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Olivetti 3D S2, Service Manual

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3-2

 

Service Manual

 

Y118040-3 

 
Operator Information  

 
At  the  end  of  the  installation,  the  Field  Engineer  must  ensure  that  the  Operator  is  in  possession  of  all  the 
information  necessary  for  operating  the  printer  correctly,  and  is  capable  of  carrying  out  the  operations  for 
replacing the bobbin and printing nozzles, and for clearing clogging caused by the filament. 
 
For this purpose, it is recommended that you provide a practical demonstration on how to perform the following 
operations: 
 

- 

Use of the console. Interpretation of error messages and, where possible, operations for removing a printer 

jam. 

 

- 

Illustration of methods for inserting and managing filaments. 

 

- 

Bobbin replacement. 

 

- 

Removal of filament clogging printer. 

 

- 

Printing nozzle replacement. 

 

- 

Printing of test file. 

 

- 

Manual printer cleaning. 

 
 
Make  the  Operator  aware  of  the  importance  of  environmental  conditions  when  choosing  the  location  for 
installing and operating the printer. 
 
Remember  that  the  printer  will  function  reliably  over  time  if  used  correctly.  In  the  case  of  any  faults,  contact 
Technical Support immediately. 

 

Summary of Contents for 3D S2

Page 1: ...Olivetti 3D S2 Printer SERVICE MANUAL Code Y118040 3...

Page 2: ...PUBLICATION ISSUED BY Olivetti S p A Telecom Italy Group Via Jervis 77 10015 Ivrea TO Italy Copyright 2016 Olivetti All rights reserved...

Page 3: ...video clips listed below which can be accessed directly from within the associated chapters For this to be possible the Service Manual and all the video clips must be copied to the same folder Video...

Page 4: ...vi Service Manual Y118040 3 This page is intentionally left blank...

Page 5: ...OFFSET 3 20 CHAPTER 4 DISASSEMBLING PARTS AND MAINTENANCE 4 1 TOOL KIT AND TEMPLATES 4 1 REPLACING THE BAKELITE BLOCKS 4 3 REPLACING THE NOZZLES 4 7 NOZZLE PRINT PLATE CALIBRATION PROCEDURE 4 10 CLEAN...

Page 6: ...OR EVERY 1000 HOURS OF OPERATION 5 1 PLANNED MAINTENANCE EVERY 2 YEARS OR 4000 HOURS OF OPERATION 5 1 CHAPTER 6 FIRMWARE 6 1 UPDATING THE FIRMWARE 6 1 CHAPTER 7 TROUBLESHOOTING 7 1 ERROR MESSAGES 7 1...

Page 7: ...F deposition technology to create three dimensional objects by sequentially depositing layers of material in 2 D The Olivetti 3D S2 printer is specially designed for small to medium sized businesses o...

Page 8: ...he inside of the printer The safety keys are located on the left side of the printer Figure 1 1 REFERENCE DESCRIPTION 1 LCD Display 2 Jog Dialer 3 SD Card slot 4 Access door 5 Access door lock 6 Switc...

Page 9: ...igure 1 2 Hot end group REFERENCE DESCRIPTION 1 Extruder 1 2 Extruder 2 3 Extruder 1 cooling fan 4 Extruder 2 cooling fan 5 Cooling fan for material being printed by Extruder 1 6 Cooling fan for mater...

Page 10: ...d group detail REFERENCE DESCRIPTION 1 Nozzle 2 Hot end 3 Hot end unlocking setscrew 4 Filament feeder unit 1 Nozzle 2 Hot end 3 Setscrew di blocco hot end 4 Gruppo di trascinamento filament 4 Filamen...

Page 11: ...REFERENCE DESCRIPTION 1 Bowden quick release couplings 2 Filament pressure adjustment screw The bobbins with the filament are installed at the rear of the machine where there is also the power switch...

