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Olivetti 3D S2 Service Manual

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Olivetti 3D S2
Printer
SERVICE MANUAL
Code: Y118040-3

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  • 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 PREFACE This document is intended to be used by technicians responsible for installing and servicing the Olivetti 3D S2 printer. The aim of the manual is to supply all the information necessary for installing and maintaining the product correctly .
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  • Page 5: Table Of Contents

    CONTENTS PREFACE ..............................iii CHAPTER 1 – OVERVIEW ........................1-1 PRODUCT DESCRIPTION ........................1-1 MAIN TECHNICAL FEATURES ......................1-2 TECHNICAL SPECIFICATIONS ......................1-9 CHAPTER 2 – PCB ASSEMBLY DESCRIPTION ................. 2-1 DESCRIPTION OF PRINTED CIRCUIT BOARD ASSEMBLIES ............2-1 POWER UNIT ............................2-2 ARDUINO PCB ASSEMBLY ........................
  • Page 6 CHAPTER 5 – PLANNED MAINTENANCE ..................5-1 GENERAL CLEANING ........................... 5-1 PLANNED MAINTENANCE EVERY 6 MONTHS 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 ........................

  • Page 7: Chapter 1 - Overview

    Chapter 1 – OVERVIEW PRODUCT DESCRIPTION The Olivetti 3D S2 printer exploits the Fused Filament Fabrication (FFF) 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 on a digital transformation path.

  • Page 8: Main Technical Features

    MAIN TECHNICAL FEATURES Printer design The main machine controls are located on the front of the printer where there is also a door for accessing the inside of the printer. The safety keys are located on the left side of the printer. 10-Safety mat reset key 4-Access door 9-Emergency...
  • Page 9 Internal light switch Printer power on LED Emergency stop push-button Reset key for safety sensitive mat after activation. On opening the front door, the hot-end group comprising of extruder 1 and extruder 2 is clearly visible. 3 – Extruder 1 4 –...
  • Page 10 4 – Gruppo di trascinamento 4 – Filament Feeder Assembly filament 3 – Setscrew di blocco hot- 3 – Hot-end Unlocking Setscrew 2 – Hot-end 1 - Nozzle Figure 1-3 Hot-end group detail REFERENCE DESCRIPTION Nozzle Hot-end Hot-end unlocking setscrew Filament feeder unit Service Manual Y118040-3...
  • Page 11 1 – Bowden Quick Release Couplings 2 – Filament Pressure Adjustment Screws Figure 1-4 Feeder assembly terminals and pressure adjustment screw REFERENCE DESCRIPTION Bowden quick release couplings Filament pressure adjustment screw The bobbins with the filament are installed at the rear of the machine, where there is also the power switch, power socket and USB port.
  • Page 12 2-Feeder 1-Bobbin Holders Figure 1-5 Rear View 3-Power Switch 4-Power Socket 5-USB Port Figure 1-6 Rear view detail REFERENCE DESCRIPTION Bobbin holders Feeder Power Switch Power Socket USB Port Service Manual Y118040-3...
  • Page 13 X axis Extruder Home Position Figure 1-7 Orientation of Olivetti 3D S2 printer axes Starting from the origin, the X axis is oriented from left to right of the work table, the abscissa increasing in this direction. The positive direction of the Y ordinate axis, starting from the front door, is towards the rear of the machine, while the positive direction of the Z axis –...
  • Page 14 Label positions and meanings On the front top part of the printer the following labels can be seen displayed. The meaning of these symbols is given in the table below. Figure 1-8 Labels on front of printer SYMBOL COLOUR WARNING MEANING TRIANGLE YELLOW...

  • Page 15: Technical Specifications

    TECHNICAL SPECIFICATIONS Case: Radiused anodised aluminium 45 x 45 with methacrylate panels Power supply: input 100-240V 50-60 Hz 125-250V / 2.8A output 12V 8.34A 100W Display: Front LCD 128 x 64 dot matrix. Printing plate: 5 mm tempered glass, heated. Maximum temperature 120°C. Extruders: 2 extruders.
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  • Page 17: Chapter 2 - Pcb Assembly Description

    Chapter 2 – PCB ASSEMBLY DESCRIPTION DESCRIPTION OF PRINTED CIRCUIT BOARD ASSEMBLIES The figure below shows the metal plate with the electronic components of the printer: Figure 2-1 REFERENCE DESCRIPTION Input/output wire terminals RAMPS Card Arduino MEGA 2560 Card (positioned under the RAMPS card) Cooling fan for RAMPS card SD Card connector and display card Fuse holder...

