on top of model is too thick add 0 010 to the ZT2T If a model layer does not stick to supports subtract 0 010 from the ZT2T If unable to calibrate automatically this value may need to be set to default in order to proceed with automatic calibration The default value is 0 0000 1 While the printer is at I...

Page 356: ...0 Y 0 7 Remove the XY Tip Calibration part from the printer 8 Inspect the part and calibrate the X and Y axes as follows See Figure 320 A Use the magnifier from the Startup Kit to view the support road B Identify the location on the X or X side of the part where the support road is best centered within the model boundaries C Read the number closest to this location This is the required X Tip Offse...

Page 357: ... calibration model is too far off to read these values may be set to default as a starting point for calibration The default values are X 0 780 and Y 0 000 1 While the printer is at Idle enter standby mode by pressing the Standby button 2 Enter the Service Calibration menu by pressing the following button sequence on the display panel 3 2 3 3 1 See Figure 321 NOTE Unusual circumstances may require...

Page 358: ...it buttons 1 1 When finished press Done 12 Press the Next button until you reach the last page 13 Press the Done button 14 Press the Save and reboot button 15 The printer will reboot and return to idle 16 Perform automatic XY Tip Calibration see XY Tip Calibration on page 340 NOTE The value for XTIP must be between 0 7300 and 0 8300 For example the value from Figure 320 is 2 you would increment th...

Page 359: ...ter replacing the XY table assembly Part Based calibration is performed to eliminate any skewing in the X and Y axes Performing part based calibration for HP Designjet 3D from the Service Calibration menu Firmware version 9 1 or newer 1 While the printer is at Idle enter standby mode by pressing the Standby button 2 Enter the Service Calibration menu by pressing the following button sequence on th...

Page 360: ...cle B 9 Using a digital caliper measure and record the diameter of circle B along the center line between A and C see Figure 324 Figure 324 Measuring diameter of B 10 Next measure and record the distance from the outside edges of circle A and B see Figure 325 Ensure that the caliper is not seated on the small bump of circle A NOTE Reference letters are not actually printed on the part If needed us...

Page 361: ...dd the lengths derived from steps 10 and 1 1 A B and B C and then subtract the width of circle B Record this total as GFront 13 Measure and record the distance from the outside edges of circles E and F Ensure the caliper is not seated on the small bump of circle E See Fig ure 327 Figure 327 Measuring distances from outside edges of E and F 14 Measure and record the distance from the outside edges ...

Page 362: ...e 329 Measuring diameter of circle F 16 Add the lengths derived from steps 14 and 15 E F and F G and then subtract the width of circle F derived from step 16 Record this total as GRear 17 Measure and record the distance from the outside edges of circles C and G Ensure the caliper is not seated on the small bump of circles C or G Record this total as GRight see Figure 330 ...

Page 363: ... of circles A and E Ensure the caliper is not seated on the small bump of circles A or E Record this total as GLeft see Figure 331 Figure 331 Measuring distances from outside edges of A and E 19 Measure and record the distance from the outside edge of the small bump on circle C to the outside edge of circle D See Figure 332 ...

Page 364: ...d record the distance from the outside edge of the small bump on circle E to the outside edge of circle D See Figure 333 Figure 333 Measuring distances from outside edges of D and E 21 Measure and record the diameter of circle D along the center line between C and E See Figure 334 ...

Page 365: ...step 22 Record this total as GLR 23 Measure and record the distance from the outside edge of the small bump on circle A to the outside edge of circle D See Figure 335 Figure 335 Measuring distances from outside edges of A and D 24 Measure and record the distance from the outside edge of the small bump on circle G to the outside edge of circle D See Figure 336 ...

Page 366: ... D G and then subtract the width of circle D derived from step 26 Record this total as GLF 27 Enter the Service Calibration menu by pressing the following button sequence on the display panel 3 2 3 3 1 See Figure 322 28 Press the Edit Configuration button 29 Press the GLeft button Enter the value recorded from step 18 by press ing the Increment Decrement and Next Digit buttons 30 When finished pre...

Page 367: ...om step 26 by pressing the Increment Decrement and Next Digit buttons 39 When finished press Done 40 Press the GLR button Enter the value recorded from step 22 by pressing the Increment Decrement and Next Digit buttons 41 When finished press Done 42 Press the Next button until you reach the last page 43 Press the Done button 44 Press the Save and reboot button 45 The printer will reboot and return...