Page 12: ...l Y118040 3 Figure 1 5 Rear View Figure 1 6 Rear view detail REFERENCE DESCRIPTION 1 Bobbin holders 2 Feeder 3 Power Switch 4 Power Socket 5 USB Port 1 Bobbin Holders 2 Feeder 5 USB Port 3 Power Switc...

Page 13: ...on The origin of the printer axes known as the extruder Home position is located at the front left corner of the printing plate Figure 1 7 Orientation of Olivetti 3D S2 printer axes Starting from the...

Page 14: ...labels are displayed For the meaning of these symbols see the table below Figure 1 9 Internal labels on lower side SYMBOL COLOUR WARNING MEANING TRIANGLE YELLOW DANGER CRUSHING TRIANGLE YELLOW DANGER...

Page 15: ...r thickness 0 10 mm Nozzle diameter 0 40 mm min layer thickness 0 10 mm recommended layer thickness 0 20 mm Nozzle diameter 0 80 mm min layer thickness 0 20 mm recommended layer thickness 0 40 mm N B...

Page 16: ...1 10 Service Manual Y118040 3 This page is intentionally left blank...

Page 17: ...l plate with the electronic components of the printer Figure 2 1 REFERENCE DESCRIPTION A Input output wire terminals B RAMPS Card C Arduino MEGA 2560 Card positioned under the RAMPS card D Cooling fan...

Page 18: ...nual Y118040 3 POWER UNIT The figure below shows the power unit and the terminal board for the wire connections Figure 2 2 ARDUINO PCB ASSEMBLY The illustration below shows the A side of the Arduino c...

Page 19: ...The two enlarged views show the jumpers located under the five driver chips circled in white all of which must have the same setting and the power selection jumper circled in dark blue Figure 2 4 Extr...

Page 20: ...2 4 Service Manual Y118040 3 The figure below shows one of the five Driver chips mounted on the RAMPS card Figure 2 5 Figure 2 6...

Page 21: ...he Emergency Stop key this key can be activated whenever a dangerous situation arises After the Emergency Stop key is activated it must be reset by rotating it in the direction indicated by the arrows...

Page 22: ...2 6 Service Manual Y118040 3 This page is intentionally left blank...

Page 23: ...ctrical disturbances and excessive voltage variations air conditioning systems and fans photocopiers motors of goods lifts or person lifts radio and TV transmitters and signal generators high frequenc...

Page 24: ...ration on how to perform the following operations Use of the console Interpretation of error messages and where possible operations for removing a printer jam Illustration of methods for inserting and...

Page 25: ...ONS FOR PRINTER INSTALLATION ON WORK TABLE 1 With the printer resting on the ground Figure 3 1 remove the top outer cover Figure 3 2 Figure 3 1 Figure 3 2 2 Remove the two pieces of protective padding...

Page 26: ...ure 3 6 Figure 3 5 Figure 3 6 4 For the best most ergonomic use of the printer choose a surface with a good level of staticity and meeting the following specifications Work table height 80 cm Work tab...

Page 27: ...the printer load it onto the forklift truck and lift it up to the height of the work table Figure 3 7 7 Lift the printer to the height of the work table arrow 1 and manually rest it on the surface arr...

Page 28: ...end group is anchored to the centre of the Z axis at the machine rear using two packing straps Before attempting to use the printer you must therefore unblock the hot end group by removing these strap...

Page 29: ...n information page with the following details Target temperature setting for extruders and printing plate A Actual temperature of extruders and printing plate B Position of extruders with respect to t...

Page 30: ...16 Main menu From the Main menu you can return to the Start page by moving to the Info screen option using the jog dialer and then pressing the jog dialer to confirm In any case if the printer remains...

Page 31: ...the printing plate to the rest position positioning the extruders at the front left corner of the printing plate Bed Setting This command can be used to modify the distance of the nozzles from the pr...