  • Page 18: Power Unit

    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 card. Figure 2-3 Service Manual Y118040-3...

  • Page 19: Ramps Pcb Assemblies

    RAMPS PCB ASSEMBLIES In the illustrations below can be seen the A side of the RAMPS card and its related block diagram. Power selection jumper Jumpers under driver IC alimentatione NOTE: 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).
  • Page 20 The figure below shows one of the five Driver chips mounted on the RAMPS card. Figure 2-5 Figure 2-6 Service Manual Y118040-3...

  • Page 21: Display Unit

    DISPLAY UNIT The figure below shows the display unit comprised of the jog dialer and the connector for the SD Card device mounted on the printer side. Jog dialer SD Card connector Figure 2-7 SAFETY SWITCHES The printer is equipped with two safety switches. The Emergency Stop key –...
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  • Page 23: Package Contents

    Chapter 3 – INSTALLATION AND PRINT TEST PACKAGE CONTENTS The following items are contained in the Olivetti 3D S2 printer package: 1 3D S2 Printer 1 Printer Door Key 1 USB Cable. Type A-B 1 AC Power Cord 1 SD Card of 4GB or more 3 Allen Keys (1.5 mm, 2.5 mm and 5 mm)
  • Page 24 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.
  • Page 25 UNPACKING AND RECOMMENDED OPERATIONS 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 (Figure 3-3) lifting them out (Figure 3-4). Figure 3-3 Figure 3-4 Y118040-3...

  • Page 26: On Work Table

    3. Remove the external cardboard packaging by lifting it upwards (Figure 3-5). On the left side of the printer there are two boxes containing the printer accessories (Figure 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: ≥...
  • Page 27 It is recommended that two persons carry out this operation, proceeding as follows: Unpack 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 (arrow 2). NOTE: The printer bottom must rest entirely on the surface Figure 3-8 Move the forklift truck away.

  • Page 28: Printer Preparation

    Figure 3-10 Figure 3-11 PRINTER PREPARATION This Chapter describes the procedures necessary for correctly configuring and preparing the Olivetti 3D-S2 printer for printing. Unblocking the hot-end group To protect the printer during shipping, the hot-end group is anchored to the centre of the Z axis (at the machine rear) using two packing straps.

  • Page 29: Menus And Navigation

    MENUS AND NAVIGATION The User Interface of the Olivetti 3D S2 printer provides the commands for carrying out the calibration, maintenance and printing operations. On powering on the printer, an initialisation screen is displayed for a few seconds giving the firmware release version, date and time.

  • Page 30: Main Menu

    MAIN MENU To access the main menu, press the jog dialer once when the printer is in rest mode with the Start page displayed. Figure 3-16 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.

  • Page 31: Prepare Menu

    PREPARE MENU From the Prepare menu you can carry out the principal machine calibrations. From this menu the following submenus can be accessed: Figure 3-17 Prepare menu submenus  Auto Home  Bed Setting  Move axis  Disable Steppers Auto Home: Positioning on the Auto Home command using the jog dialer and pressing to confirm, the printer moves the extruders and the printing plate to the rest position (positioning the extruders at the front left corner of the...
  • Page 32 Selecting the Move 10 mm submenu allows you to move the printhead rapidly along the X and Y axes (the example in the figures below shows how to move 160 mm in the positive direction along the x axis). Figure 3-19 Rapid settings menu Selecting the Move 1 mm submenu, you can move both the X and Y axes and the Z axis (printing plate) as well as the motors for feeding the filaments of Extruder 1 and Extruder 2 (N.B.