Page 368: ...ark to save the values 6 Toggle the system power down switch 7 Once the system displays Idle press Maintenance System Test Parts then select the test_XY_cal part 8 When part is completed remove from printer and let cool for five min utes 9 Locate the filled circle this indicates the front of the substrate see Figure 338 Figure 338 Locating the Filled Circle B 10 Using a digital caliper measure and...

Page 369: ... record the distance from the outside edges of circle B and C see Figure 341 Ensure that the caliper is not seated on the small bump of circle C Figure 341 Measuring distance from outside edges of B and C 13 Add the lengths derived from steps 5 and 6 A B and B C and then sub tract the width of circle B Record this total as Front 14 Measure and record the distance from the outside edges of circles ...

Page 370: ...d G 16 Measure and record the diameter of circle F along the center line between E and G See Figure 344 Figure 344 Measuring diameter of circle F 17 Add the lengths derived from steps 14 and 15 E F and F G and then subtract the width of circle F derived from step 16 Record this total as Rear 18 Measure and record the distance from the outside edges of circles C and G Ensure the caliper is not seat...

Page 371: ... of circles A and E Ensure the caliper is not seated on the small bump of circles A or E Record this total as Left see Figure 346 Figure 346 Measuring distances from outside edges of A and E 20 Measure and record the distance from the outside edge of the small bump on circle C to the outside edge of circle D See Figure 347 ...

Page 372: ...d record the distance from the outside edge of the small bump on circle E to the outside edge of circle D See Figure 348 Figure 348 Measuring distances from outside edges of D and E 22 Measure and record the diameter of circle D along the center line between C and E See Figure 349 ...

Page 373: ...p 22 Record this total as Left Rear 24 Measure and record the distance from the outside edge of the small bump on circle A to the outside edge of circle D See Figure 350 Figure 350 Measuring distances from outside edges of A and D 25 Measure and record the distance from the outside edge of the small bump on circle G to the outside edge of circle D See Figure 351 ...

Page 374: ...s total as Left Front 28 Open HP Designjet 3D Diagnostic Software and select the Current Mod eler from the pull down menu 29 Open the Open Gantry Calibration Dialog box in HP Designjet 3D Diagnostic Software 30 In the Part Calibration section there are six boxes LEFT RIGHT FRONT REAR LEFT FRONT and LEFT REAR Enter the measurements in the appropriate box 31 Once the values have been entered click o...

Page 375: ...D Diagnostic Software Front _______ ______ ____ ________ A B B C B Right _______ ______ ____ ________ C F F I F Left _______ ______ ____ ________ A D D G D Rear _______ ______ ____ ________ G H H I H Left Rear _______ ______ ____ ________ C E E G E Left Front _______ ______ ____ _______ A E E I E Figure 353 Part based calibration measurement locations ...

Page 376: ... 3 2 3 3 1 See Figure 354 Figure 354 Service Calibration button sequence 3 Press the Reset Part Based Calibration button 4 The printer will ask Do you want to zero settings and reboot Press Yes 5 Reboot the printer 6 Once the system displays Idle press Maintenance System Test Parts then select the test_XY_cal part 7 When part is completed remove from printer and let cool for five min utes 8 Locate...

Page 377: ...gure 356 Measuring diameter of B 10 Next measure and record the distance from the outside edges of circle A and B see Figure 357 Ensure that the caliper is not seated on the small bump of circle A NOTE Reference letters are not actually printed on the part If needed use the Part Measurement Equations sheet to record the values See Part Measurement Equations on page 380 ...

Page 378: ...p of circle C Figure 358 Measuring distance from outside edges of B and C 12 Add the lengths derived from steps 5 and 6 A B and B C and then sub tract the width of circle B Record this total as GFront 13 Measure and record the distance from the outside edges of circles E and F Ensure the caliper is not seated on the small bump of circle E See Fig ure 378 Figure 359 Measuring distances from outside...

Page 379: ...he distance from the outside edges of circles F and I See Figure 379 Figure 360 Measuring distances from outside edges of F and G 15 Measure and record the diameter of circle F along the center line between C and I See Figure 380 ...

Page 380: ...tract the width of circle F derived from step 16 Record this total as GRight 17 Measure and record the distance from the outside edges of circles A and D See Figure 381 Figure 362 Measuring distances from outside edges of A and D 18 Measure and record the distance from the outside edges of circles D and G See Figure 382 ...

Page 381: ... Figure 364 Measuring diameter of circle D 20 Add the lengths derived from steps 18 and 19 A D and D G and then subtract the width of circle D derived from step 20 Record this total as GLeft 21 Measure and record the distance from the outside edge of circle G to the outside edge of circle H See Figure 384 Figure 365 Measuring distances from outside edges of G and H ...