Page 32: ...N B to move the filaments set the Extruder temperature to the melting point of the material used Figure 3 20 Intermediate settings menu Disable steppers If you need to move the X and Y axes manually u...

Page 33: ...perature menu you can adjust the temperature of Nozzle 1 To do this use the jog dialer to move to the Nozzle command then confirm by pressing the dialer Rotate the jog dialer to set the temperature to...

Page 34: ...on When you select this command the acceleration speed of the motors of the X and Y axes is displayed NOTE currently there is no need to modify this parameter Selecting Endstop abort you can enable or...

Page 35: ...you can reload the default parameter values set in the factory Figure 3 27 SD CARD MENU Selecting Print from SD using the jog dialer and confirming you can display the contents of the SD Card inserted...

Page 36: ...wise direction To select a given command or menu press once on the jog dialer Select the Control menu Position on the Temperature menu and select it To modify the temperature of Extruder 1 select Nozz...

Page 37: ...piece proceed as described below 1 Insert the SD Card supplied in the package into the slot at the front of the printer Select Print from SD to access the file manager Select the file to print for ex...

Page 38: ...anaged by the programs that will be used subsequently for generating the gcode file for printing in 3D Creating a GCODE from a 3D model Once the 3D model in STL format is ready it must be further proc...

Page 39: ...spect to the vertical plane 40 from the surface the layer deposited may not have a suitable support surface underneath and may therefore cede compromising the quality of the printed work piece To avoi...

Page 40: ...distortions in the piece printed To cancel printing access the menu and move to Stop Print using the jog dialer then confirm by pressing the jog dialer Printing is cancelled Figure 3 34 Stop print Not...

Page 41: ...e on the display before accessing the printing area because some parts may still be very hot even after printing has finished Never apply force to lever off the printing plate glass Do not apply exces...

Page 42: ...henever the heads are adjusted changed etc or when operations are carried out on the bakelites or on the nozzles The part to print for offset calibration is located in the following subfolder of the S...

Page 43: ...tly After interventions relubricate as indicated in the specifications At the end of operations perform a test to check that the printer functions correctly without any problems TOOL KIT AND TEMPLATES...

Page 44: ...2 SHIM 2 9 mm FOR ADJUSTING THE DISTANCE OF Y AXIS MOTORS 3 SHIM 1 5 mm FOR ADJUSTING THE HEIGHT OF THE X AXIS PULLEYS 4 TEMPLATE FOR ADJUSTING THE HEIGHT OF THE Z AXIS MOTOR PULLEY All files in gcod...

Page 45: ...Setting the temperature of the hot end Bring the extruder to the temperature necessary for the type of filament installed referring to the filament temperature table When the temperature is reached en...

Page 46: ...f the thrust gear block 4 Once the filament is extruded from the hot extruder lower the temperature to 140 C as described in the paragraph Setting the temperature of the hot end WARNING for the operat...

Page 47: ...bakelite block NOTE To make this operation easier the wrench supplied with the printer has a low profile Figure 4 7 8 Before mounting the new bakelite block you are advised to pass a metal wire of di...

Page 48: ...ad being careful not obstruct the hole Now manually screw the bakelite back onto the hot end block until the end then give it a further half turn with the 12 mm hex wrench to tighten the group perfect...

Page 49: ...ot end from the menus as described in Figure 4 4 Command sequence for inserting extracting the filament from the extruder REPLACING THE NOZZLES To avoid the hot end block getting jammed due to the use...

Page 50: ...on on and select the Move Axis menu Select Move 1 mm Select Move Z then rotate the jog dialer anti clockwise to move the printing plate downwards Figure 4 11 Command sequence for lowering the printing...

Page 51: ...perform the NOZZLE PRINT PLATE ADJUSTMENT PROCEDURE 6 At the end of these operations carry out the printing test Should you need to adjust the printing plate proceed from step 6 in the Chapter UNMOUN...