  • Page 33: Control Menu

    CONTROL MENU The Control menu gives you access to all printer parameter settings, allowing you to modify each one singly as you need. From this menu you can access the following submenus: Figure 3-22 Control menu and related submenus  Temperature ...
  • Page 34 Selecting Fan speed you can vary the rotating speed of the two fans mounted on each of the two extruders. Figure 3-25 Motion: 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.

  • Page 35: Sd Card Menu

    By selecting Restore failsafe and confirming, 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, navigate between the files saved on it, select and print a file.

  • Page 36: Loading The Bobbins With Filaments

    LOADING THE BOBBINS WITH FILAMENTS ”Plastic 1. Position the bobbin on its holder and insert the filament inside the feeder as shown in the video clip layer bobbin and plastic layer settings”. Regulate the temperature of the hot-end to the appropriate operating value for the type of filament loaded (for example, 200°C for PLA), proceeding as described below: ...

  • Page 37: Printing A Test Piece

    On terminating printing, the machine executes the Homing procedure for the carriage and switches off the heaters to allow the extruders to return to ambient temperature. All printing processes can be monitored from the printer display’s Start screen. The printing format supported by the Olivetti 3D S2 printer has the extension .gcode. NOTE Y118040-3...
  • Page 38 Creating a printable file using the Olivetti 3D S2 printer The steps necessary for producing your own printable .gcode files using the Olivetti 3D S2 printer are described in this paragraph. Creating a 3D model The first step is to create a three-dimensional model of the object you want to print.
  • Page 39 GCODE Printing ”PRINTING A TEST PIECE”. Now to print your GCODE, proceed as explained in the paragraph Overhang and generation of support material Overhang is the term used to describe those portions of model that cannot be printed using the FFF printing process without the help of suitable support underneath.
  • Page 40 To restart printing just press the jog dialer. Figure 3-33 Restarting printing NOTE: when printing is suspended, the high nozzle temperature may result in material continuing to flow, resulting in 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.
  • Page 41 Removing printed pieces You may find that the printed piece is very strongly bonded to the glass printing plate. This is due to use of the bonding solution to create good adhesion of the first layer to the plate, creating a "vacuum" effect which literally glues the piece to the glass.

  • Page 42: Calibrating The Extruder Offset

    CALIBRATING THE EXTRUDER OFFSETS To be able to print with the dual extruder you must calibrate the offsets of the two printheads. Before proceeding with the offset calibration, adjust the nozzle height as described in the Chapter NOZZLE REPLACING THE NOZZLES”.

  • Page 43: Chapter 4 - Disassembling Parts And Maintenance

    Chapter 4 – DISASSEMBLING PARTS AND MAINTENANCE To ensure maximum safety conditions and a successful outcome of operations, observe the following instructions: For all disassembly and reassembly operations, switch off and disconnect the printer from the mains power supply. Carry out all operations in areas that are clean and free from obstacles. Follow procedures scrupulously;...
  • Page 44 All files in .gcode format for the parts composing the kit are provided on the SD Card supplied with the product. This allows you to create these tools and templates autonomously, using the Olivetti 3D S2 printer . Service Manual...

  • Page 45: Replacing The Bakelite Blocks

    REPLACING THE BAKELITE BLOCKS Preventive and maintenance inspections are advised every 6 months or every 1000 hours of operation. The photo below shows the two hot-ends of the extruder block with the cooling fans rotated upwards. Hot-end Setscrew Hot-ends Bakelite Blocks Nozzles Figure 4-3 In most cases, the block arrives with the filament already inserted inside.
  • Page 46 Figure 4-4 Command sequence for inserting/extracting the filament from the extruder The internal software saves your work in memory, the printer then extrudes and retracts the filament, according to an automatic sequence, so that you will find the filament extruding out of the thrust gear block.
  • Page 47 Extract the hot-end group from its conduit. Figure 4-6 With the hot-end group released, use the 12 mm hex wrench to unscrew the bakelite block. NOTE: To make this operation easier, the wrench supplied with the printer has a low profile. 12 mm Hex Wrench 12 mm Hex Wrench Figure 4-7...
  • Page 48 Figure 4-8 Still with the hot-end hot, take the new block of bakelite and wind Teflon tape 4 times around the thread, 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 perfectly.