Page 382: ...and record the diameter of circle H along the center line between G and I See Figure 386 Figure 367 Measuring diameter of circle H 24 Add the lengths derived from steps 22 and 23 G H and H I and then subtract the width of circle H derived from step 24 Record this total as GRear 25 Measure and record the distance from the outside edge of circle C to the outside edge of circle E See Figure 387 ...

Page 383: ...easure and record the distance from the outside edge of circle E to the outside edge of circle G See Figure 388 Figure 369 Measuring distances from outside edges of E and G 27 Measure and record the diameter of circle E along the center line between C and G See Figure 389 ...

Page 384: ...le E derived from step 28 Record this total as GLR 29 Measure and record the distance from the outside edge of circle A to the outside edge of circle E See Figure 390 Figure 371 Measuring distances from outside edges of A and E 30 Measure and record the distance from the outside edge of circle E to the outside edge of circle I See Figure 391 ...

Page 385: ... E I and then subtract the width of circle E derived from step 32 Record this total as GLF 33 Enter the Service Calibration menu by pressing the following button sequence on the display panel 3 2 3 3 1 See Figure 354 34 Press the Edit Configuration button 35 Press the GLeft button Enter the value recorded from step 18 by press ing the Increment Decrement and Next Digit buttons 36 When finished pre...

Page 386: ... step 26 by pressing the Increment Decrement and Next Digit buttons 45 When finished press Done 46 Press the GLR button Enter the value recorded from step 22 by pressing the Increment Decrement and Next Digit buttons 47 When finished press Done 48 Press the Next button until you reach the last page 49 Press the Done button 50 Press the Save and reboot button 51 The printer will reboot and return t...

Page 387: ... mark to save the values 6 Toggle the system power down switch 7 Once the system displays Idle press Maintenance System Test Parts then select the test_XY_cal part 8 When part is completed remove from printer and let cool for five min utes 9 Locate the filled circle this indicates the front of the substrate see Figure 374 Figure 374 Locating the Filled Circle B 10 Using a digital caliper measure a...

Page 388: ...record the distance from the outside edges of circle B and C see Figure 377 Figure 377 Measuring distance from outside edges of B and C 13 Add the lengths derived from steps 1 1 and 12 A B and B C and then subtract the width of circle B Record this total as Front 14 Measure and record the distance from the outside edges of circles C and F Ensure the caliper is not seated on the small bump of circl...

Page 389: ...C and F 15 Measure and record the distance from the outside edges of circles F and I See Figure 379 Figure 379 Measuring distances from outside edges of F and I 16 Measure and record the diameter of circle F along the center line between C and I See Figure 380 ...

Page 390: ... tract the width of circle F derived from step 16 Record this total as Right 18 Measure and record the distance from the outside edges of circles A and D See Figure 381 Figure 381 Measuring distances from outside edges of A and D 19 Measure and record the distance from the outside edges of circles D and G See Figure 382 ...

Page 391: ... Figure 383 Measuring diameter of circle D 21 Add the lengths derived from steps 18 and 19 A D and D G and then subtract the width of circle D derived from step 20 Record this total as Left 22 Measure and record the distance from the outside edge of circle G to the outside edge of circle H See Figure 384 Figure 384 Measuring distances from outside edges of G and H ...

Page 392: ... and record the diameter of circle H along the center line between G and I See Figure 386 Figure 386 Measuring diameter of circle H 25 Add the lengths derived from steps 22 and 23 G H and H I and then subtract the width of circle H derived from step 24 Record this total as Rear 26 Measure and record the distance from the outside edge of circle C to the outside edge of circle E See Figure 387 ...

Page 393: ...easure and record the distance from the outside edge of circle E to the outside edge of circle G See Figure 388 Figure 388 Measuring distances from outside edges of E and G 28 Measure and record the diameter of circle E along the center line between C and G See Figure 389 ...

Page 394: ...E derived from step 28 Record this total as Left Rear 30 Measure and record the distance from the outside edge of circle A to the outside edge of circle E See Figure 390 Figure 390 Measuring distances from outside edges of A and E 31 Measure and record the distance from the outside edge of circle E to the outside edge of circle I See Figure 391 ...

Page 395: ...s total as Left Front 34 Open HP Designjet 3D Diagnostic Software and select the Current Mod eler from the pull down menu 35 Open the Open Gantry Calibration Dialog box in HP Designjet 3D Diagnostic Software 36 In the Part Calibration section there are six boxes LEFT RIGHT FRONT REAR LEFT FRONT and LEFT REAR Enter the measurements in the appropriate box 37 Once the values have been entered click o...