Page 52: ...er as described in Figure 3 29 Command sequence for setting the temperature then extract the filament as described in Figure 4 4 Command sequence for inserting extracting the filament from the extrude...

Page 53: ...nd Disable steppers 6 The calibration must be repeated at five different points of the printing plate The first with the nozzles positioned at the centre of the plate the other four at a distance of a...

Page 54: ...4 12 Service Manual Y118040 3 Position 1 Centre Position 2 front left Position 3 front right Position 4 rear right Position 5 rear left Figure 4 17 Figure 4 18 Pos 5 Pos 4 Pos 3 Pos 2 Pos 1...

Page 55: ...ING AND LUBRICATING THE GUIDE RAILS OF THE X AND Y AXES Preventive and maintenance inspections are recommended every 6 months or every 1000 hours of operation Clean the guides along their whole length...

Page 56: ...ry 1000 hours of operation 1 Unscrew the screws at the side of the printer console A 2 Extract the console with all its electronic parts Figure 4 19 3 Unscrew and remove the screw B 3 mm hex loosen sc...

Page 57: ...Y118040 3 Service Manual 4 15 4 On the RAMPS card the drivers of the three axes and of the extruders are positioned as shown below Figure 4 21 X Axis Y Axis Z Axis Extruder1 Extruder 2...

Page 58: ...1 10V tolerance 0 0 05V Extruder 2 1 10V tolerance 0 0 05V If the voltage value measured is low work on the trimmer using small slotted screwdriver to bring the voltage to the nominal value If it is...

Page 59: ...first power off the machine and disconnect it from the electrical outlet 1 Cut the two straps and lift the sheath so as to have unobstructed access to the motor wires Figure 4 23 2 Ensure that the con...

Page 60: ...in Figure 3 29 Command sequence for setting the temperature set the following temperatures Nozzle 220 C Nozzle 2 220 C Surface 60 C 2 Wait for the length of time necessary for the elements to reach t...

Page 61: ...y the arrows and extract the Teflon cannula through which the filament passes Figure 4 26 2 Extract the cannulas from the passthroughs on the upper body Figure 4 27 3 Undo the screws on the upper part...

Page 62: ...and then the two bobbin holders Unscrew all the fixing screws highlighted NOTE for technical servicing operations it is sufficient to remove only the centre panel Figure 4 29 5 To remove the right si...

Page 63: ...head screwdriver apply a light force to the snap hooks to release the two switches At this point separate altogether the side panel Figure 4 31 7 To remove the left side panel unscrew all the fixing s...

Page 64: ...a toothed pulley one belt being fitted onto the motor the other idle The procedures for replacing the components of the right or left transmissions are identical The images shown in this Chapter relat...

Page 65: ...as described in the Chapter UNMOUNTING THE UPPER BODY AND PANELS depending on which side of the printer you need to work 2 Unmount the belt of the Y axis as shown in the video clip Y axis belt replac...

Page 66: ...age below shows all the unmounted parts Figure 4 36 5 Working on the setscrew 1 with a hex key 2 mm remove the pulley from the motor Now unscrew the cross head screws 2 so as to separate the motor fro...

Page 67: ...he setscrew 3 To finish extract the shim that must feel slightly gripped Figure 4 38 7 During the reassembly phase insert a shim of 2 9 mm between the motor and the printer s metal frame push the moto...

Page 68: ...o the metal support up to the height indicated by the C shaped template The idle pulley assembly must be the same height as the internal profile of the template At this point tighten the nut 1 to fix...

Page 69: ...ement of the X axis is provided by a belt transmission with toothed pulleys one belt being fitted onto the motor the other idle The photos below show the components making up the mechanical transmissi...

Page 70: ...HE UPPER BODY AND PANELS depending on which side of the printer you need to work 2 Unmount the belt of the X axis as shown in the X axis belt replacement video clip 3 Unscrew the two hex screws 4 mm f...