  • Page 49: Replacing The Nozzles

    11. Screw the setscrew on again, tightening moderately, to fasten the hot-end group. 12. Move the cooling fan back to its operating position. 13. Adjust the nozzle–printing plate distance as described in the next Chapter NOZZLE PRINT PLATE CALIBRATION PROCEDURE” ”REPLACING THE NOZZLES”.
  • Page 50 In order to select a given command or menu you must press the jog dialer.  From the Menu Start page select the Prepare menu.  Position 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.
  • Page 51 Apply 3 windings of Teflon tape to the nozzle thread taking care not to cover the hole. Figure 4-13 “NOZZLE – PRINT PLATE ADJUSTMENT PROCEDURE”. After have remounted the nozzle, perform the At the end of these operations, carry out the printing test. Should you need to adjust the printing plate, ”UNMOUNTING THE PRINTING PLATE”.

  • Page 52: Nozzle - Print Plate Calibration Procedure

    NOZZLE - PRINT PLATE CALIBRATION PROCEDURE This operation must be executed on a periodic basis or every time you carry out operations on the nozzle or on the bakelite block. Put the printer into operation by moving the power switch to the On position. The Menu Start page appears on the display.
  • Page 53 The image below shows the hot-end group in the Auto Home position. Zero point Figure 4-15 Once you have found the zero point, from the Prepare menu click on Disable steppers. This will allow you to move the extruders manually along the X-Y axes. Figure 4-16 Command sequence for Auto Home and Disable steppers The calibration must be repeated at five different points of the printing plate.
  • Page 54 Position 1 Centre Position 2 front left Position 3 front right Position 4 rear right Position 5 rear left Figure 4-17 Pos.5 Pos.4 Pos.1 Pos.2 Pos.3 Figure 4-18 4-12 Service Manual Y118040-3...

  • Page 55: Cleaning And Lubricating The Guide Rails Of The X And Y Axes

    Carry out the calibration as illustrated in the video clip “Nozzle print plate calibration procedure”. WARNING: for the operations described in the video clip, you are advised to use heat-resistant gloves to avoid burns caused by the operating temperature of the extruder block. the operations described up to here must be carried out on both extruders.

  • Page 56: Verifying And Adjusting The Driver Voltages

    VERIFYING AND ADJUSTING THE DRIVER VOLTAGES Preventive and maintenance inspections are recommended every 6 months or every 1000 hours of operation. Unscrew the screws at the side of the printer console (A). Extract the console with all its electronic parts. Figure 4-19 Unscrew and remove the screw (B) (3 mm hex), loosen screw (C) and rotate the fan anti-clockwise.
  • Page 57 On the RAMPS card, the drivers of the three axes and of the extruders are positioned as shown below. Extruder1 X Axis Y Axis Extruder 2 Z Axis Figure 4-21 Y118040-3 Service Manual 4-15...
  • Page 58 To check the driver voltage, with the machine powered on place the positive (red) test lead of the tester on the driver trimmer and the negative (black) test lead on the first screw, furthest to the left, of the green connector on the RAMPS card.

  • Page 59: Checking The Wiring Of The Extruder Block And Hot-End Motors

    CHECKING THE WIRING OF THE EXTRUDER BLOCK AND HOT-END MOTORS Preventive and maintenance inspections are recommended every 6 months or every 1000 hours of operation. Before attempting any of the operations described in this Chapter, first power off the machine and disconnect it from the electrical outlet.

  • Page 60: Checking That Heating Elements Maintain Operating Temperature

    Hot-end Wires Figure 4-25 If this is not true replace the damaged hot-end(s). CHECKING THAT HEATING ELEMENTS MAINTAIN OPERATING TEMPERATURE Preventive and maintenance inspections are recommended every 6 months or every 1000 hours of operation. These inspections relate to the heating elements and the thermo-sensors of the hot-end groups and work table. Using the LCD panel as shown in Figure 3-29 Command sequence for setting the temperature, set the...