Page 396: ...D Diagnostic Software Front _______ ______ ____ ________ A B B C B Right _______ ______ ____ ________ C F F I F Left _______ ______ ____ ________ A D D G D Rear _______ ______ ____ ________ G H H I H Left Rear _______ ______ ____ ________ C E E G E Left Front _______ ______ ____ _______ A E E I E Figure 393 Part based calibration measurement locations ...

Page 397: ...ould be on 0 and the small hand on 5 3 Tighten the adjustment screw do not over tighten the screw and recheck the reading Reading should be same as step 2 4 Remove the zero block gauge block from the fixture Figure 394 Tension gauge zero setting CAUTION The X Y Drive Belt Tension must be checked and adjusted with the system and belts at room temperature approximately 20 minutes to cool to room tem...

Page 398: ...el position within the build envelope as viewed from the front of the printer 4 Position the dial indicator on the rear section of the X Drive belt cen tered between the Head Assembly and the left side of the build enve lope Figure 395 Figure 395 X belt tension location 5 Check the tension Figure 396 The large hand on the gauge should read between 25 and 35 mils and the small hand should read betw...

Page 399: ...he belt tension by turning the X belt tensioning nut on the X Drive Idler Tension Adjust gear Figure 397 Figure 397 X Drive Belt Tension Adjustment 7 Remove the belt fixture and run the head back and forth several times 8 Continue to adjust and check the tension until the tension meets specifi cation 9 Reinstall side and top panels X belt tension bolt ...

Page 400: ...n the top section of the Y Drive belt at the center point of the belt Figure 398 Figure 398 Y Drive Belt Tension Check 5 The large hand on the gauge should read between 0 and 30 mils and the small hand should read between 4 and 5 Figure 399 NOTE The Y Drive system consists of two drive belts one on each side of the build envelope Each belt must be checked adjusted and of equal values Dial Indicato...

Page 401: ... ure 400 9 Adjust increase decrease the tension by turning the tensioning nut Fig ure 400 so that the dial indicator reads between 25 and 35 Figure 400 Y drive belt tension adjustment 10 Remove the belt fixture and move the head forward and back across the gantry several times 1 1 Reattach the belt tension gauge and recheck the tension 12 Continue to adjust and check the tension until the tension ...

Page 402: ...nt of a file name and the selection of a storage location This file should be updated any time maintenance is performed that affects the factory calibration Send Calibration The Send Calibration button allows you to send the complete set of factory calibrations to the printer as a single file This includes but is not limited to Tip Offset Tip Depth YLash X Correction and the gantry DAT file This f...

Page 403: ... and will always be zero 8 Next move the XY table until the dial indicator is over the front left FL corner mark Figure 401 Measure and record the difference e g the dial indicator reads 0 004 in 9 Move the XY table until the dial indicator is over the front right FR cor ner mark Figure 401 Measure and record the difference e g the dial indicator reads 0 010 in 10 Move XY table until the dial indi...

Page 404: ... 388 Figure 402 HP Designjet 3D measurement points and worksheet BL FL FR BR ...

Page 405: ... 389 Figure 403 HP Designjet Color 3D measurement points and worksheet BL FL FR BR ...

Page 406: ... matches the value from the calculator e g 0 014 7 While holding the rod in position tighten the front left FL guide rod screw 8 Move the dial indicator to the front right FR corner mark 9 Set the gauge to zero by turing the outer ring of the gauge 10 Position the table level adjustment tool on front right Y guide rod Note that the adjustment tool prong must rest on the sheet metal shelf 1 1 Using...

Page 407: ...lator e g 0 001 16 While holding the rod in position tighten the back right BR guide rod screw 17 Recheck the four corners by moving the gauge over the corner marks The maximum difference allowed between the highest and lowest read ings is 0 003 in 18 Repeat the XY leveling process until the measurements are within specifi cation ...

Page 408: ...flon washer from the right side Pivot Block Pin 3 Move the Toggle Bar to the right 4 Loosen don t remove the model side Heater Block Mount screws and the model side Heater Block Clamp screws NOTE This procedure must be accomplished in its entirety and in the order presented The procedure consists of 3 procedures Drive wheel alignment Idler Wheel adjustment and Liquefier alignment Spring removal to...

Page 409: ...axially on the Motor shaft gently move the Toggle Bar to the left until the Alignment Rod rests in the groove of the Drive Wheel 12 Adjust the Drive Wheel until the Alignment Rod is centered in the groove of the Drive Wheel 13 Tighten the Drive Wheel set screw 14 Verify proper Drive Wheel alignment A Gently move the Toggle Bar to the right then back to the left while observing the Drive Wheel and ...