Page 71: ...8040 3 Service Manual 4 29 6 Unscrew the four Allen screws 2 5 mm and remove the motor Figure 4 45 The photo in the figure below shows all the unmounted parts Figure 4 46 Pulley Setscrew Motor Hex Scr...

Page 72: ...r mounting push the pulley up against the shim and close the setscrew At the end remove the shim that must be slightly clinched Figure 4 47 8 Remount the idle pulley following the indications given in...

Page 73: ...n the two photos Figure 4 49 11 Adjust the pulley in height working on the screw using a flathead screwdriver When the correct height is achieved tighten the two nuts while holding the screw still At...

Page 74: ...d disconnect it from the electrical outlet The procedures for replacing the motors of Extruder 1 and 2 are identical The photos shown in this Chapter refer to the Extruder 1 motor 1 Unmount the body a...

Page 75: ...ettings Unscrew the Allen screws 2 5 mm highlighted below with circles that fix the motor to the extruder block Figure 4 53 5 Unscrew the Allen screw 1 5 mm so as to separate the bowden from the motor...

Page 76: ...o unmount the thrust block The image on the right shows the thrust assy components Figure 4 55 7 Unscrew the setscrew 3 1 5 mm and remove the gear mounted on the motor shaft Figure 4 56 8 Reassemble f...

Page 77: ...the shaft head 5 and tighten the setscrew Figure 4 57 10 With the hex screw 6 torque tightened position the bowden with the holes for the filament centred on each other on the same vertical axis Figur...

Page 78: ...PANELS 2 Unscrew the two Allen screws 5 mm fastening the motor mounting to the printer body Disconnect the motor quick connector Figure 4 60 3 Undo the 1 5 mm setscrew 1 and remove the gear mounted on...

Page 79: ...ollow the next step carefully 5 After have remounted the motor mounting position the pulley so that the distance between its outer part and the base is 17 3 mm To make this operation easier use the te...

Page 80: ...ed to unmount both the side panel and the rear centre panel as described in the Chapter UNMOUNTING THE UPPER BODY AND PANELS 2 Remove the sleeve from the conduit in the metal plate which supports the...

Page 81: ...sing a spatula or similar tool and working very gently lever lightly between the metal frame of the table and the glass with its resistance This operation serves to separate the two parts when the rub...

Page 82: ...placing the glass and resistance assembly you must regulate four points on the printing plate Imagining a 20 cm square positioned at the centre of the table the four corners are the points at which Ex...

Page 83: ...ght adjustment is not carried out correctly bad printing quality might result In extreme cases it could cause a collision between the hot end and the printing plate damaging the machine NOTE the first...

Page 84: ...g dialer B 3 Extract the console so as to be able to access the electronic parts 4 Undo the four locking screws C Figure 4 69 5 Disconnect the flat cable D from the console 6 Disconnect the flat cable...

Page 85: ...ed in this Chapter first power off the machine and disconnect it from the electrical outlet 1 Undo the screws A 2 Disconnect the two quick connect terminals B The figure below shows the Y axis sensor...

Page 86: ...key all the machine functions can be reactivated Before attempting any of the operations described in this Chapter first power off the machine and disconnect it from the electrical outlet 1 Lift the...

Page 87: ...to the relay Figure 4 75 5 Extract the wire of the mat from the hole in the transparent bed above the electronic parts then free the mat from the guides at the front and on the left side Figure 4 76...

Page 88: ...the operating temperature of the extruder block 1 Carry out the operations described in the Chapter REPLACING THE BAKELITE BLOCKS up to Step 6 without however lowering the temperature to 140 2 With t...

Page 89: ...e cleaner remove the melted material so as to free the output hole This operation must be carried out quickly while the nozzle is still hot If the material tends to solidify heat the nozzle after remo...

Page 90: ...4 48 Service Manual Y118040 3 This page is intentionally left blank...