  • Page 61: Unmounting The Upper Body And Panels

    UNMOUNTING THE UPPER BODY AND PANELS 1. Release the two bowdens by pressing on the black ring nuts in the directions indicated by 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.
  • Page 62 To remove the three rear panels, remove first the retainer 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. Bobbin Holder and Retainer Figure 4-29 5.
  • Page 63 6. Rotate the panel paying due attention to the safety switch wires. Using a flathead 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 screws highlighted. Figure 4-32 To reassemble follow the same procedures described above but in reverse order.

  • Page 64: Y Axis Belt Replacement

    Y AXIS BELT REPLACEMENT Preventive and maintenance inspections are recommended after 2 years or 4000 hours of operation. Before attempting any of the operations described in this Chapter, first power off the machine and disconnect it from the electrical outlet. 1.

  • Page 65: Replacing The Y Axis Motor And Idle Pulley

    REPLACING THE Y AXIS MOTOR AND IDLE PULLEY Before attempting any of the operations described in this Chapter, first power off the machine and disconnect it from the electrical outlet. 1. Unmount the upper body and the right or left side panel as described the Chapter ”UNMOUNTING THE UPPER BODY AND PANELS”...
  • Page 66 The image below shows all the unmounted parts. Figure 4-36 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 from its metal mounting. Figure 4-37 4-24 Service Manual...
  • Page 67 After have screwed the motor back onto its metal mounting, mount the pulley regulating it as follows: place a 2.9 mm shim on top of the motor, then insert the pulley onto the shaft, pushing it against the shim and tighten the setscrew (3).
  • Page 68 To unmount the idle pulley, loosen the nut (1) and unscrew the slotted screw (2) on the pulley. Figure 4-40 10. When assembling the pulley, adjust as follows: screw the pulley onto 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.

  • Page 69: Axis Belt Replacement

    X AXIS BELT REPLACEMENT Preventive and maintenance inspections are recommended after 2 years or 4000 hours of operation. Before attempting any of the operations described in this Chapter, first power off the machine and disconnect it from the electrical outlet. Movement of the X axis is provided by a belt transmission with toothed pulleys, one belt being fitted onto the motor, the other idle.

  • Page 70: Replacing The X Axis Motor And Idle Pulley

    REPLACING THE X AXIS MOTOR AND IDLE PULLEY Before attempting any of the operations described in this Chapter, first power off the machine and disconnect it from the electrical outlet. ”UNMOUNTING THE Unmount the upper body and the right or left side panel as described in the Chapter UPPER BODY AND PANELS”...
  • Page 71 Unscrew the four Allen screws (2.5 mm) and remove the motor. Pulley Setscrew Motor Hex Screws Figure 4-45 The photo in the figure below shows all the unmounted parts. Figure 4-46 Y118040-3 Service Manual 4-29...
  • Page 72 Remount the pulley of the motor with the following adjustments: insert a 1.5 mm shim between the pulley and the motor mounting, push the pulley up against the shim and close the setscrew. At the end, remove the shim that must be slightly clinched. Shim of 1.5 mm Setscrew Figure 4-47...
  • Page 73 10. Between the pulley and the hot-end group guide support, insert a 1.5 mm shim as shown in the two photos. Positioning shim of 1.5 mm 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.

  • Page 74: Unmounting The Extruder Block Motors

    UNMOUNTING THE EXTRUDER BLOCK MOTORS Preventive and maintenance inspections are recommended after 2 years or 4000 hours of operation. Before attempting any of the operations described in this Chapter, first power off the machine and disconnect it from the electrical outlet. The procedures for replacing the motors of Extruder 1 and 2 are identical.
  • Page 75 ”Plastic layer bobbin and plastic Release the bowden and remove the cannula as shown in the video clip layer settings”. Unscrew the Allen screws (2.5 mm), highlighted below with circles, that fix the motor to the extruder block. Bowden released and cannula removed Figure 4-53 Unscrew the Allen screw (1) (5 mm) so as to separate the bowden from the motor assy.
  • Page 76 Unscrew the (5 mm) Allen screw (3) to unmount the thrust block. The image on the right shows the thrust assy components. Figure 4-55 Unscrew the setscrew (3) (1.5 mm) and remove the gear mounted on the motor shaft. Figure 4-56 Reassemble following the procedures just described but in reverse order.
  • Page 77 During reassembly pay particular attention to the following points. The setscrew of the gear must be inserted into the flat side of the shaft (4). Align the gear with 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).