Page 410: ...roove of the Drive Wheel Drive wheel must be axially aligned along the centerline between the model liquefier heater blocks and the main toggle block within 0025 D If the Alignment Pin is misaligned repeat steps 11 through 14 Figure 409 Wheel alignment check 1 of 2 Alignment Pin Drive Wheel As the Toggle Bar is moved right and left the Alignment Pin should not deflect fore or aft as the Drive Whee...

Page 411: ...e Drive Wheel so that the set screw head is on the bottom of the Wheel Figure 41 1 2 Check Adjust the Right Model side Idler Wheel clearance Figure 41 1 A Place the Toggle Bar in the full Left position B Check the clearance between the Drive Wheel and the Idler Wheel a 003 inch feeler gauge shim stock should have a light drag when placed between the Drive Wheel and the Idler Wheel C Place the Togg...

Page 412: ...ithout drag If drag is present re check adjustments Figure 41 1 Idler Wheel Adjustment Right Side 3 Check Adjust the Left Support side Idler Wheel clearance Figure 412 A Move the Toggle Bar to the full Right position B Check Adjust the clearance between the Drive Wheel and the Idler Wheel a 003 inch feeler gauge shim stock should have a light drag when placed between the Drive Wheel and the Idler ...

Page 413: ... the Idler Wheel by hand The Idler Wheel should spin freely without drag If drag is present re check adjustments Figure 412 Idler Wheel Adjustment Left Side Liquefier Alignment This aligns the Liquefier Tubes with the filament path 1 Right Model side A Move the Toggle Bar to the full Right position B Make sure the right side Heater Block Mount and Clamp screws are loose C Make sure that the Liquef...

Page 414: ...rocedure must be performed after Liquefier Alignment on page 397 is performed 1 Install the Heat Shield install and tighten the 2 retaining screws make sure the teflon washers are installed between the Heat Shield tabs and the Translator 2 Install the new Liquefier Tips Figure 413 A You must identify the correct replacement tip The uPrint uses two tip types You must make sure a SUPPORT tip is used...

Page 415: ...he way up against the heater block F Verify the tip is fully inserted into the heater block and that the stainless steel shield is aligned Figure 414 Tip stainless steel shield alignment G Use 7 64 T Handle Allen wrench to firmly tighten the heater block clamp screws H Repeat step 2 for second tip 3 Verify Right Model side alignment A Move the Toggle Bar to the full Right position NOTE Make sure T...

Page 416: ...e aligned with the toggle head pinch point 0 0065 The pinch point is the same as the centerline of the Alignment Rod If the Support Filament Guide interferes with the Alignment Rod recheck Liquefier Alignment on page 397 F Perform a physical check of the alignment by pushing down on the top of the Alignment Rod so that it enters the inlet of the Liquefier Alignment is not correct if additional pre...

Page 417: ... air duct at top press in on clips to fit the plenum to the Translator 3 Install the Head Cover squeeze the side tabs to fit the Translator 4 Power the printer up 5 From the display panel press Maintenance System Tips and perform the following calibrations A Z calibration B XY Tip offset calibration NOTE Follow the Head Installation Checklist after completing Toggle Plate Assembly replacement Unac...

Page 418: ...wrench Tip wipe height block Adjusting tip wipe assembly height 1 Remove tip wipe assembly by pulling out of tip wipe bracket See Figure 417 2 Remove the plastic screw caps by prying apart with a standard screw driver See Figure 417 Figure 417 Tip wipe assembly location 3 Insert the tip wipe assembly height block into the tip wipe assembly bracket See Figure 418 Figure 418 Tip wipe assembly height...

Page 419: ...e 419 Toggle assembly location 5 Using a 7 64 allen wrench loosen but do not remove the tip wipe assembly bracket screws See Figure 420 Figure 420 Tip wipe assembly bracket screw locations 6 Slowly position the tip wipe assembly bracket upwards so tip wipe assembly height block touches the model and support tips See Figure 421 ...

Page 420: ...ten the tip wipe assembly bracket screws 8 Slowly move the toggle assembly away from the tip wipe assembly height block 9 Position the plastic screw caps over the tip wipe assembly bracket screws and press into place 10 Reinstall the tip wipe assembly into the tip wipe assembly bracket ...