Page 91: ...rops of grease per guide Use a jet of compressed air to clean the extruder block and the cooling fans taking care to remove filament residues and any foreign bodies deposited on the parts PLANNED MAIN...

Page 92: ...5 2 Service Manual Y118040 3 This page is intentionally left blank...

Page 93: ...PC the latter serving for display management as well as providing the Repetier slicing software To perform firmware updating the following files folders are necessary which can be found on the techni...

Page 94: ...ence of installation operations Figure 6 2 Figure 6 3 Figure 6 4 Figure 6 5 Figure 6 6 Figure 6 7 1 The screens captured and illustrated from this step onwards refer to installation of the U8glib libr...

Page 95: ...b ZIP file and click on Open Figure 6 9 Figure 6 8 Figure 6 9 5 The message at the bottom left Library added to your libraries Check the include library menu circled in red confirms that installation...

Page 96: ...ti 3D S2 printer and activate it by pressing the ON key 7 Open the Device Management window on the PC and identify the COM port to which the printer is connected Figure 6 11 Figure 6 11 8 Proceeding w...

Page 97: ...and select the Printer Settings button Figure 6 12 Figure 6 12 10 In the Connection tab select the COM port identified previously in the Device Management window in this case COM22 and the Baud Rate...

Page 98: ...side bar scroll downwards to the parameter Hot end offset mm identify the values of the extruder T1 in this case X55 75 Y 0 50 Figure 6 14 Figure 6 14 12 Close the Repetier Host program 13 Return to t...

Page 99: ...nd then press the Open key Figure 6 16 Figure 6 16 15 Press on the Configuration_Cartesian h tab On the HOTEND_OFFSET_X and HOTEND_OFFSET_Y rows insert the values of the X and Y axes for extruder T1 f...

Page 100: ...uages UI Next to define LANGUAGE_CHOICE insert the number corresponding to the language you want to set 1 for English Figure 6 18 17 Open the Instruments menu and select Arduino Genuino Mega or Mega 2...

Page 101: ...the port related to Arduino Genuino Mega or Mega 2560 Board Figure 6 20 Figure 6 20 19 Press the arrow The message Loading appears and the firmware loading phase begins Figure 6 21 NOTE ignore the mes...

Page 102: ...the screen Figure 6 22 Figure 6 22 NOTE In the future it may be necessary to issue further updates to the release subsequently to Version 1 1 In this case if the Arduino environment arduino 1 6 8 win...

Page 103: ...Y118040 3 Service Manual 6 11 The firmware version is displayed when you power on the printer Figure 6 23...

Page 104: ...6 12 Service Manual Y118040 3 This page is intentionally left blank...

Page 105: ...TROUBLESHOOTING Below are provided some useful guidelines for first level Technicians on the technical approach to adopt when servicing the printer 1 The Operator encountering the problem supplies inf...

Page 106: ...e defective part Eliminating the defect Carry out the repair allowing the printer to return to its normal functions Printer testing At the end of the intervention carry out overall cleaning of the pri...

Page 107: ...working on the printing plate The material does not flow out of the nozzle correctly The glass is too near the nozzle Check the distance between the nozzle and the printing plate working on the nozzle...

Page 108: ...feeder unit but occasionally unexpected slipping occurs and the material is not extruded From a visual inspection it can be seen that the filament is very marked or eaten by the gear The tension is t...

Page 109: ...ring of the extruder motors Extruder motor defective Replace the extruder motor The filament pressure adjustment screw is too loose Tighten the filament pressure adjustment screw Printing is out of ph...

Page 110: ...7 6 Service Manual Y118040 3 This page is intentionally left blank...

Page 111: ...l for producing decorative articles that are pleasant to the touch It offers excellent resistance to UV radiation and is therefore not subject to changes in colour Simple to print it can also be sande...

Page 112: ...as a real wood feeling and even smells like wood Excellent post printing workability OPERATING TEMPERATURE The table gives the extruder and work table temperatures according to the type of filament us...

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