  • Page 78: Unmounting The Z Axis Motor

    UNMOUNTING THE Z AXIS MOTOR Before attempting any of the operations described in this Chapter, first power off the machine and disconnect it from the electrical outlet. ”UNMOUNTING THE UPPER BODY AND Unmount the rear centre panel as described in the Chapter PANELS”.
  • Page 79 During reassembly follow the next step carefully. 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 template supplied). Height to set (17,3 mm) Figure 4-62 Y118040-3 Service Manual...

  • Page 80: Unmounting The Printing Plate

    UNMOUNTING THE PRINTING PLATE Before attempting any of the operations described in this Chapter, first power off the machine and disconnect it from the electrical outlet. To work more comfortably you are advised to unmount both the side panel and the rear centre panel as ”UNMOUNTING THE UPPER BODY AND PANELS”.
  • Page 81 Remove the eight brackets fastening the glass with its resistance to the metal frame of the printing table. Anchoring brackets Figure 4-65 Using a spatula or similar tool, and working very gently, lever lightly between the metal frame of the table and the glass with its resistance.
  • Page 82 The image below shows the glass with its resistance. The detail shows a portion of the resistance that covers entirely the underside of the glass. Portion of resistance Figure 4-67 After replacing 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 Extruder 1 is at a distance of 0.08 mm from the glass.
  • Page 83 Bring the nozzles to the zero point using the Auto Home procedures in the menu as described in Figure 4-16 Command Sequence for Auto Home and Disable Motors WARNING: to avoid reverse currents produced by the motors damaging the electronic parts, move the extruders very gently and using small limited movements.
  • Page 84 UNMOUNTING THE DISPLAY Undo the screws on the side of the printer console (A). Undo the setscrew of the jog dialer (B). Extract the console so as to be able to access the electronic parts. Undo the four locking screws (C). Figure 4-69 Disconnect the flat cable (D) from the console.

  • Page 85: Unmounting The End-Of-Travel Sensors

    UNMOUNTING THE END-OF-TRAVEL SENSORS The printer is equipped of three end-of-travel sensors, one for each axis. The sensors occupy fixed positions and therefore need no adjustment. Before attempting any of the operations described in this Chapter, first power off the machine and disconnect it from the electrical outlet.

  • Page 86: Unmounting The Safety Mat

    UNMOUNTING THE SAFETY MAT The safety mat ensures that the machine is powered off in the event of the printer being subjected to any kind of abnormal pressure (e.g. caused by the operator’s hands or objects accidentally left inside the machine). When the safety mat intervenes, the blue reset key on the right side of the printer lights.
  • Page 87 Disconnect the two wires (A) and (B) connecting the mat to the relay. Figure 4-75 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 To reassemble follow the same procedures described above but in reverse order.

  • Page 88: Cleaning The Hot-End Group

    CLEANING THE HOT-END GROUP The hot-end group must be cleaned whenever material is not extruded smoothly or the type of material used for the filament is changed. WARNING: for carrying out the operations described in the following steps, use of heat-resistant gloves is advised to avoid burns caused by the operating temperature of the extruder block.
  • Page 89 With the 12 mm and 10 mm hex wrenches unscrew the nozzle from the hot-end group. 12 mm hex wrench 10 mm hex wrench Figure 4-78 Holding the nozzle in your hand and using a metal pipe cleaner, remove the melted material so as to free the output hole.
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  • Page 91: Chapter 5 - Planned Maintenance

    Chapter 5 – PLANNED MAINTENANCE GENERAL CLEANING For correct printer operation it is recommended that certain parts of the printer are cleaned on a periodic basis, and anyway every time the machine is serviced or planned maintenance is carried out . Cleaning the outer case Switch off the printer and disconnect it from the power socket Clean the outer case of the printer, the methacrylate panels and the surface of the safety mat using a...
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  • Page 93: Chapter 6 - Firmware