Page 421: ...ponents page 409 XY Table area components page 413 Z Stage area components page 415 Chamber heater area components page 416 Cables page 417 Material Bay Components page 418 Tools page 419 Consumables page 419 Hard Drive Installation Checklist page 420 Toggle Head Assembly Installation Checklist page 421 XY Table Assembly Installation Checklist page 422 Controller Board Checklist page 423 HP Design...

Page 422: ... 19 Insulation Foam Front Panel 1 4 CQ656 671 15 Panel Door 1 5 CQ656 671 12 Panel Top 1 Not Shown CQ656 671 16 Insulation Foam Top Panel 1 6 CQ656 671 14 Panel Right Side 1 Not Shown CQ656 671 18 Insulation Foam Right Panel 1 7 CQ656 67120 Glass Door Assembly 1 8 CQ656 67124 Door Solenoid 1 9 CQ656 67125 Door Sensor 1 Not Shown CQ656 67126 Door Solenoid Sensor Holder 1 10 CQ656 67129 Foot Vibrati...

Page 423: ...O Card 1 2 CQ656 67176 Power Distribution Board PDB 1 3 CQ656 67178 Controller Board 1 4 CQ656 67179 Single Board Computer SBC 1 5 CQ656 67184 Differential Line Filter 1 6 CQ656 67185 AC Input 1 7 CQ656 67141 Circuit Breaker 1 8 CQ656 67186 Electronics Bay Cooling Fan 1 9 CQ656 67180 Hard Drive with Software 1 2 3 4 5 6 7 8 9 1 ...

Page 424: ...Figure 424 Electronics bay component locations Item Part Number Description Qty 1 CQ656 67181 120 VDC Auxiliary Power Supply 1 2 CQ656 67182 24 VDC Power Supply 1 3 CQ656 67183 5 12 VDC Power Supply 1 1 2 3 ...

Page 425: ...ea components Item Part Number Description Qty 1 CQ656 67159 Toggle Head Cover 1 2 CQ656 67158 Toggle Head Manifold 1 Not Shown CQ656 67195 Tip Shroud 2 Not Shown CQ656 67196 T16 Model Liquefier 1 Not Shown CQ656 67197 T16 Support Liquefier 1 1 2 ...

Page 426: ... 410 Figure 426 Head area components Item Part Number Description Qty 1 CQ656 67149 Toggle Head Assembly 1 2 CQ656 67148 Filament tube Support 1 3 CQ656 67147 Filament tube Model 1 1 2 3 ...

Page 427: ... 411 Figure 427 Head area component locations Item Part Number Description Qty 1 CQ656 67150 Head Board 1 2 CQ656 67153 Toggle Bar 1 3 CQ656 67151 TC Amp Board 1 3 1 2 ...

Page 428: ...e 428 Head area component locations Item Part Number Description Qty 1 CQ656 67154 Toggle Sensor Cable 1 2 CQ656 67152 Toggle Sensor 1 3 CQ656 67155 Substrate Sensor 1 4 CQ656 67156 Substrate Sensor Arm 1 3 1 2 4 ...

Page 429: ...tions Item Part Number Description QTY 1 CQ656 67157 Umbilical Hose 1 2 CQ656 67193 Umbilical Cable 1 3 CQ656 67147 Model Material Tube 1 4 CQ656 67131 Y Motor 1 5 CQ656 67132 X Motor 1 6 CQ656 67137 Y Motor Belt 1 7 CQ656 67148 Support Material Tube 1 2 3 4 5 6 1 7 ...

Page 430: ...e component locations Item Part Number Description Qty 1 CQ656 67134 XY Table 1 Not Shown CQ656 67135 X Drive Belt 1 Not Shown CQ656 67136 Y Drive Belt 2 Item Part Number Description Qty 1 CQ656 67122 Y Home sensor 1 2 CQ656 67122 Y EOT End of Travel Sensor 1 1 2 1 ...

Page 431: ... 67194 Chamber Thermocouple K type 36 inch 1 3 CQ656 67122 Z EOT End of Travel Sensor 1 4 CQ656 67142 Chamber Fan 2 5a CQ656 67138 Z Stage 8x6 1 5b CQ656 67139 Z Stage 8x8 6 CQ656 67133 Z motor leadscrew and energy chain 1 7 CQ656 671 10 Purge Bucket 1 8 CQ656 67198 Tip Wipe assembly 1 Not Shown CQ656 67128 LED Light Bar 2 1 2 3 4 5 6 7 8 ...

Page 432: ... 416 Chamber heater area components Figure 433 Chamber heater area components Item Part Number Description Qty 1 CQ656 67143 Heater Finned Strip 2 2 CQ656 67146 Thermostat 121 DEG C Disc 2 1 2 ...

Page 433: ...6 67169 Cable Panel Ground 1 CQ656 67170 Cable Controller to PDB 50 pos 1 CQ656 67171 Cable Controller to PDB 20 pos 1 CQ656 67173 Cable Communication RJ45 3 ft 1 CQ656 67174 Cable Inline RJ45 1 CQ656 67175 Cable Material Bay Communication Power Internal 1 CQ656 67187 Cable Chamber Heater 1 CQ656 67188 Cable X axis Stepper with energy chain 1 CQ656 67189 Cable Lower Harness 1 CQ656 67190 Cable Upp...

Page 434: ...al Bay Assembly 1 5 CQ656 67109 Material Bay Cable 1 6 CQ656 67107 Model Material Tube dual bay 1 7 CQ656 67105 Model Material Tube single bay 1 8 CQ656 67108 Support Material Tube dual bay 1 9 CQ656 67106 Support Material Tube single bay 1 Not Shown CQ656 67199 Model Material Suitcase Red Handle 1 Not Shown CQ656 67200 Support Material Suitcase Black Handle 1 Not Shown CQ656 67201 Suitcase Storag...

Page 435: ...14 P430L Ivory Single Spool 40cu in 1 CQ656 67215 P430L Red Single Spool 40cu in 1 CQ656 67216 P430L Green Single Spool 40cu in 1 CQ656 67217 P430L Black Single Spool 40cu in 1 CQ656 67218 P430L Yellow Single Spool 40cu in 1 CQ656 67219 P430L Blue Single Spool 40cu in 1 CQ656 67220 P430L Gray Single Spool 40cu in 1 CQ656 67221 P430L Orange Single Spool 40cu in 1 CQ656 67222 SR30L Support Single Sp...

Page 436: ...choose Set Net work from the display panel and enter the appropriate network addresses The customer should provide this information After all the addresses have been edited select Done Use the Manage 3D Printers button in HP Designjet Software Solution to connect to the printer Choose Add Manually Download the printer firmware using the most current version Download instructions for performing the...

Page 437: ...leads are connected correctly Clean and vacuum the system Power system up and verify that head reaches temperature and the system homes correctly Using DataStat or HP Designjet 3D Diagnostic Software enter the Z Tip to Tip value that came with the head and cycle power Load material Perform the Z Calibration and XY Offset Calibration Run a part to ensure part quality is acceptable and that head is ...

Page 438: ...g procedure Check Adjust the X Drive Belt tension Check Adjust the Y Drive Belt tension Manually move the table in both the X and Y direction to ensure it moves smoothly Clean and vacuum the system Power system up and verify that system homes correctly Load material Perform the Part Based Calibration procedure Perform the Z Calibration and XY Offset Calibration Run a small test part to ensure part...

Page 439: ... Y Z homing process must be run before building a part Unload material Power down the system Replace the controller board Power up the system When prompted download the printer firmware Enter Head Maintenance This will cause the system to run the complete homing process Exit Head Maintenance Load material Run a small test part to ensure part quality is acceptable and that the XY table is functioni...

Page 440: ...r s operation Select a Modeler Modeler States Modeler Setup HP Designjet 3D Diagnostic Software Configuration Show Printer Status Materials Tip Offset and Liquefier Calibration Gantry Temperatures Outputs Table Calibration Get Calibration Send Calibration Get Configuration Test Parts Reset Password Connect Select a Modeler From the Current Modeler drop down list select a modeler to connect to with...

Page 441: ...e from the current list of modelers Display Units Select the display units by clicking the Display Units drop down list and selecting your preferred units You can choose to display units in inches or millimeters The default display unit is inches Printer Status HP Designjet 3D Diagnostic Software printer status provides the ability to set the machines serial number and detailed information about t...

Page 442: ...e 0 off 255 100 Support Temp The support liquefier temperature and its set point in C Support PWM The pulse width modulation value 0 off 255 100 Chamber Temp The actual chamber temperature and its set point in C Product Version The current version number for the complete firmware release Build Version The build number for current firmware Firmware Version The current version for the firmware PLD V...

Page 443: ...upport Latched The support material cartridge latch state Support in Head The state of the support material in the printer True material moved out of the cartridge False material not moved out of the cartridge Door Latched The state of the door latch solenoid Door Open The state of the door switch Serial Number This is a unique number assigned to each spool Material Type This is the type of materi...