    UPDATING THE FIRMWARE To interface the Olivetti 3D S2 printer with the PC and carry out firmware updating, both the IDE Arduino software and the U8glib library must be installed on the PC, the latter serving for display management as well as providing the Repetier slicing software.
  • Page 94 The sequence of operations to perform for loading the firmware is described below. Launch the IDE Arduino software “arduino-1.6.8-windows”. The screens shown in the figures below, captured from the PC screen, show the sequence of installation operations. Figure 6-2 Figure 6-3 Figure 6-4 Figure 6-5 Figure 6-6...
  • Page 95 4. Search for the U8glib.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 has completely successfully (Figure 6-10). Figure 6-10 Y118040-3 Service Manual...
  • Page 96 6. Connect the PC to the USB port of the Olivetti 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).
  • Page 97 9. Launch the Repetier-Host program 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 115200 , then confirm with the OK button (Figure 6-13). Figure 6-13 Y118040-3 Service Manual...
  • Page 98 11. Press the Connect button that changes from red to green. Using the 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.
  • Page 99 14. From the folder MK_S2-Olivetti select the file MK_S2-Olivetti.ino and 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, found earlier using the Repetier-Host program (in this case, X55.75 and Y-0.50) (Figure 6-17).
  • Page 100 16. Select Configuration h § then, using the scroll bar at the side, scroll down to Languages 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 2560 Board. Then select Arduino/Genuino Mega or Mega 2560 Board in the Board Manager menu (Figure 6-19).
  • Page 101 18. Open the Instruments menu, select Port and then, from the submenu that opens, 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 message: ”Updates available for some of your libraries”...
  • Page 102 20. Wait until firmware loading ends, notified by a message Loading Completed that appears in red at the bottom left of 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.
  • Page 103 The firmware version is displayed when you power on the printer. Figure 6-23 Y118040-3 Service Manual 6-11...
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  • Page 105: Chapter 7 - Troubleshooting

    Chapter 7 – TROUBLESHOOTING ERROR MESSAGES On the display the following error messages may appear:  MINTEMP: error heating Extruder block 1 and/or Extruder block 2.  MAXTEMP: printing plate error. To troubleshoot the condition giving rise to these error messages, carry out the following checks with the printer switched off: Connector connections at back inner side of machine.

  • Page 106: Fault Categories

    Problem identification Taking into account all the information gathered (information provided by the Operator, printer error signals, representation of error on putting printer into operation, visible damage or wear etc.), identify the precise problem that the printer presents and that needs to be eliminated. Sometimes the fault results from more than one defect: for this reason it is important to separate the various problems and deal with them one at a time.

  • Page 107: Diagnostic Messages

    DIAGNOSTIC MESSAGES Problems Cause Solution Power supply voltage absent or Check that power supply incorrect. specifications and if it is present. Power cord inserted badly or Make sure the power cord is damaged. inserted correctly or replace it. Printer does not power on Fuse blown Replace the fuse.
  • Page 108 Problems Cause Solution glass been aligned correctly: too thick a line The thickness and width of the line indicates that there is too little Check the distance between the printed for the first layer varies space between nozzle nozzle printing plate along the length of the line.
  • Page 109 Problems Cause Solution Problem connected with wiring Check the wiring of the extruder of extruder motors. motors. Extruder motor defective. Replace the extruder motor. Filament not extruded. filament pressure Tighten filament pressure adjustment screw is too loose. adjustment screw. X / Y axes belts are not correctly Adjust the belt tensions.
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  • Page 111: Appendix Aaccessories

    Appendix A ACCESSORIES TYPES OF FILAMENT BOBBINS The filament can be composed of the different materials introduced below: Polylactic acid, is a Bio polymer of vegetable origin, which is completely recyclable, very versatile and with good mechanical and elastic properties. Its shiny finish makes it ideal for producing decorative articles that are pleasant to the touch, and with excellent resistance to ultraviolet light (not subject therefore to variations in colour).
  • Page 112 WOOD Polylactic Acid containing 46% wood dust. This filament can be used in innumerable applications in the different design fields. Easily printable it has 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 used. FILAMENT TYPE MATERIAL TEMP PLATE TEMP...

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