Page 444: ...bration on page 343 Temperatures The temperature control dialog allows you to adjust the set points for the head and chamber temperatures for both modeling and at standby These are set at the factory and should only be changed if noted to be incorrect Temperature Limits Temperature Building Set Point Standby Set Point Head 310 C 100 C Support 310 C 100 C Chamber 77 C 77 C Temperature Min Max Head ...

Page 445: ...ridge latch Checking or unchecking the toggle button enables or disables the latch Motor Enabled The check button shows the state of the model top feed motor solenoid Checking or unchecking the toggle button enables or disables the solenoid Motor Running The check box shows the state of the model top filament feed motor Checking or unchecking the toggle button enables or disables the motor Support...

Page 446: ...format produced by HP Designjet 3D Software Solution The Test Part dialog allows you to browse for and select the sample or test file and to download it to the printer The Test Parts are not preserved during a software upgrade To remove unwanted test parts upgrade the software to the current level and only the factory test parts will remain on the system Reset Password This button resets the admin...

Page 447: ...d on workstation or lap top computer Null modem cable Laplink with DB9 style connectors pins 2 and 3 swapped Computer with Windows XP Windows Vista or Windows 7 Connecting with Tera Term 1 Verify printer is powered ON 2 Connect the Null modem cable or USB to serial converter cable from the computer to the printer serial port connector 3 Open Tera Term 4 Once Tera Term is started the New Connection...

Page 448: ...ct the Serial radio button see Figure 436 6 From the Port pull down menu select the COM port that the USB to serial converter is connected to see Figure 436 Figure 436 New Connection Settings 7 Click OK 8 Click on Setup Serial Port see Figure 437 ...

Page 449: ...rect values Click OK see Figure 438 Figure 438 Serial Port Setup 12 The connection should now be established A To test the connection type ss and press the Enter key Information should post on the screen if the connection was successful NOTE If text does not appear in Tera Term you may have the wrong COM Port selected there may be an issue with the Null Modem Cable or there may be an issue with th...

Page 450: ...XY axis home position It locates the X and Y axis limit switches sets the origin and places the head over the purge bucket Used for testing X Y limit sensors During boot up process a bad sensor could leave the machine stuck in initializing fh will help find the right sensor Example fh The values which are displayed are explained below see Figure 439 Figure 439 Find Home NOTE For a list of commands...

Page 451: ...king the Z foam sensor touch down points Z stage going bad Example fz The values which are displayed are explained below see Figure 440 Figure 440 Find Z Home Actual Travel Limits This is the distance between the BOT Begin Of Travel and EOT End Of Travel Sensors in inches Set origin to This gives an offset to the BOT sensors so the machine is not moving into the sensors during a build Surface at t...

Page 452: ...change the temp to not match system software specification causing errors System Software version check Figure 441 Switch status Average surface This is the Average distance in inches between the sub strate and the Z BOT sensor The machine is looking for the planarity of the substrate if the substrate is not flat then the machine will not home Lowest surface This is the lowest distance in inches b...

Page 453: ...board passes the power on self test and to see the reason for the last reset For the reason a new hard drive will not boot The main problem is the voltage checking process will have a voltage fail during POST this prevents the hard drive from booting Verify all voltages are ok Figure 442 Get POST ...

Page 454: ...er in which it appears The command RT 1000 0 tm will help troubleshoot temperature issues in maintenance mode only The command RT 100 0 fh or RT 100 0 fz will help verify any X Y Z sensors that had issues before the repair are tested and operational Parameters Example rt 20 1 tm Figure 443 Repeat signed integer count This parameter specifies the number of times the command is to be run signed inte...

Page 455: ...ecord of the most recent exceptions that occurred within the controller The exceptions are printed in chronological order Use this command to get the history of system errors printed on the screen This works best to troubleshoot past error codes and see if they relate to the current issue Displays in chronological order Figure 444 Load exception ...

Page 456: ... and wiggle the umbilical cable to check for wire issue Also to check if the PWM works to system specifications you should see a slow change in PWM like 20 to 30 to 40 not 10 to 100 The information is displayed on a single line in the following format MM DD YY HH MM SS m cur set pwm ts s cur set pwm ts c cur set on off Figure 445 Monitor temperatures Examples 9 mz Move Z Parameter Description cur ...

Page 457: ...sensor 1 1 my move y This command moves the head in the y axis Parameters Float Position This is the absolute position it moves to in inches when the command is sent from the Console and in device units when the command is sent through the DPM Example my 3 0 moves the Y Axis 3 inches away from the Y Home sensor 12 cl chamber light This command turns the chamber light on and off Example cl 1 Parame...

Page 458: ... 442 ...

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